Discussion on the development of CNC tools in China

Any strong country must have a strong manufacturing base including metal cutting. Throughout the 21st century, metal cutting is still the dominant method in the mechanical manufacturing industry. Cutting (including grinding) accounts for more than 90% of the total, and tool consumption costs account for 2% to 5% of manufacturing costs. Whether it is a special machine or a flexible manufacturing unit, CNC manufacturing systems are the mainstream in today's metal cutting industry. In CNC manufacturing systems, tool shanks and cutting tools can account for 10% or more of the total system investment. The efficiency and capabilities of flexible manufacturing units and special equipment systems depend to a large extent on the state of the art of the tool and tool assist system employed.
I. Global machining industry, machine tool market and cutting tool industry The global machine tool industry market has become both active and over-competitive. In the frequent exchanges between trade and technology, the differences in competitiveness between developed and developing countries are also increasingly confusing. At the same time, the demand for low-cost, high-performance, high-quality, and faster delivery of products has made the development of new products and new technologies unprecedented in development speed and space. 
In recent years, the consumer market for metal cutting and metal forming machine tools has been reduced from $39 billion to $36 billion, one of the reasons being the widespread use of machining centers. The number of processing centers in the United States has increased from 11% in the early 1980s to 25% today. Worldwide, it is expected to reach $6.6 billion from $4.5 billion between 1998 and 2005. At the same time, the traditional milling machine market is expected to decline from $1.6 billion to $1.5 billion over the same period. In the next decade, more than 50% of manufacturing demand for manufacturing may be completed by machining centers. 
The market share of cutting tools in the world is about $10 billion, and the consumption of tools is expected to increase by more than 3% per year in the near future. In 1998, the world cutting tool market consumption ratio was as follows: reamer 2%, broach/hob 7%, alloy end mill 7%, tap 6%, turning tool 23%, high speed steel end mill 7%, boring tool 8 %, saw blade 11%, drill bit 12%, milling tool 17%. As the concept of high-speed machining is widely accepted, the global demand for CBN and diamond cutting tools is expected to increase from 5% in 1998 to 11% in 2005.
In 2000, many tool manufacturers found that the demand for carbide tools increased by more than 40%. This growth may indicate that HSS tools are increasingly being replaced by cemented carbide tools in many manufacturing areas and have lost their former glory. 
Second, the status quo and development of foreign metal cutting tools 1. Cutting tool materials and coating technology
Different types of cutting tool materials have progressed, including high speed tool steel, cemented carbide, cermet, ceramic, polycrystalline cubic boron nitride (PCBN) and polycrystalline diamond (PCD). High-speed tool steel (HSS) is a high-toughness tool material that can be fabricated into sharp cutting tools of various complex geometries and sizes that cannot be made with other materials. The high wear resistance CBN and PCD superhard materials are suitable for high speed and small feed processing. Between these two materials are cemented carbide, cermet and ceramic tool materials, which are widely used in the processing industry for a variety of cutting speeds and feed requirements. 
Synchronous with tool materials, chemically coated CVD and physical coating PVD technology, today almost 75% of carbide tools are coated tools, of which CVD coatings account for about 80%. 
Contemporary CVD coatings are characterized by a multilayer coating. Its coating structure includes TiCN, TiC, TiN, ZrCN and Al2O3. Thanks to the good control of the CVD process, tool manufacturers now offer consistently stable coating tools from 5μm to 20μm thickness, as well as multi-layer coatings for single-layer coatings up to 0.2μm for high-hardness workpieces. Alloy tool. 
The PVD physical coating technology has made commercial coatings with a coating thickness of 2 μm to 5 μm on cermet and cemented carbide substrates. Typical commercial coatings include TiN, TiCN, TiAlN, CrN, TiB2, and multilayer coatings such as TiN/TiAlN. The PVD coating process has the unique advantage of providing ultra-fine grain, smooth, low-friction and high-temperature thermal cracking to sharp cutting edges. 
Nano-PVD coatings (each coating thickness is even as thin as 2 nm, such as TiN/TiAlN coatings) and nanocomposite coatings (TiN or TiAlN nanocrystals are embedded in the matrix of Si3N4) are in the development stage. 
