Tools help the development of new energy industry

Now the energy industry has become a hot topic, and its development has always 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 have attracted more and more attention. The rapid development of the energy industry has also put forward higher requirements for its related manufacturing industries. Among them, tools are ※As one of the key factors, under the premise of ensuring processing quality and production efficiency, for the energy industry, especially the new energy industry, we must be concerned about how companies should choose suitable tools for themselves.

Use deduction and induction to get ※ suitable products

The selection of tools is a very logical job. Every new project is like a reasoning problem. You need to use deduction and induction to get the suitable product. In short, it is a process of continuous disassembly and assembly. The customer's part is a very specific thing. You must break this thing down into as small and detailed attributes as possible. Each attribute has an impact on the design of the tool. By summarizing these effects, you can get the product you need. .

For example, the processing of turbine blades, fan blade molds, a 5MW fan, the blades can reach 60m long and 5m wide, the corresponding mold is also a big guy: from a geometric point of view, the large volume requires quick removal of the allowance , Among Iscar products, there are FeedMill series tools that can work under high-speed feed conditions and fast metal cutting products such as plunge milling cutters; long tool lengths may cause long tool overhangs; long overhangs require To quickly remove the allowance, it is necessary to reduce the cutting resistance; in the case of long overhang, it is easy to generate vibration, which requires the cutting edge to have strong impact resistance and good toughness; there is a space curved surface on the blade, and the tool needs to have arc elements. Taken together, the following results can be obtained: FeedMill for fast face milling, pocket roughing, MillShred for deep pocket profiling roughing, and round inserts for finishing the pocket.

Another example is the blades of steam turbine turbines. The blade materials used at the high temperature and high pressure inlet end of steam turbines in thermal power stations are all high temperature alloys. The material itself has high strength and toughness. The surface plastic deformation during processing produces serious work hardening, which makes the chips strong. Tough, so the cutting force is large and the cutting temperature is high. The cutting resistance is reflected in the tool design. It is necessary to increase the rake angle and relief angle of the tool to reduce the cutting force; to suppress the influence of cutting temperature, the relevant results can be obtained through the knowledge of the tool coating. The thermal conduction of the insert (tool) to mitigate temperature shocks acts like a thermal barrier because it has a much lower thermal conductivity than the tool base and workpiece material. For high-temperature alloys, Iscar's SPS82C and IC380 are PVD and titanium nitride coatings designed for this difficult-to-machine material.

A common feature of the shape of parts in the energy industry is that they are large, and the material of the workpiece is characterized by the processing of steel, stainless steel and superalloy. , and has a complete product line to meet the processing of large workpieces.

Beginning in 2009, Iscar has an upgrade of HeliDo for milling products, which is simply double-sided of the insert. The direct result is that you can get twice the number of cutting edges on one insert. If you study it carefully, you will find that At the same time of double insert, through dovetail insert positioning groove, larger cutting rake angle, and small negative chamfering edge, we can increase the life of the insert very well. HeliDo products will be one of the main directions in the future. As for the improvement of coating, except for SPS82C and IC380, which are two special products for superalloys, all coatings have corresponding upgrades of SUMO (speed magic) technology, which is a re-coating technology, that is, in On the basis of ordinary PVD and CVD coating, a layer of alumina is added to make the cutting edge surface smoother, reduce the formation of built-up edge, and increase tool life.

From the beginning of research and development to the actual sales, for conventional metal processing, the life of Beam Magic coated tools has increased by 10% to 30% compared with Iscar's own old products. For non-metallic materials in the wind power generation industry, such as composite materials such as glass fiber, carbon fiber and synthetic resin, Iscar's polycrystalline diamond cutting tools (we call it "PCDLine"), as well as the practical use of small wave-edged cutting tools in foreign countries It has been proved to be effective in preventing scaling, breakage, and crushing. These tools have common keywords: sharp cutting edge, large rake angle, rake face polishing, high-speed cutting, and fine chips.

Seco helps you unleash unlimited wind energy

During the development of the new energy industry, wind energy, as a clean and renewable energy source, has attracted more and more attention from countries around the world. European countries, the United States and China have all given strong support and promotion in their own energy planning.

