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Tool management helps enterprises achieve efficiency and cost reduction

generally speaking, the consumption of tools in the automotive industry accounts for 3% to 5% of the total production cost of petroleum processing products for the production of composite polyurethane adhesives from a single part. However, by optimizing the application and process flow of tools, it can save 15% or even 30% of the total production cost. In our company, through the early control and management of cutting tools, we can effectively ensure the later production and efficiency improvement, and lay a solid foundation for reducing the cost of cutting tools

tool usage

there are two kinds of tool usage in our company. One is a turnkey project, which is fully contracted by the machine tool manufacturer (including tool scheme design, selection and procurement). Through the technical exchange with the manufacturer, joint review of the scheme, pre acceptance and final acceptance, on the premise of ensuring the product quality, we put forward specific requirements for the selection of cutting tools in combination with the product process planning of the technical department, so as to meet the use of the production site and the needs of tool management in the future

although it is a turnkey project, we should not be lax at all. We should also make full preparations and market research in the early stage. In 2008, our company completed a turnkey project of engine production line. During the technical exchange with machine tool manufacturers at the initial stage of preparation, we found that there were objections to the tool structure for processing cylinder head seat ring. The tool auxiliary structure provided by the manufacturer could not meet our tool supply and storage, and there were hidden dangers in the processing quality, especially the short service life of auxiliary structure, which would not meet the requirements of mass production after production. After the communication, the tool manufacturer still insisted on using the structural tool, and said that the tool had a good effect in a domestic automobile engine factory. After a comprehensive understanding and communication and analysis with the machine tool manufacturer, we finally gave up the implementation plan of the tool manufacturer. In April, 2009, we received information that an automobile engine factory has changed its structure due to the high cost and unstable quality of the cutting tools using this structure. Through the effective management and control in the early stage, our company has ensured the production efficiency and cost control after the engine production line is put into operation, thus avoiding the waste of at least 600000 yuan caused by the replacement of auxiliary tools

another case is the project completed by the engine business department of our company, that is, the equipment supplier is only responsible for providing machine tools, and the tool selection and procurement are completed by ourselves. On the premise of ensuring product quality, we choose the most suitable and cost-effective tool scheme according to the process scheme planning of the technical department and the product advantages of existing tool suppliers (such as Sandvik, kennamatel, guhring, MAPAL, Walter, etc.). At present, the production capacity projects with successful cases and more than 10000 sets of mass production include: 477 cylinder head project and later capacity expansion project, 472 engine cylinder head capacity expansion project, etc

effective tool management

at present, in the tool management project that Wuhu Ruili Tool Co., Ltd. cooperates with our engine business department, we mainly take the following measures and methods:

first, we should start from the source, that is, when the new project starts, we should start to implement tool management. Combined with the on-site use status and tool management experience, the management requirements for the tool manufacturer, tool structure and tool parameter selection are put forward. Secondly, tool management is carried out in the machining process of the engine. Not only provide on-site tool grinding and tool adjustment, but also the main task is to optimize, improve and manage the tool process and inventory according to the process plan of the technical department on the premise of ensuring the product quality in the on-site processing process. At the same time, each product is equipped with a tool technician, plus a tool supervisor stationed at the production site to ensure that the tool management can improve the production efficiency and reduce the tool cost. Here, we can see the achievements made by the cost consumption of a single tool since the SOP production of 372 engine products was implemented (see Figure 1)

Figure 1 average annual decline in the cost of a single tool of 372 engine consumption

successful case of tool management

case 1: the cast iron frame line of sqr481 engine products has been used since the project began SOP production φ 25 the convex table of the frame is processed by the end milling cutter. Because the convex table is large, interpolation processing is required, resulting in obvious tool joint marks on the processing surface. At the same time, the production rate of processing convex worktops is 120s/piece, which seriously restricts the production efficiency and becomes a bottleneck for the productivity improvement of the framework line. Therefore, we combined factors such as production line processing technology and fixture design, and re selected a larger diameter φ 32 end milling cutter (see Figure 2), processing only takes 60s/there are 36 enterprises above the scope of the base, the production efficiency is doubled, at the same time, the service life of the cutter is increased to 800 pieces, and the cost consumption of a single cutter is saved by 0.4 yuan/piece

Figure 2 larger diameter φ 32 end milling cutter

case 2: after the self-produced SQR372 engine product can be expanded from 400 sets per day to 770 sets per day, the operation knowledge of the t-twist universal machine for rough machining the spark plug hole of the cylinder head 3203 three edge fried dough twist drill (see Figure 3) has frequent tool jams during cutting (see Figure 4), resulting in the scrapping of the cylinder head. This phenomenon occurs almost 2-3 times a day, and the production efficiency is almost the same as before

Figure 3 the three edge fried dough twist drill before improvement

after multi-directional practical tests, such as changing the cutting parameters, modifying the geometric parameters of the drill and changing the processing mode of the drill, this problem has not been solved. Finally, we analyzed and determined that the biggest change in the process of capacity improvement was the change of the original machine tool, so we came to the conclusion that the existing tools could not meet the processing requirements of the new machine tool. In order to completely solve this problem, we re selected a two edge straight groove drill with large chip capacity (see Figure 5), and carried out trial cutting after being approved by the technologist of the technical department, and achieved good results. Since it was put into production for half a year, there has been no knife sticking, thus ensuring the daily production efficiency of the workshop

Figure 4 Abnormal tool sticking phenomenon on site

case 3: our company just started a "turnkey" production line project of SOP in 2008. When processing the crankshaft hole of cast iron cylinder block of sqr481 engine product, the machined surface roughness is very unstable, and there are obvious tool withdrawal marks. The service life of the boring blade for machining the crankshaft hole is normal, and can only reach 50 pieces/blade at most. The adjustment of the tool takes half an hour each time, and the one-time size is not 100% guaranteed each time, which seriously affects the production efficiency

after several times of practice, we have comprehensively analyzed and formulated the following two measures: first, improve the tool processing method, that is, change the boring tool from the previous rotary tool withdrawal to static tool withdrawal, which greatly reduces the tool withdrawal marks on the workpiece surface; The second is to reduce the number of one-time clamping blades of the boring cutter, and change the precision machined 4 blades into 2 blades, which not only solves the problem of one-time qualified adjustment of the cutter, but also solves the problem of surface roughness of the machined workpiece, and the machining life of the boring cutter blade is immediately increased to 120 pieces/blade. Reasonable tool improvement measures effectively ensure the smooth production, improve the production efficiency, solve the quality problems such as poor tool marks and roughness, reduce the time of tool replacement and detection, and save the cost of a single tool by 24.8 yuan/piece

Figure 5. The improved two edge straight groove drill


effective tool management can quickly optimize the tool, greatly improve the performance and life of the tool, improve the production efficiency and processing quality level, help enterprises reduce manufacturing costs, and put enterprises in a favorable position in the fierce competition. Effective tool management plays an important role in helping enterprises improve efficiency and reduce costs in the processing of main parts such as automobile engine cylinder block, cylinder head, frame, crankshaft, camshaft and connecting rod, which has attracted more and more attention of enterprises

now we summarize our experience in tool management through learning and independent innovation:

1 Tool file information management is an essential and important link in tool management, which plays a guiding role in tool application. It is an indispensable basis for us to apply tools in practice. Making all applied tools have laws to follow and rules to choose from is a prerequisite for improving product processing quality, ensuring production needs, improving production efficiency, reducing tool costs and reducing tool inventory funds. (end)

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