Discussion on Localization Application of Cutting Tools in Power Generation Equipment Manufacturing
At present, China's power generation equipment manufacturing industry is developing very rapidly. The manufacture of large-scale supercritical, ultra-supercritical and mega-scale nuclear power equipment has spread throughout Northeast, Southwest, East China and North China. Since large-scale units generally work under high-temperature and high-pressure conditions, many product parts use difficult-to-machine materials such as high-strength alloy steel, stainless steel, and nickel-based superalloys, titanium alloys, and the cutting performance of these materials is poor. In the past, the use of imported tools in large quantities was an important measure taken by power generation equipment manufacturers. Because the quality of imported tools is relatively stable, the tools currently available from domestic companies do not exist in terms of performance, quality, efficiency and longevity. Small gap. However, imported tools are expensive, some are 6 to 7 times higher than domestic similar tools, and the delivery period is long, which cannot meet the requirements of users. In particular, the current power generation equipment manufacturers have reduced the variety, quantity and funds of imported tools as an important measure to achieve the goal of reducing costs and increasing efficiency. From the perspective of large steam turbine plants that manufacture power generation equipment in the past few years, the annual import volume of tools has reached 1-2 million yuan (RMB), which is not small. Therefore, in order to reduce production costs, localization of tools should be said to be an important measure. But how is the feasibility of localization of tools? Will the use of domestically produced tools affect the processing quality of the products and affect the production schedule? Gu Zuwei, consultant of Harbin Electric Group (Qinhuangdao) Heavy Equipment Co., Ltd., gave a detailed answer in an interview with the metal processing online reporter. Consultant of Harbin Electric Group (Qinhuangdao) Heavy Equipment Co., Ltd. Gu Zuwei From the recent examples of the use of domestically produced tools to replace imported tools in major steam turbine plants and motor factories in the country, the selection of high-quality domestically produced tools will not affect the processing quality and progress of the products, and basically meet the needs of production. The main reasons are some national key tool factories, such as Zhuzhou Diamond Cutting Tool Co., Ltd. (hereinafter referred to as Zhu Drill), Xiamen Golden Heron Special Alloy Co., Ltd. (referred to as Xiamen Golden Heron), Harbin No. 1 Tool Factory (abbreviated as Ha Yigong) and Harbin In recent years, the company has deployed many world-class processing equipment and testing instruments, and has also strengthened the training of technicians at home and abroad and the development of new and efficient tools. Localization of tools At present, the main ways of localization of tools implemented in China are: Innovative homemade Typical examples are Harbin Steam Turbine Works (abbreviated as Haqi) and Dongfang Steam Turbine Works (referred to as Dongqi). The second plant originally processed steam turbine rotor longitudinal tree wheel grooves. The tools are basically imported, and Harbin orders various specifications from abroad every year. The capital of the wheel groove milling cutter is about 30 million yuan. However, the second factory has been innovated and self-made by adding high-precision imported equipment and instruments. The wheel-slot milling cutters developed and produced so far have basically met the needs of factory production, some of which The tool design and key manufacturing technology have been patented, and the comparison of efficiency and life in use with similar foreign tools is no less inferior, and some coated tool life exceeds imported tools. For example, the vertical tree wheel groove milling cutter developed by the second factory (see Figure 1 for structural form) has been appraised by experts and is consistently considered to have reached the level of similar foreign tools. 2. Cooperative development Longitudinal tree root broach is the key tool for processing shipbuilding, nuclear power generators and other products. This type of tool has high manufacturing precision (profile and shape tolerance), requires small tool deformation and long service life, and imported tools are expensive (up to several 100,000 yuan / group), after the cooperation of Harbin and Zhejiang Hengfeng Tools Co., Ltd., the vertical tree type root broach was finally developed and applied to production. Using the same method, the SM35N grade indexable milling insert of stainless steel material developed by Haqi and Mudanjiang Tools Co., Ltd. has achieved remarkable processing results, and its blade has reached the level of similar foreign tools, and the material of the grade It has obtained national patents and applied it on milling parts of stainless steel materials throughout the country. The ultra-fine grain solid carbide milling cutter jointly developed by Shanghai Steam Turbine Works and Xiamen Golden Heron has been developed, tested and improved over a year. Efficiency and tool life basically reach the same type of tools abroad. Zhuxi recently cooperated with Harbin Electric Group (Qinhuangdao) Heavy Equipment Co., Ltd. to carry out face milling on the nuclear island component surfacing nickel base alloy material. The processing efficiency reached the cutting level of similar tools of a German company, but the price is only One-third of imported knives are popular with operators. 3. Purchase domestic tool factory famous brand tools Many domestic tool factories have developed a number of new advanced and efficient tools in recent years, and have improved them by first testing (trial or comparison with foreign similar tools). Finally, they have passed the verification and are considered by the factory to meet the product processing requirements. After ordering, such as the hard alloy shallow hole drill produced by Haliang, the large diameter cemented carbide rough surface milling cutter produced by Ha Yigong, the aluminum high speed steel wave edge end mill developed by Southwest Tool Factory, Taiyuan tool The factory's interchangeable head-type spiral end mills, etc. These tools are high-quality brand-name tools of famous domestic tool manufacturers. Their processing efficiency and cutting performance have basically reached the level of similar foreign tools, such as the generator developed by Ha Yigong. Rotor groove large-diameter disc-shaped indexable milling cutter has also replaced imported tools for rotor groove processing in domestic generator plants. The structure of the domestically produced high-efficiency milling cutter typical of each of the above plants is shown in Figs. 2 to 4 . Tool localization promotion suggestions From the above examples of use, many tools developed in China have been properly processed due to the combination of tool material selection, structural improvement, manufacturing technology breakthrough, and reasonable selection of geometric parameters, which has improved the overall tool manufacturing level in China. . At present, some of the tools manufactured in China can replace imports, which also gives us confidence to further develop the localization of tools, so that we can see that the localization of tools in the power generation equipment manufacturing industry is promising. In order to accelerate the development and promotion of domestically produced tools on a larger scale and occasion in the power generation equipment industry, it is recommended to take the following necessary measures: (1) Led by the China Knife Association or the User Industry Association, for the common products, processing key or common technologies of the industry, the tool production, scientific research (institutions) and users will jointly discuss the tool localization plan and formulate practical and feasible Measures are resolved in batches and in phases according to urgent needs and feasibility. (2) In order to accelerate the research and development and promotion speed of domestically produced tools, the cooperation of production, learning, research and use units should be based on user units, because user units need these highly efficient new tools to solve the bottlenecks affecting production, and at the same time The tool test must be combined with the actual production. After the site acceptance, the tool can be officially handed over to the production application. (3) The development and promotion of domestically produced tools must be inhabited. In principle, the design and manufacture of new tools should be mainly handled by domestic tool factories and research institutes (institutions), but some projects can provide conditions and design and manufacturing capabilities. The user unit is responsible, but the two parties can also participate in cooperation as needed. For new tools developed by domestic tool factories, the tool factory should provide technical delivery and service to the user units, and provide technical training for the relevant process, technical personnel and operators to enable them to use the new tools correctly and reasonably. (4) For tools that are difficult to machine (high-temperature alloy, titanium alloy, stainless steel), priority should be given to research and must be achieved after obtaining practical processing results. This article is from the exclusive report of Metal Processing Online (). No individual or group unit can be reprinted or copied without permission! If necessary, please contact the Metal Processing Online Editorial Department! Cable Seal,Security Seal,Container Seal WENZHOU GCSEAL CO. LTD. , http://www.sealsshipping.com