During the development of the new energy industry, wind energy, as a clean and renewable energy source, has attracted more and more attention from countries around the world. European countries, the United States and China have all given strong support and promotion in their own energy planning. As a leader in the wind power industry, Seco Tools can not only provide high-quality tools and professional processing technology, but also always focus on providing overall solutions for metal cutting needs. In the long-term cooperation with famous wind turbine parts manufacturers all over the world, Seco has accumulated rich experience and strictly meets the almost "harsh" processing requirements of wind power parts manufacturers.

The working environment of the fan unit is harsh, and many factors such as fatigue resistance, reliability and vibration absorption have extremely high requirements. For wind turbines, gearboxes, wind turbine hubs, wind turbine bearings (slewing bearings and gears), wind turbine spindles, and wind turbine bases are all extremely important working parts. At the same time, they are also parts that are difficult to process, require high precision, and have a large processing volume. Seco provides a series of process solutions to help users in the wind power industry stand out in the fierce market competition.

The wind turbine gearbox is one of the important components of the wind turbine. Because the wind turbine installation site has complex working conditions and high requirements on reliability and service life, the gearbox body must have sufficient rigidity, appropriate 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 huge in size, requiring hundreds of hours of precision machining. Parts are processed by high-precision double-table horizontal boring and milling machining centers.

Machining types of wind turbine gearboxes include milling (corn milling cutter and three-sided edge), drilling (Perfomax series) and boring (bridge plate boring head). It is worth mentioning that the diameter of the connection hole of the gearbox exceeds 2m, and its tolerance requirement is H7, which is quite difficult to process. Seco's Graflex bridge plate boring head standard products cover the diameter of 204~2155mm; Jumbo (JUMBO) bridge plate boring head, ※The large diameter can reach 3200mm. They are all composed of high-strength aluminum alloy (Fortal) and steel interface, taking into account the needs of flexibility, body weight and rigidity. In fine boring, it can meet the precision requirements of IT5 and Ra0.6, and the size adjustment is also extremely convenient, which can be completed directly on the machine tool. At the same time, the modular design can also meet the process requirements of large-diameter outer circle turning and back boring. For example, the A731001Jumbo bridge boring tool uses TCMT16T308-F2TK2000 inserts for rough boring, the cutting linear speed Vc reaches 150m/min, the feed speed Vf reaches 25mm/min, and the cutting depth ap reaches 5~6mm. The fine boring adopts CCMT09T304-F2TK1000 insert, the cutting linear speed Vc reaches 120m/min, and the cutting depth ap0.3mm. These high-performance cutting parameters can not only ensure the customer's extremely high part accuracy, but also greatly reduce the customer's production cycle.

The wheel hub is also one of the important components of the wind turbine. Its structure and stress deformation are complex, which will directly affect the normal operation and service life of the wind turbine. Therefore, it has the characteristics of high strength, good reliability, long fatigue life and strong vibration absorption to meet the working conditions of -20℃~40℃. The common material is as-cast ductile iron with low temperature and high impact toughness. The main types of machining for wheel hubs are milling and drilling.

Wind power hubs are huge and generally have a long processing cycle. A customer once encountered such a machining problem: even though all of its machines were running at full capacity, it was not able to complete production tasks on time. In order to help customers overcome difficulties, Seco specially designed a non-standard indexable forming tool with a diameter of 360mm and R85mm, supplemented by 335.19-1207EN2R85-D09, F40M insert, the cutting line speed Vc reaches 200m/min, and the feed per tooth is Quantity fz0.14mm, cutting depth ap1~2mm, the production efficiency is greatly improved, the production cycle of this wheel hub is shortened from the original 30h to within 16h. The customer was able to deliver the goods smoothly and avoid major losses.

Seco's DoubleOctomill R220.48 face milling cutter is ideal for wheel hub milling. The inserts of the double-eight-sided milling cutter are designed with a positive rake angle, and each insert has 16 cutting edges. The same milling cutter can meet the application of roughing and finishing, and has unmatched economy and versatility.

