Technical Director, Supercharger Branch, Donghua Machinery Factory, Datong, Shanxi  Huang Liyun
The main product of our factory is the production of automobile supercharger, including the two processes of casting mold design and production, part casting and processing.
In order to process the mold, our factory purchased a Taiwan Liwei MCV-760AP machining center in 1995. In recent years, with the continuous expansion of the product market of our factory, more and more projects, and due to the continuous improvement of user requirements, the supply cycle requirements are getting shorter and shorter, and the processing speed of the original machining center can no longer meet the needs. In order to meet the needs of the task, only the machine can be rotated, and the personnel are three shifts. Although the production needs are met temporarily, the machining center is overloaded for a long time, which is very unfavorable to the equipment, and the labor cost is continuously increased, which reduces the efficiency of the product and weakens the product. Market competitiveness of products. Due to the large cost of purchasing new high-speed machining centers and the long procurement cycle, the production of the products can not be interrupted during this period. For this reason, the factory requires technicians to innovate and tap the potential, improve the current process, and dig the largest of the old equipment. Potential, to ensure the production needs during the procurement of new equipment and reduce production costs, improve the efficiency of machining center mold processing.
After in-depth analysis of the processing route by technicians, on the basis of research on related companies, innovations were made from three aspects: mold design, optimized programming, and optimized tool selection, and the expected results were obtained, as follows:
1. Innovative module design to reduce the amount of mold roughing
     The original mold processing idea is: First, the square module is cast according to the outer dimensions of the mold, and the six surfaces are milled by a common milling machine to form a square with a certain dimensional precision; then, the cavity is processed according to the programmed processing program on the machining center. That is, stepwise milling from a solid square into a workpiece cavity. In this way, it takes a lot of layering processing from the roughing path, and it takes 2 to 3 days for a roughing of a mold. After investigation, the factory purchased a SD-1318 foam engraving machine, which was first processed into a lost mold with polystyrene foam (a set of lost molds was completed in a few hours), and the cavity was evenly balanced. 2~3mm, then casting the module, after the surface is sandblasted, the machining center is machined by the ordinary milling machine, and the machining of the machining center is 2~3mm. The roughing time of one die is half a day. ~1 day. Processing a set of molds can save 30% to 40% of the time according to the complexity of the mold.
2. Optimize the programming method to avoid the phenomenon of empty knife
The mold processing of our factory has been using Mastercam software. The original rough machining programming uses the most commonly used roughing parallel milling method, and there are many empty cutters. After the module design is changed, we use the contour contouring method in the rough machining programming, and the stepping of the cutting parameters is changed to large, which basically avoids the air knife phenomenon, saves the processing time and improves the processing efficiency. .
3. Optimize tool selection and improve machining efficiency
The original roughing tool was machined with a common R10 ball end mill. Due to the large amount of machining, the blade wears quickly, and one blade has only two cutting edges. After investigation, the Korean KorloyΦ25mm rounded end mill was selected for roughing. Compared with ordinary R10 ball end mills, KorloyΦ25mm round end mills have a significant advantage in surface roughness, and achieve the same high theoretical level of machining residuals, compared with ball end mills. The step size of the round end milling cutter is several times wider, so the total cutting length is shortened, the machining time is greatly shortened, and the machining efficiency is improved. In addition, the rounded end milling cutter has eight cutting edges per milling insert, which greatly saves the cost of the tool.
In summary, after the innovation and potential of the technicians, the original design and process are innovated and improved, which greatly improves the processing efficiency of the machining center, reduces the labor intensity of workers, and reduces the fatigue of personnel and equipment. It played an important role in the timely completion of factory tasks.
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