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The development of the energy industry has attracted people’s attention. In addition to the traditional energy industry, emerging clean energy sources such as wind power, nuclear power, solar energy, and tidal energy are receiving more and more attention. The rapid development of the energy industry also affects the related manufacturing industries. Put forward higher requirements, among them, the tool is one of the most critical factors, in the premise of ensuring the processing quality and production efficiency, for the energy industry, especially the new energy industry, how companies should choose the tool for their own is we must care of.
Use deduction and induction to get the most suitable product
Choosing a tool is a very logical job. Every new project is like a reasoning problem. You need to use the deduction and induction to get the most suitable product. In simple terms, it is a continuous process of dismantling. The customer's part is a very specific thing, you must disassemble this thing as small as possible, detailed properties, each property has an impact on the design of the tool, summed up these effects, you can get the products you need .
For example, the processing of turbine blades, fan blade molds, a 5MW fan, its blades can reach 60m long, 5m wide, the corresponding mold is also a big guy: From a geometric point of view, large volume requires rapid removal of excess Among the Iscar products, there are products for the Feed Mill series which can be operated under high speed feed conditions and the plunge milling cutter, which is a fast metal cutting product; the large length may cause the tool suspension to grow up; in the case of long overhangs To quickly remove the margin, it is necessary to reduce the cutting resistance; in case of long overhang, it is easy to generate vibration, which requires the cutting edge to have strong impact resistance and good toughness; the space surface on the blade requires the arc element of the tool. Taken together, the following results can be obtained: Feed Mill rapid surface milling, cavity roughing, Mill Shred for deep cavity profile roughing, and then finishing the cavity with a round blade.
Another example is the blades of turbine turbines. The materials used in the high-temperature and high-pressure inlets of steam turbines in thermal power stations are made of high-temperature alloys. The material itself has high strength and toughness, and the plastic deformation of the surface during processing results in severe work hardening, making chips strong. Tough, so cutting force, high cutting temperature. The cutting resistance is reflected in the tool design. It is necessary to reduce the cutting force by increasing the rake angle and the back angle of the tool. The influence of the cutting temperature can be suppressed. The relevant results can be obtained through the knowledge of the tool coating. The coating is suppressed from the cutting zone to The thermal conduction of the blade (knife) reduces the impact of temperature and acts like a layer of insulation film because it has a much lower thermal conductivity than the tool body and the workpiece material. For high-temperature alloys, ISPC's SPS82C and IC380 are PVD and titanium carbonitride coatings designed for this difficult-to-machine material.
One of the common features of the energy industry is the large size of the parts. The workpiece material is characterized by the machining of steel, stainless steel, and superalloys. Iscar has proposed rapid metal cutting (FMR) at a very early time. The concept, and a complete product line to meet the processing of large parts.
Starting in 2009, ISCAR had an upgrade of the Heli Do for milling products. In simple terms, the double-sided cutting of the blades resulted in a double cutting edge number on one blade. After careful study, you will It was found that with a double blade at the same time as a dovetail-type blade positioning groove, a larger cutting rake angle, and a small negative chamfer on the edge, we can well increase the life of the blade. The Heli Do product will be the main direction for the future push. The improvement of the coating, in addition to SPS82C and IC380 these two special products for high-temperature alloys, all the coating has a corresponding SUMO (speed magic) technology upgrade, which is a re-coating technology, that is, On the basis of common PVD and CVD coating, a layer of alumina is added to make the surface of the blade more smooth, reduce the formation of BUE, and increase the tool life.
From the beginning of research and development to the actual sales, for the conventional metal processing, the beam magic coated cutter has a 10% to 30% increase in life span in comparison with Iscar's own old products. For non-metallic materials in the wind power industry, such as Glass Fiber, carbon fiber and synthetic resin composite materials, Iscar's polycrystalline diamond tools (we call it "PCD Line"), and the actual application of small wave-shaped cutting tools in foreign countries. In use, it has been proved that it can effectively prevent scales, damage, and crushing. These tools have common keywords: sharp edges, large rake angles, rake face polishing, high-speed cutting, and small chips.