The newly developed cemented carbide tool coatings include a combination of an external PVD TiN or TiAlN coating with an internal CVD TiN/TiCN/TiN coating. The internal CVD coating provides excellent substrate adhesion and wear resistance, while the external PVD coating provides a strong, ultra-fine grain, non-fragile, smooth surface finish. This CVD-PVD combined coating helps to extend the tool life of the tool during interrupted cutting of difficult-to-machine metal materials and steel machining. The new PVD TiCN or TiAlN coated cermet tools have improved reliability in the finishing and semi-finishing of turning and milling steel, stainless steel and cast iron. Their chemical composition is stable, with high red hardness and the ability to maintain high-speed cutting, ensuring reduced dimensional tolerances of machined parts, good surface quality, high efficiency and longer tool life. 
Ceramic knives also have important developments. Conventional Al2O3 white ceramic tools have been replaced by ultrafine particulate Al2O3-TiCN black ceramics. Its high strength and high wear resistance are suitable for turning and boring of cast iron, alloy steel, tool steel and stainless steel with hardness up to 60HRC. PVD TiN coatings have contributed to the further improvement of the wear resistance of these tools. The development of silicon carbide-reinforced Al2O3 ceramics has made high-speed processing of nickel-based alloys a reality. 
The high thermal conductivity and toughness of pure Si3N4 based ceramics are used for high speed machining of cast iron (engine cylinders, brake drums, brakes). The CVD Al2O3 coating allows Si3N4-based ceramics to be used in the processing of gray-mouth ductile cast iron. 
As a complementary tool material for reinforced Al2O3 cermets, SIALON sialon polymer materials have revolutionized the productivity of nickel-based alloy processing. For example, processing superalloy materials at a surface speed of 3500 sfm (feet per minute) 718 chrome-nickel alloy and PH stainless steel is a strong evidence of a SIALON sialon as a tool material. 
High-speed machining requires super-hard cutting tools. Among them, polycrystalline diamond (PCD) is suitable for processing very high abrasion resistant high silicon aluminum alloy (including Si >12%), non-ferrous materials and composite materials; polycrystalline cubic boron nitride (PCBN) is suitable for hard ferrous materials Turning, boring and milling. 
A recent development in the field of coatings has been to firmly coat pure diamond films on cemented carbide substrates by means of CVD coating. Diamond-coated carbide tools offer the performance of PCD tools and the flexibility of the tool design and use process by means of mold-forming chipbreakers. 
Cutting tool manufacturers are meeting this need by developing solid lubricants like MoS2 or WC/C. When combined with PVD TiAlN coated tools and solid lubricants, it significantly improves the performance of metal cutting, especially for drilling and tapping of steel and aluminum alloys. 
Today's applications of super-abrasive cutting tools such as diamond tools for non-ferrous metals, CBN tools for high-speed cutting and grinding of ferrous metals have become exemplary. Although the cost of purchasing tools is 20 to 50 times higher than that of conventional tools, it is quite cost-effective to use such super-abrasive tools because it has a service life of at least 100 times longer than other tools. 
2. Design of cutting tools
High-speed machining users require dynamic balancing of cutting tools to reduce tool balancing time, extend tool life, improve the accuracy of machined parts and increase spindle bearing life. 
Drilling and boring tool systems are also constantly improving and developing. Replaceable bit alloy inserts have become a trend, and the drill bit can be replaced after the drill tip is worn without the need to remove it from the tool holder. Such drill bits are now available in the market as small as 0.5 inches in diameter. Tool manufacturers are currently manufacturing such drills with a diameter of 0.25 inches. A high-speed precision fine-tuning file system with a 0.5μm adjustment mechanism has also entered the market. 
For titanium metal processing with high metal removal rates, the newly developed heavy-cut end mills can accommodate up to 72 indexable inserts. This tool is designed to provide a wide variety of tool helix angles and axial edge inclinations by lap joints of individual blades. This change disturbs the resonance during cutting, so that deep milling can be performed without resonance. 
3. Tool system structure
Manufacturers are increasingly interested in the use of HSK tool systems to support high speed machining. Although this tooling system was initially expensive, HSK seems to improve the rigidity and stability of the system as well as product accuracy during high-speed machining and reduce tool change time. Tool suppliers are continually improving the HSK tooling system to accommodate machine spindle speeds of up to 60,000 r/min. 