The processing of wind power components also includes fan spindles, fan bases, connecting flanges, fan towers, planet carriers, fan blades, etc. For the machining of these parts, Seco has complete solutions for turning, milling and hole machining. Seco Tools adheres to the concept of "becoming a strategic partner of customers" and is committed to improving processing efficiency and competitiveness for customers.

"High-energy rate processing" has become the focus

The remarkable development of China's economy is continuing, and it is not an exaggeration to describe it as a shortage of supply. The power supply required for the rapid progress of the railway network and building construction is definitely in a state of shortage. However, if a large number of machinery and equipment are introduced, the investment cost will be very large. ※ Nearly customers are increasingly demanding "high-efficiency production" and "high-efficiency production" with existing equipment.

Since the temperature of the generator blade is very high during operation, the material of the generator blade is mostly made of heat-resistant alloy. Moreover, due to its complex shape, not only turning tools, but also various types of tools such as drills and end mills are used in the machining process. Sumitomo Electric Carbide has AC500 series for hard-to-cut materials in turning inserts, MD type multi-purpose drills for hard-to-cut materials in drills, and GS milling cutter series for hard-to-cut materials in end mills. There are stocks in stock, and the corresponding sizes are also quite rich, which can fully meet the complex processing requirements of customers. The above-mentioned tools are all special grades developed for machining difficult-to-cut materials, so they can exhibit excellent performance in terms of wear resistance and chipping resistance.

The remarkable development of China's economy is continuing, and it is not an exaggeration to describe it as a shortage of supply. The power supply required for the rapid progress of the railway network and building construction is definitely in a state of shortage. However, if a large number of machinery and equipment are introduced, the investment cost will be very large. ※ Nearly customers are increasingly demanding "high-efficiency production" and "high-efficiency production" with existing equipment. Therefore, Sumitomo Electric's recommended plan for cemented carbide is the following products with the keyword "high energy rate machining".

Turning: For ultra-high feed machining greater than f=0.5mm/r, the SE and GE types of high-energy rate chip breakers with excellent chip handling are recommended. When the feed requirement is higher (~0.8mm/r), the wiper type LUW and GUW are recommended.

Milling: It is recommended to use the high-feed milling cutter MS1400. Although the depth of cut cannot be greater than 1.5mm, the feed can correspond to 2mm/edge.

Drilling processing: The newly developed J-shaped chisel edge thinning improves chip handling, and with the special chip flute shape, it can also exert excellent chip discharge performance during high-feed machining. In addition, the use of new PVD coating and DEX coating has achieved a longer life. Carbide multi-purpose drills GS/HGS type are recommended here. If the hole diameter exceeds 12.5mm, it is recommended to use the SMD type drill with replaceable head.

High hardness material processing

For high-speed/high-energy-rate machining of high-hardness materials, there are 4 types of coated CBN materials according to different applications. BNC100 is recommended for high-speed/continuous machining, BNC160 is recommended for weak interrupted machining, BNC200 is recommended for general high-energy rate machining, and BNC300 is recommended for strong interrupted machining. In addition, the wiper series is recommended for high-feed machining or high-precision machining.

The slewing ring is a typical difficult-to-cut part in wind power components. Depending on the capacity (size) of the wind turbine, there are various sizes, and the slewing ring with a diameter of more than 2m is particularly difficult to machine. In particular, when the bearing surface is processed after quenching (hard turning), the machining accuracy is strict, the tool life is short, and there are many mounting holes.

The first recommendation when machining the bearing surface after quenching (HardTurning) is BNC160, which has excellent wear resistance and can be used for machining large-sized workpieces. If high-speed machining is required, BNC100 is recommended. Our company has prepared 3 kinds of cutting edge treatment for various CBN materials, and you can choose the appropriate cutting edge treatment according to the damage degree of the tool and the required surface roughness.

Mounting hole processing

The installation hole of the slewing ring is generally about φ25mm, and the hole depth is about 100mm. When machining these holes, it is recommended to use the WDX type shown on the right. Each insert has 4 corners, which is economical and economical. ※A suitable insert chipbreaker has good chip discharge when machining deep holes with L/D=5. However, if the hole accuracy is required to be less than ±0.15mm, the aforementioned SMD type is recommended.