High mountain to help you unleash <br> <br> wind energy in the new energy industry in the development of wind energy as a clean and renewable energy, more and more attention around the world, Europe, the United States and China are the country's energy Give strong support and advancement in planning.
In the development of the new energy industry, wind energy, as a clean and renewable energy source, has been increasingly valued by countries around the world. Countries in Europe, the United States, and China have all provided strong support and advancement in their national energy plans. As a leader in the wind power industry, Seco Tools not only provides high-quality tools and professional processing technology, but also focuses on providing total solutions for metal cutting needs. In the long-term cooperation with world-renowned wind turbine component manufacturers, Seco has accumulated rich experience and strictly met the near-rigorous processing requirements of wind power component manufacturers.
The working environment of the fan unit is harsh, and there are extremely high demands on many factors such as fatigue resistance, reliability, and vibration absorption. For wind turbines, gearboxes, wind turbine hubs, wind turbine bearings (slewing bearings and gears), fan shafts, and wind turbine seats are all extremely important components. At the same time, they are also parts that are difficult to process, require high precision, and have a large amount of processing. Shanko provided a series of process solutions to help wind power industry users stand out in the fierce market competition.
Wind turbine gearbox is one of the important components of wind turbines. Because of the complex working conditions, reliability, and long service life requirements of the wind turbine installation site, the gear box body must have sufficient rigidity, suitable support structure, and wall thickness to meet the complex force requirements. Commonly used materials are ductile iron and other high-strength cast irons. The mechanical structure of the gearbox is complex and the size is huge, requiring hundreds of hours of precision machining. Parts are processed more with high-precision double-table horizontal boring and milling machining centers.
The machining types of wind turbine gearboxes include milling (corn milling cutters and three-sided blades), drilling (Perfomax series) and boring (bridge hoes). It is worth mentioning that the diameter of the connection hole of the gearbox is more than 2m, and its tolerance requirement is H7. This processing is quite difficult. Seco's Graflex bridge-type boring head standard products cover dimensions of 204 to 2155 mm in diameter; JUMBO bridge boring heads, with a maximum diameter of 3200 mm. They are all made of high-strength aluminum alloy (Fortal) and steel interfaces. Take into account the need for flexibility, body weight and rigidity. The highest precision of IT5 and Ra0.6 can be achieved in precision boring, and the size adjustment is extremely convenient, and can be directly performed on the machine tool. At the same time, the modular design can also meet the demand for large-diameter cylindrical dolls and back rakes. For example, the A731001 Jumbo bridge plate boring boring tool adopts TCMT16T308-F2 TK2000 blade for rough boring, cutting line speed Vc up to 150m/min, feed speed Vf up to 25mm/min, cutting depth ap up to 5~6mm, and fine boring using CCMT09T304-F2. TK1000 blade, cutting line speed Vc 120m/min, deep cut ap0.3mm. These high-performance cutting parameters can not only ensure the customer's high part accuracy, but also greatly reduce the customer's production cycle.
The hub is also one of the important parts of the wind turbine. Its structure and stress deformation are complex. It will directly affect the normal operation and service life of the wind turbine. Therefore, it has high strength, good reliability, long fatigue life and strong vibration absorption characteristics to meet the operating conditions of -20 °C ~ 40 °C. The common material is cast low temperature high impact toughness ductile iron. The main machining types of hubs are milling and drilling.
Wind turbine hubs are bulky and generally have long processing cycles. A customer has encountered such a processing problem: Although all its machine tools are operating at full capacity, they cannot complete production tasks on time. In order to help customers overcome difficulties, Seco designed 360mm and R85mm non-standard indexable forming tools for them, supplemented by 335.19-1207EN2R85-D09, F40M blades, with a cutting speed Vc of 200m/min, and feed per tooth. The amount fz0.14mm, cutting depth ap1 ~ 2mm, production efficiency greatly improved, the production cycle of the hub from the original 30h shortened to 16h. The customer was able to deliver smoothly and avoid major losses.