4. Tool quality and accuracy
20 years ago, the accuracy of CNC machines reaching 25 μm was considered the limit. Nowadays, the machine tool manufacturing accuracy is close to 1/10 of the original precision value. At the same time, SPC control and online inspection have a good control of the consistency of the quality of the parts being machined. There is no longer a need for grouping options based on part machining errors when assembling parts. High-precision machine tools and precision products processed by them have been reported to have played a decisive role in driving productivity in the United States over the past 20 years. Although many factors have contributed significantly to the significant improvement in machining accuracy, data collection, metering equipment, and application of process standardization have played a key role in further improving the precision of manufacturing. 
5. Cutting Tool Manufacturers and Services
In recent years, there have been some comprehensive tool manufacturers. Some major cutting tool suppliers are more focused on developing their core business and expanding their business through restructuring and acquisitions. Sandivik has acquired 35 companies in the past decade and in 2002 completed acquisitions of three key companies, Walter and Valenite. The same is true of the US Kenner Company. Cutting tool manufacturers are able to offer a wider range of products and services by streamlining off-the-shelf sales and service channels. 
The world's leading tool manufacturer's business philosophy is to actively provide quality services to customers' productivity improvement. By working closely with R & D institutions (research and development), we create unique solutions for our customers. Affordable products and services, and a partner for improving customer productivity. 
Third, the difference between the domestic and international metal cutting tool industry 1. Comparative Analysis of Modern Metal Cutting Tools and Traditional Tools
We call the "CNC tool", especially the tool and tool aid system used in conjunction with advanced and efficient CNC manufacturing systems such as machining centers, CNC lathes, CNC boring and milling machines, and CNC drills. It includes integral alloy tools, superhard tools, indexable inserts, tool assist systems, indexable tools, superhard materials and coating technology. These should belong to the category of modern metal cutting tools. Its technical level, performance and quality directly affect the production efficiency and quality of processed products of millions of expensive CNC manufacturing systems in China, which directly affect the production of machinery manufacturing industry in the whole country. Technical level and economic benefits. The characteristics of the analysis are shown in the table below.
Comparative analysis of modern metal cutting tools and traditional tools. Tool materials:
Traditional tools - common tool steel, high speed steel, welding alloys Modern cutting tools (CNC tools) - Carbide, Co-HSS, ceramics, CBN, PCBN, PCD, powder metallurgy high speed steel, superhard material + coating Tool hardness:
Traditional tool - high speed steel: 60HRC
Modern cutting tool (CNC tool) - up to 90HRC Hardness of processed product:
Traditional tools - generally ≤28HRC
Modern cutting tools (CNC tools) - turning and milling can reach more than 60HRC of hardened steel. Cutting speed:
Traditional tools - processing steel, cast iron: Vc ≤ 30m / min (70 ~ 80m / min)
Modern cutting tool (CNC tool) - machining steel, cast iron: indexable coating alloy blade: Vcmax = 380m / min; CBN blade: Vcmax = 1000 ~ 2000m / min; processing aluminum alloy: Vcmax = 5000m / min
Tool manufacturing accuracy:
Traditional tools - 10 micron (0.0xxmm)
Modern cutting tool (CNC tool) - micron (0.00xxmm)
Tool and tool system speed:
Traditional tool - 2000r/min
Modern cutting tool (CNC tool)—60000r/min
Key technologies:
Traditional tools - general mechanical manufacturing, cutting principle, heat treatment, special machine, special tooling and process modern cutting tool (CNC tool) - CAD, CAM, material science, mechanics (dynamic balance, dynamic stiffness, etc.), precision machinery manufacturing, CNC machining technology , powder metallurgy, nanotechnology, coating technology and CAX, ERP and other computer information management technology tool consumption costs and metal removal:
Traditional tools—high-speed steel tools account for about 65% of all tool costs, and cut-off chips account for only 28% of total cuttings.
Modern cutting tools (CNC tools) - indexable tools, alloy tools and superhard tools account for 34% of all tool costs, and cut chips account for 68% of the total chip volume.
