Some foreign cutting tool companies have experienced years of development and have relatively mature product processing solutions in many key areas, such as the automotive industry, energy industry, aerospace industry, medical industry and mold industry. Some domestic enterprises started late, but developed rapidly. Their products are gradually applied to various industries, and they can also provide excellent solutions for enterprises. The solutions for parts in different fields are described below.
1. Typical solutions of Walter
(2) Drill countersunk holes on the workpiece
3. Low number of cutting tools required The Berlin Gas Turbine Plant also places particular emphasis on the long life of the Walter carbide indexable inserts. Thanks to this special tool from Walter, 2 products can now be processed simultaneously (precise minimum batch size). This is just the opposite of the high-speed steel milling cutter used in the previous reverse countersunk drilling. The previous tool has been completely worn out after a countersinking process and needs to be changed. Therefore, in the process of producing 16 parts, a total of 256 high-speed steel tools need to be reground, but now only 8 indexable carbide inserts are required. Compared with high-speed steel milling cutters, the wear rate of indexable inserts is very low, and the return on investment is fast.
Siemens Power and Gas has also seen significant cost savings from the tools: each external tool clamp takes about 10 minutes, and the new tool uses 8 indexable inserts, requiring a total time of only 80 minutes, compared to the previous use of 256 high-speed tools. The cutting time required for steel milling cutters is much shorter. The cost of Walter's solution is relatively low. Compared with the previous hourly rate of thousands of euros for knives, the current hourly rate is only about 50 euros.
4. More convenient and efficient Walter's complex tool holder is equipped with a fully automatic mechanism, and the actual cost is higher than that of the previous manual tool holder, but the additional cost can be recovered in less than one year. In addition, this type of knife holder is also durable, and only needs to replace the guide liner at ordinary times. However, setup, operation and maintenance of new tools requires extensive training. Zapke sees the switchover as a major success, as the new automated system is much easier to manage and operate than the previous solution, resulting in significantly shorter lead times. In addition, the surface quality is much better than previous knives.
5. Application
(1) Siemens is using Walter MODCO®'s internally cooled solid carbide countersunk drill to process a flange counterbore for a CD-1 gas turbine shaft,
(2) The protruding length of the solid carbide reverse countersunk drill clamped on the boring and milling machine is 250mm,
(3) A total of 16 holes and counterbores are drilled on the flange of the CD-1 gas turbine shaft.
(4) The counterbore at the rear of the CD-1 shaft flange is 56mm deep and 98mm in diameter,
