In the metal cutting industry, there is no choice but to adopt advanced technology. Future processing needs are growing, and only advanced processing techniques can be used to meet these needs. Cutting tool technology is rapidly evolving in response to changing production demands and increasingly challenging workpiece materials. Today's mechanical processing plants need to look at their cutting tools and tool suppliers in a different way than in the past. Chris Mills, project manager for aviation tool development at Sandvik Coromant, points out that in the case of aerospace manufacturing, in order to meet the manufacturing needs of the industry for the next 20 years, the manufacturing capacity needs to be doubled on the existing basis. How can this be done? Is it almost impossible to simply double the number of machine tools while the machining process remains at the current level? Increasing the number of state-of-the-art machine tools means adding the same proportion of machine operators, which is unimaginable, because today's mechanical processing plants have difficulty hiring enough qualified workers to operate the machine. Therefore, the need to increase the processing capacity by a factor of two must be met by technological advancement, that is, using the existing number of cutting workers to accomplish more work. So, where do these technological advances come from? Machine tools are of course included, they are getting faster and faster, and their precision is getting higher and higher. However, the artifacts themselves are not developing in the same gradual way, they are basically constantly changing. Today, workpieces are not only increasingly demanding in terms of accuracy, delivery and quality, but are increasingly being manufactured using difficult-to-machine materials that have never been encountered before. These materials include titanium alloys, nickel-based alloys, and compacted graphite iron (CGI), as well as various engineering composites (in more and more applications, composites are replacing metal materials). In other words, today's workpieces are growing faster and more powerful than the machines used to cut them. In order to compensate for the gap between machine tools and workpieces, and to increase the processing capacity to meet the processing needs, in today's metal cutting industry, the most important technological advances will come from cutting tools. The role of cutting tools – and tool suppliers – is changing faster and faster, surpassing any other elements of the machining process. In fact, the cutting tools have changed so much that any progressive mechanical processing plant now needs to re-evaluate its concept of cutting tools. Not only do they need to study how to select a particular tool, but they also need to revisit the basic concepts that affect the entire shop tooling application. Some of these core ideas are obsolete today, as the rules for cutting tools have changed. Recently, three companies related to cutting tools have provided insights into how today's machine shops need to think differently about tooling applications. These companies include: 1 Diamond Innovations: world-leading supplier of cubic boron nitride (CBN) and polycrystalline diamond (PCD) tool materials; 2 Precision Dormer: two companies provide high efficiency A consortium of companies that drill and cut tools; 3 Sandvik Coromant: the world's number one supplier of metal cutting tools. The engineering experts at these companies have listed a number of elements that affect the cutting tool characteristics and applications today, some of which include: (1) Challenging workpiece materials. Includes alternative metal materials and difficult-to-machine alloy materials. Some of these materials are less than 1/4 of the steel, and some materials can cost as much as hundreds of dollars per pound. (2) Increasingly complex workpiece geometries. For example, thin-walled workpieces and aerospace components of complex shapes. (3) Large size workpieces. In particular, there is an increasing demand for turbines and various heavy mechanical parts. The high cost per piece of these workpieces places high demands on the machining.
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