Key equipment for tool manufacturing:
Traditional tools - special planes and general machining equipment; rigid production of modern cutting tools (CNC tools) - CNC machine tools: tool grinding and machining centers, CNC lathes, alloy profiles and blade pressing and sintering equipment, blade deep machining CNC grinding machines Flexible production tools using machine tools:
Traditional tools - general metal cutting machine tools: lathes, milling machines, planers, boring machines, etc. Modern cutting tools (CNC tools) - CNC lathes, CNC milling machines, machining centers, assembly lines, flexible production lines Capital investment and company scale:
Traditional tools - the pursuit of low-cost, large-scale production, unlimited investment in total investment, is a labor-intensive modern cutting tool (CNC tool) - the pursuit of differentiation, multi-variety, small batch, capital investment of more than tens of millions of dollars, is knowledge , technology, talent, capital-intensive sales and markets:
Traditional tools - the market level involves all mechanical processing and maintenance industries; store warehousing, distributors, market mature, ready to use; main competition: price competition modern cutting tools (CNC tools) - with CNC machine tools, Combine with CNC machining technology of processed products to purchase tools, technical supporting sales, store-style market network, distributors, and even professional tool management companies for enterprises; main competition methods: comprehensive cost performance and technical services, reducing manufacturing costs To improve efficiency and human resources:
Traditional tools - industrial workers account for the majority, single technology, special machine production, overall quality requirements are not high, modern cutting tools (CNC tools) - technology development, marketing, technical services, CNC technology workers, finance, management, etc., the majority of talent integration High quality requirements.
2. The status quo of the domestic tool industry
Due to the lack of sufficient understanding of the difference between modern metal cutting tools and traditional cutting tools in China's machine tool industry, the development of CNC tools and CNC machine tools has been seriously out of line in the development strategy for a long time. The level is far from the requirements of modern manufacturing.
According to the 2002 China Machinery Industry Yearbook, 29 key enterprises in the tool industry completed industrial sales value of 1.43 billion yuan in 2002 (RMB current price, which is equivalent to 8.6% of Sandivik's 2002 research and development expenses), with a total loss of 39,960,400 yuan (RMB) ). The average number of employees in the industry is 32,600, the per capita sales value is 43,800 yuan (RMB), and the per capita annual income of employees is 8,626 yuan. More than 95% of domestic tool companies remain at the level of traditional metal cutting tool manufacturing. (The Sandivik Group of Companies had a workforce of 37,000 in 2002 and achieved sales of $5.04 billion.)
3. Domestic CNC tool manufacturing enterprises
The development of domestic CNC cutting tools began in the early 1980s, and was first produced for several machine tool accessory factories for the machining center main equipment. However, due to insufficient investment in technology, capital, equipment and human resources, there is insufficient understanding of modern metal cutting tools, low starting point, slow development over the years, and even facing the threat of being eliminated.
From the mid-1980s to the end of the 1990s, Chengda CNC Tool Factory, Harbin Engineering Numerical Control Co., Ltd., Shanghai Machine Tool Accessories Factory, Zhuzhou 601 Factory, Zigong 764 Factory, etc. are domestic CNC tools, tool systems, indexable alloys. The main production plant for blades. Chengdu Tool Research Institute produces indexable threaded inserts, combing knives and coating technology; Dalian Fuji and other joint ventures to Japan with non-standard shaped tool export products and technical drawings. The rising star is Chengdu Yingge CNC Tool & Die Co., Ltd. and Shaanxi Pinding Cemented Carbide Co., Ltd. 
Over the years, with the joint efforts of many professional CNC tool manufacturers in China, the general precision (10 micron class) and the tool center with indexing speed below 8000r/min have been able to partially replace imported tools. The needs of most CNC machining users are mainly related to tool life, appearance and packaging. The gap between the 601 factory's indexable inserts in terms of product development, cutting performance, market share and imported blades is also gradually decreasing. Chengdu Yingge has a high starting point of software and hardware investment, a new business philosophy and rapid development, making its "EG·NC" brand CNC tools unique in China. Although there is a big gap compared with modern foreign cutting tools, in recent years, every family has made great progress. In order to reduce the price of imported tools on the market, it has contributed to the matching of CNC machining in various industries in China. 
However, these professional and non-professional tool manufacturers have a small technical strength, production capacity and asset size, full productivity and market share compared to any modern tool company in the world. And the production of hard alloy materials, coating technology research and processing, blade manufacturing and tooling, tool system manufacturing are each a camp, "interlaced like a mountain", there is no close joint formation of the cutting tool industry chain, fighting alone, even low prices Low level and low grade competition. 
