China's PCBN tool production in the world today, cubic boron nitride production growth rate of 15% to 20%, while China's 1990 CBN production is about 112,600 carats, in 1992 it reached 415,000 carats, in 1997 was 750 Ten thousand carats. Among them, CBN for manufacturing tools accounts for about 50%. Although the research and development of CBN tool materials in China is relatively fast, the annual output of domestic super-hard composite blades is only about 1/10 of that of General Electric Company of the United States. Annual production of PCBN tools: 7,000 in 1996, 13,000 in 1997, and 20,000 in 2000.
The market and economic benefits of PCBN tools As a new tool material for the 21st century, PCBN tools, its use has shown great economic benefits, which has attracted the attention of all industrial countries in the world. The development and utilization of superhard material tools is one of the keys to maintaining technological and economic advantages in advanced industrial countries such as the United States. However, due to its high tool cost and the user's lack of understanding of this new super-hard material tool, the domestic application of PCBN tool is still in the trial and pending development stage. For most users, it only happens in production. PCBN tools are only considered when using other tool materials that do not solve the problem or when PCBN tools are used in the introduction technology.
PCBN tools are mainly used in the domestic market: automotive, oil exploration, mining companies, related steel pipe plants, power plant equipment and steam turbine plants, and other types of machinery plants. At present, the potential domestic market has:
FAW Group introduced nearly 100 sets of CNC machine tools for the synchronous gearbox production line of Hino technology and the localization of more than 200 “second-hand†equipment for the production of automatic parts for the key parts of the US “Chrysler 488†engine. The US Chrysler 2.2L engine costs $600, and the tool cost is $12.08, which is about 2%. The proportion of FAW Group is 0.58%. At the same time, it also brings the problem that the tool level is relatively backward and it is difficult to stabilize the manufacturing quality. The German-made cylinder bore double-shaft boring machine imported from the group can not supply the product. It is replaced by the AT6 hot-pressed ceramic tool of Jinan Metallurgical Research Institute. The cutting speed is only 497m/min. In addition, the British cylinder head gun hinge Catheter hole 镗 valve seat 12 shaft 镗 hinge automatic line random gun reamer, replaced with cemented carbide gun reamer produced by Baicheng Hydraulic Parts Factory, PCBN boring tool replaced by Jinan Metallurgical Research Institute AT6 hot-pressed mixed ceramic tool, Japanese surface spray Molybdenum synchronous ring car oil line CNC machine tool random Hitachi ultra-hard blade, replaced by ZK10-UF blade of Zigong Cemented Carbide Factory. These problems reflect that domestic PCBN tools are difficult to adapt to different cutting speeds and materials, and can not adapt to automobile manufacturing process. In the model, specifications and varieties to be supplemented development, quality also needs a previous grade. According to statistics, in 2000, China's annual automobile production needs 150 to 200 billion yuan of supporting parts. Only maintenance of automobile maintenance requires 50 billion yuan of spare parts. Many of these parts require PCBN tool processing, which gives development of PCBN tools. Provides a wider space.
PCBN tools can successfully perform a hard finishing process, which can replace the grinding process in addition to saving on the use of cooling lubricants and the economic and ecological advantages associated with them. Ford uses a hard finishing process instead of a grinding process, which saves 50% on investment and shortens the production cycle. It replaces 11 grinding machines with only 5 CNC lathes. China has more than 400 grinding machines dedicated to bearing production, and bearing exports have been showing good momentum, and supply is in short supply. At present, the processing of the inner and outer rings of bearings is mainly processed by ceramic tools. The PCBN tools have not been effectively developed. For example, the use of PCBN tools for hard cutting of bearing steels will have economic benefits. It has reached several billion yuan.
About 50% of ceramics for electrical and electronic devices and ceramic-made parts used as structural materials and tool materials need to be machined. The annual diamond grinding wheel used for processing ceramics in China amounts to $112 million. If it is replaced with superhard tool materials. Engineering ceramics, to achieve the use of cars, the economic benefits are considerable.