Seco's Double Octomill double octagonal R220.48 face milling cutter is ideally suited for wheel milling. The blades of double octagonal milling cutters adopt positive rake angle design. Each insert has 16 cutting edges. The same milling cutter can meet the requirements of rough and fine machining applications. It has unmatched economy and versatility.
The processing of wind power components includes fan shafts, fan bases, connection flanges, fan towers, planet carriers, and fan blades. For the machining of these parts, Seco has a complete solution for turning, milling and hole machining. Seco Tools adhering to the concept of "become a strategic partner for customers" is committed to improving processing efficiency and competitiveness for customers.
"High energy rate processing" has become the focus of <br> <br> development of China's economy is continuing to be impressive, with a demand to describe is not an exaggeration. The rapid progress of the construction of the railway network and the building required the necessary power supply to be definitely insufficient. However, investment costs will be very large if large quantities of machinery and equipment are introduced. Recently, customers are increasingly demanding that existing equipment be used for "high-energy-rate production" and "high-efficiency production."
Since the temperature of the generator blades is very high during operation, the heat-resistant alloy is often used as the material. Moreover, because of its complex shape, not only cutting tools, but also drills and end mills are used in the machining process. Sumitomo Electric Carbide has hard-to-cut materials for cutting materials in the turning inserts, AC500 series, multi-purpose drill bits for hard-to-cut material processing in MD, and GS milling cutters for hard-to-cut material processing in end mills. With inventory, the corresponding size is also quite rich, and it can fully meet the complex processing requirements of customers. All of the above-mentioned tools are special materials developed for machining difficult-to-cut materials. Therefore, they have excellent performance in terms of wear resistance and chipping resistance.
The remarkable development of the Chinese economy is continuing. It cannot be overemphasized that the demand for supply exceeds demand. The rapid progress of the construction of the railway network and the building required the necessary power supply to be definitely insufficient. However, investment costs will be very large if large quantities of machinery and equipment are introduced. Recently, customers are increasingly demanding that existing equipment be used for "high-energy-rate production" and "high-efficiency production." Therefore, the recommended solution for the Sumitomo Electric hard alloy is the following product with the keyword "high energy rate processing" as a keyword.
Turning: High-efficiency chip-breaker SE series and GE type with excellent chip treatment are recommended for ultra-high feed machining with f=0.5mm/r. When the feed requirement is higher (~0.8mm/r), the wiper type LUW type and GUW type are recommended.
Milling: The high feed milling cutter MS1400 is recommended. Although the depth of cut cannot exceed 1.5mm, the feed can correspond to 2mm/edge.
Drilling processing: The newly developed J-shaped cross-cutting thinning improves chip treatment and, together with the special flutes, enables excellent chip discharge during high feed machining. In addition, due to the use of the latest PVD coating and DEX coating, long life is achieved. The carbide multi-purpose drill GS/HGS type is recommended here. If the hole diameter is more than 12.5mm, it is recommended to use SMD drill bit with replaceable drill bit.
High hardness material processing <br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br> High Hardness Materials BNC100 is recommended for high-speed/continuous machining, BNC160 is recommended for weak intermittent machining, BNC200 is recommended for high-energy machining, and BNC300 is recommended for strong intermittent machining. In addition, the series of light-removing tools is recommended for high feed machining or high-precision machining.
The slewing bearing ring is a representative hard part in wind power components. Depending on the size (size) of the wind turbine, the size of the wind turbine also varies, and a slewing bearing ring having a diameter of more than 2 m is particularly difficult to process. In particular, when the bearing surface is processed after quenching (hard car), the machining accuracy is strict, the tool life is short, and the mounting hole is large.
The first recommendation for Hard Turning after bearing surface quenching is BNC160, which has excellent wear resistance and can handle large-size workpieces. If high-speed machining is required, BNC100 is recommended. The company prepares various CBN materials. Three kinds of cutting edge treatment can be selected according to the degree of damage of the tool and the required surface roughness.
Mounting holes <br> <br> slewing ring mounting hole is generally recommended WDX type shown on the right the processing of these holes is about 25 mm, hole depth of about 100mm.. Each blade has 4 corners available for economical use. The most suitable blade chipbreaker is also good for chip discharge when processing L/D=5 deep holes. However, if the hole accuracy is less than ±0.15mm, the aforementioned SMD type is recommended.
