I. Introduction <br> <br> Dongfeng Motor Co., Ltd. is the production of commercial vehicles Forge plating and forging of large-scale professional manufacturer, with more than 40 money from 20MN to 120MN full range of forging forging unit in Production = 100,000 tons of forgings, and has a forging production workshop with an annual output of more than 5,000 pairs of molds, 3 CNC milling machines, Mikron high-speed milling, and a large number of electrical processing and machining equipment.
With the rapid development of the modern economy, the market has put forward higher and higher requirements for the quality, price and delivery time of new product forgings. As the key tool for the production of new products forgings, the quality, price and delivery time of the forging die have become the key factors for the success of new product development. The traditional forging die processing method has been difficult to meet the needs of the market. Dongfeng Motor Co., Ltd. commercial vehicle forging factory forging die manufacturing system has been under great pressure in recent years. The production workshop basically has holidays. Key equipment 3 classes Production, but it is still difficult to meet the quality and delivery requirements of some new products.
Forging die manufacturing urgently requires a high-quality, high-efficiency processing method to improve the quality of the forging die, shorten the manufacturing cycle, and reduce the manufacturing cost. The emergence of high-speed machining technology has solved some of the problems faced by forging die manufacturing. Therefore, high-speed machining technology has been rapidly developed in the forging die manufacturing industry. Dongfeng Motor Co., Ltd. commercial vehicle forging factory introduced a Swiss Mikron high-speed machining center (VCP1000Duro) for the processing of precision and complex forging dies such as crankshafts and flails.
Second, the comparison of the two processes
At present, the process route of forging die processing of Dongfeng Motor Co., Ltd. commercial vehicle forging factory is generally: Forging die shape processing→ Arc milling or copy milling rough machining groove → Heat treatment → Grinding reference surface → EDM or several holding electricity Spark rough, finishing groove → fitter polishing groove → surface strengthening treatment. This processing method has low efficiency, low quality, and long production cycle.
The high-speed milling forging process is: forging die shape processing → heat treatment → grinding the reference surface - high-speed milling processing groove → surface strengthening treatment. It can be seen from the above. The high-speed machining forging die process eliminates the groove roughing, Electric spark rough. Finishing. Four steps such as fitter grinding.
High-speed milling also saves on electrode materials, the wood used in the model, and the man-hours and costs of making electrodes and models.
In addition, when milling at high speed, a small diameter radius can be used to machine a small fillet radius, which enables fine manufacturing and saves a lot of rest, grinding and polishing time.
Third, the characteristics of high-speed milling
l High-efficiency high-speed milling is a different processing method than traditional machining. Compared with its high-speed cutting, the spindle feed speed is high and the cutting amount is small, but the amount of material removal per unit time is increased by 3 -6 times, 5-10 times that of electric machining, and high-speed milling simplifies the machining process and shortens the mold manufacturing cycle. It can shorten the average manufacturing cycle of the die by more than half.
2. High precision due to high-speed milling. L cutting depth and small knot, high speed, stable operation, low vibration. At the same time, at high speed cutting, more than 95% of the cutting heat is carried away by the chips, so the workpiece deformation is small, you can get With high processing precision and surface finish, high-speed milling can solve the problem of no precision mold processing methods in front of the commercial vehicle forging factory of Dongfeng Motor Co., Ltd., and improve the manufacturing quality of the mold.
3. Low manufacturing cost can save a lot of graphite, wood and a large number of electrode manufacturing and wood mold manufacturing hours, while high-speed milling consumes some tools, but consumes only 1/2 of the graphite electrode.
Fourth, the benefit analysis
Take a crankshaft forging die as an example. At present, the total process of the traditional forging die processing process is 22 channels, the total time is 256 hours, and the processing time of the groove is 179 hours (40 hours of copy milling, 94 hours of electric sparking 94 hour). The total process of high-speed milling of the crankshaft forging die is 17 lanes with a total time of 120 hours, of which the processing tank time is only 44 hours. Compared with the traditional forging die machining process, the total time of the main circuit is reduced by 1/2, the machining time of the groove is shortened by 3/4, and the machining accuracy is improved. The inspection is performed within the tolerance of O.lmm and the surface roughness. For Ra 0.4, the mold is polished without polishing with a fitter. In addition, it can save a lot of graphite and wood, and the economic benefits are very significant.
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