High-speed milling of molds and cast iron materials. According to the ISTA (International Special Tooling Association) statistics on the world mold market in the 1990s, the United States is close to 140 billion US dollars, Europe is more than 100 billion US dollars, Japan is more than 12 billion US dollars, South Korea is more than 1.3 billion US dollars, and China is more than 1.1 billion US dollars. The output value is about 900 million US dollars, the import value is about 285 million US dollars, and the export value is about 73 million US dollars. The Hong Kong region has more than 1.2 billion US dollars, and the Taiwan province has more than 700 million US dollars. The production cycle of high-speed milling of molds is 1/3 of that of traditional electric machining methods. For example, when a forging die of crankshaft is made using die steel with hardness of HRC50, it is found that using high-speed CNC milling machine takes only about 20 hours, and EDM is used. However, it takes 64 hours to manufacture a steel die-casting mold with a socket outer casing. If the electric discharge machining method is required for 50 to 60 hours, and high-speed milling is used, the manufacturing time is reduced to 14 hours. In the mold processing, the use of PCBN tools for processing is very good.
Scope of application and development trend As an excellent super-hard material, PCBN has developed rapidly in industrialized countries and has been widely used. For example, in the United States, Japan, Germany and other countries, a large number of automotive manufacturing and difficult-to-machine materials have been processed. The use of PCBN tools is steadily achieved, and both have achieved good processing results and great economic benefits. The development of PCBN in China and its promotion and application are not satisfactory, and it has been in a low level of embarrassment for a long time. The statistical results show that the annual consumption of PCBN cutters in the United States in 1996 was 600 million US dollars. In contrast, the annual demand for automotive industry, which accounts for more than 90% of China's PCBN tool usage, is only about 1 million yuan. Less.
There are inherent disadvantages affecting the promotion and application of PCBN tools. In 1992, China's PCBN production was 415,000 carats, only 1% of Russia's output. At the same time, the application ratio of CBN and diamond in China is extremely unreasonable. In 1992, the ratio of CBN to diamond production in China was below 1/240, while the industrialized countries in the same period. It is about 1/10. The rapid development of the diamond industry has largely benefited from the processing of some widely used hard and brittle materials such as cemented carbide, glass, ceramics and stone. Compared with diamond, there is no such advantage in the application of PCBN tools. PCBN tools are mainly used in the cutting of iron group metals. For a long time, people have been accustomed to using ordinary abrasive tools to complete the processing of these materials. In order to make PCBN tools not only in the field where ordinary abrasives are difficult or difficult to process, but also to replace the traditional processing status of ordinary abrasives, it is necessary to greatly improve the application technology level of PCBN tools in China.
With the continuous improvement of the precision of CNC machine tools and machining centers, and the advancement of localization of automobiles, the application market of PCBN tools will become more and more extensive. In order to further promote the application of PCBN in China, we should do the following work:
According to China's national conditions, appropriate introduction of foreign automation of higher production lines and patented technology, digestion and absorption of foreign PCBN tool use technology.
Strengthen the development of new products of PCBN tools and the promotion of new technologies and new processes, continuously expand the application fields of PCBN tools, improve the overall technical level and market competitiveness of PCBN tool industry, survive by variety and quality, and seek for the use of PCBN tools. development of.
PCBN tool manufacturers should take the road of integration of science, industry and trade, accelerate the process of industrial grouping, and participate in the competition of international markets to promote the development of PCBN tool industry and improve economic efficiency.
Formulate a national unified PCBN industry standard, establish an authoritative PCBN tool monitoring organization, implement product standardization and serialized management, and implement strict inspection and monitoring of product quality.
Strengthen the research on cutting performance of PCBN tool materials and the promotion of related knowledge, provide cutting conditions for users and tool production units, and provide users with correct theoretical guidance. All tool material manufacturers, users and research institutes must strengthen cooperation. , working together for the application and development of PCBN tool materials.