Use deduction and induction to get the most suitable product
Choosing a tool is a very logical job. Every new project is like a reasoning problem. You need to use the deduction and induction to get the most suitable product. In simple terms, it is a continuous process of dismantling. The customer's part is a very specific thing, you must disassemble this thing as small as possible, detailed properties, each property has an impact on the design of the tool, summed up these effects, you can get the products you need .
For example, the processing of turbine blades, fan blade molds, a 5MW fan, its blades can reach 60m long, 5m wide, the corresponding mold is also a big guy: From a geometric point of view, large volume requires rapid removal of excess Among the Iscar products, there are products for the Feed Mill series which can be operated under high speed feed conditions and the plunge milling cutter, which is a fast metal cutting product; the large length may cause the tool suspension to grow up; in the case of long overhangs To quickly remove the margin, it is necessary to reduce the cutting resistance; in case of long overhang, it is easy to generate vibration, which requires the cutting edge to have strong impact resistance and good toughness; the space surface on the blade requires the arc element of the tool. Taken together, the following results can be obtained: Feed Mill rapid surface milling, cavity roughing, Mill Shred for deep cavity profile roughing, and then finishing the cavity with a round blade.
Another example is the blades of turbine turbines. The materials used in the high-temperature and high-pressure inlets of steam turbines in thermal power stations are made of high-temperature alloys. The material itself has high strength and toughness, and the plastic deformation of the surface during processing results in severe work hardening, making chips strong. Tough, so cutting force, high cutting temperature. The cutting resistance is reflected in the tool design. It is necessary to reduce the cutting force by increasing the rake angle and the back angle of the tool. The influence of the cutting temperature can be suppressed. The relevant results can be obtained through the knowledge of the tool coating. The coating is suppressed from the cutting zone to The thermal conduction of the blade (knife) reduces the impact of temperature and acts like a layer of insulation film because it has a much lower thermal conductivity than the tool body and the workpiece material. For high-temperature alloys, ISPC's SPS82C and IC380 are PVD and titanium carbonitride coatings designed for this difficult-to-machine material.
One of the common features of the energy industry is the large size of the parts. The workpiece material is characterized by the machining of steel, stainless steel, and superalloys. Iscar has proposed rapid metal cutting (FMR) at a very early time. The concept, and a complete product line to meet the processing of large parts.
Starting in 2009, ISCAR had an upgrade of the Heli Do for milling products. In simple terms, the double-sided cutting of the blades resulted in a double cutting edge number on one blade. After careful study, you will It was found that with a double blade at the same time as a dovetail-type blade positioning groove, a larger cutting rake angle, and a small negative chamfer on the edge, we can well increase the life of the blade. The Heli Do product will be the main direction for the future push. The improvement of the coating, in addition to SPS82C and IC380 these two special products for high-temperature alloys, all the coating has a corresponding SUMO (speed magic) technology upgrade, which is a re-coating technology, that is, On the basis of common PVD and CVD coating, a layer of alumina is added to make the surface of the blade more smooth, reduce the formation of BUE, and increase the tool life.
From the beginning of research and development to the actual sales, for the conventional metal processing, the beam magic coated cutter has a 10% to 30% increase in life span in comparison with Iscar's own old products. For non-metallic materials in the wind power industry, such as Glass Fiber, carbon fiber and synthetic resin composite materials, Iscar's polycrystalline diamond tools (we call it "PCD Line"), and the actual application of small wave-shaped cutting tools in foreign countries. In use, it has been proved that it can effectively prevent scales, damage, and crushing. These tools have common keywords: sharp edges, large rake angles, rake face polishing, high-speed cutting, and small chips.
High mountain to help you unleash <br> <br> wind energy in the new energy industry in the development of wind energy as a clean and renewable energy, more and more attention around the world, Europe, the United States and China are the country's energy Give strong support and advancement in planning.
In the development of the new energy industry, wind energy, as a clean and renewable energy source, has been increasingly valued by countries around the world. Countries in Europe, the United States, and China have all provided strong support and advancement in their national energy plans. As a leader in the wind power industry, Seco Tools not only provides high-quality tools and professional processing technology, but also focuses on providing total solutions for metal cutting needs. In the long-term cooperation with world-renowned wind turbine component manufacturers, Seco has accumulated rich experience and strictly met the near-rigorous processing requirements of wind power component manufacturers.
The working environment of the fan unit is harsh, and there are extremely high demands on many factors such as fatigue resistance, reliability, and vibration absorption. For wind turbines, gearboxes, wind turbine hubs, wind turbine bearings (slewing bearings and gears), fan shafts, and wind turbine seats are all extremely important components. At the same time, they are also parts that are difficult to process, require high precision, and have a large amount of processing. Shanko provided a series of process solutions to help wind power industry users stand out in the fierce market competition.
Wind turbine gearbox is one of the important components of wind turbines. Because of the complex working conditions, reliability, and long service life requirements of the wind turbine installation site, the gear box body must have sufficient rigidity, suitable support structure, and wall thickness to meet the complex force requirements. Commonly used materials are ductile iron and other high-strength cast irons. The mechanical structure of the gearbox is complex and the size is huge, requiring hundreds of hours of precision machining. Parts are processed more with high-precision double-table horizontal boring and milling machining centers.
The machining types of wind turbine gearboxes include milling (corn milling cutters and three-sided blades), drilling (Perfomax series) and boring (bridge hoes). It is worth mentioning that the diameter of the connection hole of the gearbox is more than 2m, and its tolerance requirement is H7. This processing is quite difficult. Seco's Graflex bridge-type boring head standard products cover dimensions of 204 to 2155 mm in diameter; JUMBO bridge boring heads, with a maximum diameter of 3200 mm. They are all made of high-strength aluminum alloy (Fortal) and steel interfaces. Take into account the need for flexibility, body weight and rigidity. The highest precision of IT5 and Ra0.6 can be achieved in precision boring, and the size adjustment is extremely convenient, and can be directly performed on the machine tool. At the same time, the modular design can also meet the demand for large-diameter cylindrical dolls and back rakes. For example, the A731001 Jumbo bridge plate boring boring tool adopts TCMT16T308-F2 TK2000 blade for rough boring, cutting line speed Vc up to 150m/min, feed speed Vf up to 25mm/min, cutting depth ap up to 5~6mm, and fine boring using CCMT09T304-F2. TK1000 blade, cutting line speed Vc 120m/min, deep cut ap0.3mm. These high-performance cutting parameters can not only ensure the customer's high part accuracy, but also greatly reduce the customer's production cycle.
The hub is also one of the important parts of the wind turbine. Its structure and stress deformation are complex. It will directly affect the normal operation and service life of the wind turbine. Therefore, it has high strength, good reliability, long fatigue life and strong vibration absorption characteristics to meet the operating conditions of -20 °C ~ 40 °C. The common material is cast low temperature high impact toughness ductile iron. The main machining types of hubs are milling and drilling.
Wind turbine hubs are bulky and generally have long processing cycles. A customer has encountered such a processing problem: Although all its machine tools are operating at full capacity, they cannot complete production tasks on time. In order to help customers overcome difficulties, Seco designed 360mm and R85mm non-standard indexable forming tools for them, supplemented by 335.19-1207EN2R85-D09, F40M blades, with a cutting speed Vc of 200m/min, and feed per tooth. The amount fz0.14mm, cutting depth ap1 ~ 2mm, production efficiency greatly improved, the production cycle of the hub from the original 30h shortened to 16h. The customer was able to deliver smoothly and avoid major losses.
Seco's Double Octomill double octagonal R220.48 face milling cutter is ideally suited for wheel milling. The blades of double octagonal milling cutters adopt positive rake angle design. Each insert has 16 cutting edges. The same milling cutter can meet the requirements of rough and fine machining applications. It has unmatched economy and versatility.
The processing of wind power components includes fan shafts, fan bases, connection flanges, fan towers, planet carriers, and fan blades. For the machining of these parts, Seco has a complete solution for turning, milling and hole machining. Seco Tools adhering to the concept of "become a strategic partner for customers" is committed to improving processing efficiency and competitiveness for customers.
"High energy rate processing" has become the focus of <br> <br> development of China's economy is continuing to be impressive, with a demand to describe is not an exaggeration. The rapid progress of the construction of the railway network and the building required the necessary power supply to be definitely insufficient. However, investment costs will be very large if large quantities of machinery and equipment are introduced. Recently, customers are increasingly demanding that existing equipment be used for "high-energy-rate production" and "high-efficiency production."
Since the temperature of the generator blades is very high during operation, the heat-resistant alloy is often used as the material. Moreover, because of its complex shape, not only cutting tools, but also drills and end mills are used in the machining process. Sumitomo Electric Carbide has hard-to-cut materials for cutting materials in the turning inserts, AC500 series, multi-purpose drill bits for hard-to-cut material processing in MD, and GS milling cutters for hard-to-cut material processing in end mills. With inventory, the corresponding size is also quite rich, and it can fully meet the complex processing requirements of customers. All of the above-mentioned tools are special materials developed for machining difficult-to-cut materials. Therefore, they have excellent performance in terms of wear resistance and chipping resistance.
The remarkable development of the Chinese economy is continuing. It cannot be overemphasized that the demand for supply exceeds demand. The rapid progress of the construction of the railway network and the building required the necessary power supply to be definitely insufficient. However, investment costs will be very large if large quantities of machinery and equipment are introduced. Recently, customers are increasingly demanding that existing equipment be used for "high-energy-rate production" and "high-efficiency production." Therefore, the recommended solution for the Sumitomo Electric hard alloy is the following product with the keyword "high energy rate processing" as a keyword.
Turning: High-efficiency chip-breaker SE series and GE type with excellent chip treatment are recommended for ultra-high feed machining with f=0.5mm/r. When the feed requirement is higher (~0.8mm/r), the wiper type LUW type and GUW type are recommended.
Milling: The high feed milling cutter MS1400 is recommended. Although the depth of cut cannot exceed 1.5mm, the feed can correspond to 2mm/edge.
Drilling processing: The newly developed J-shaped cross-cutting thinning improves chip treatment and, together with the special flutes, enables excellent chip discharge during high feed machining. In addition, due to the use of the latest PVD coating and DEX coating, long life is achieved. The carbide multi-purpose drill GS/HGS type is recommended here. If the hole diameter is more than 12.5mm, it is recommended to use SMD drill bit with replaceable drill bit.
High hardness material processing <br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br> High Hardness Materials BNC100 is recommended for high-speed/continuous machining, BNC160 is recommended for weak intermittent machining, BNC200 is recommended for high-energy machining, and BNC300 is recommended for strong intermittent machining. In addition, the series of light-removing tools is recommended for high feed machining or high-precision machining.
The slewing bearing ring is a representative hard part in wind power components. Depending on the size (size) of the wind turbine, the size of the wind turbine also varies, and a slewing bearing ring having a diameter of more than 2 m is particularly difficult to process. In particular, when the bearing surface is processed after quenching (hard car), the machining accuracy is strict, the tool life is short, and the mounting hole is large.
The first recommendation for Hard Turning after bearing surface quenching is BNC160, which has excellent wear resistance and can handle large-size workpieces. If high-speed machining is required, BNC100 is recommended. The company prepares various CBN materials. Three kinds of cutting edge treatment can be selected according to the degree of damage of the tool and the required surface roughness.
Mounting holes <br> <br> slewing ring mounting hole is generally recommended WDX type shown on the right the processing of these holes is about 25 mm, hole depth of about 100mm.. Each blade has 4 corners available for economical use. The most suitable blade chipbreaker is also good for chip discharge when processing L/D=5 deep holes. However, if the hole accuracy is less than ±0.15mm, the aforementioned SMD type is recommended.
Shanghai Na Long Tech Co., Ltd , https://www.na-long.com