These companies face many difficulties at different levels: (1) shortage of funds. CNC tooling is a capital-intensive industry with high investment and high starting point; (2) Financial taxes and fees are too high. The state implements production-type value-added tax, and CNC tooling is a high-tech product with high added value. The input tax is small, and the value-added tax is more than 10%. Compared with the developed countries, the consumption-based value-added tax and income-based value-added tax are compared with those in the enterprise. At the beginning of the venture, the tax burden is too heavy, which seriously affects the development speed of the enterprise; (3) lack of core technology and research and development strength, lack of core competitiveness; (4) the crisis of customer trust caused by the low quality of domestic CNC tools over the years, making it a market The difficulty of expansion is increased; (5) the shortage of professional and technical talents; 6) the theoretical and applied research level and experimental methods of tool technology in domestic universities are far behind the world's advanced level, which makes the development of the tool industry lack sufficient technical support and stamina. . 
Fourth, the discussion on the development of CNC tools in China
1. Opportunities and challenges
(1) Environmental opportunities
After China's accession to the WTO, it will become the world's processing center. The competitive pressure of joining the WTO will greatly stimulate the mechanical processing industry to accelerate the pace of technological transformation, improve the efficiency and technology level of the manufacturing industry, and narrow the gap with developed countries. Accelerating the adjustment of product structure has led to continued investment in fixed assets, and the pace of upgrading and upgrading has accelerated. In 2002, the total investment in fixed assets of the whole society broke 4 trillion yuan, reaching 4.3202 trillion yuan, an increase of 16.1% over the previous year, the highest growth rate since 1996. From January to February 2003, industrial production in the country increased by 17.5%.
The production and sales of CNC machine tools are booming. 2002 is another golden year for China's machine tool industry. The annual output of CNC machine tools was 24,803 units, an increase of 31.6% year-on-year; the import of CNC machine tools was 25,097 units, with an amount of US$1.884 billion, an increase of 33.53% year-on-year; In 2003, the number of CNC machine tools will reach 30,000 units, the total output value of the machine tool industry will increase by about 15%, the output value will reach 840-85 billion yuan, and the consumption of metal processing machine tools in China will exceed 6 billion US dollars. In fact, in the first half of 2003, almost all orders for CNC machine tool manufacturing plants in China have been filled, and full-time production of horsepower is underway. A consumer market for machine tools and tools with both production and sales is forming. In addition to the need for new tooling, the increase in machine tool demand has also resulted in continuous long-term tool consumption, providing a very broad space for the CNC tool market. 
The automotive industry is developing at a high speed. In 2002, vehicle production increased by 38.9% compared with 2001. At present, the tools in several domestic automobile production lines are basically dependent on imports. After joining the WTO, the automobile industry is facing the pressure of the car to improve the quality while greatly reducing the price. The localization of tool procurement is an inevitable trend. 
(2) Challenges and threats
1 The continuous influx and price reduction of imported tools China's tool industry has long been facing full opening to the outside world, and the domestic market has long realized the globalization of tool procurement. Foreign tool vendors have entered the Chinese market for more than a decade. The sales network and technical service system have been fully established. There are several offices in major cities in China, with more than 1,000 sales and technical service employees. They have almost monopolized China's high-end tool market with its high-quality products, perfect technical services, and ever-decreasing product sales prices (now the price of imported tools has dropped to almost 2/3 to 1/2 of 10 years ago). In the process of economic globalization, multinational tool companies have occupied increasingly comprehensive advantages in technology, resources, information services, etc., and the strength of domestically produced tools is farther and farther.
2 Taiwan knives - price killer Due to the impact of the international financial environment, Taiwan's tool industry has lost more than 80% in recent years. As a result, they began to hit China's CNC tool market at a low price. Some tool prices are even lower than the price of domestic CNC tools. They are squeezed into the market with low profit and low cost strategies, and they are called price killers in the CNC tool market. 
3 The threat of customer trust Because of the long-term dependence on imports, the gap between domestic CNC tools and imported tools in technology, service, quality and publicity, the importance of CNC tools in the final product quality of processed products, etc. The trust of domestic CNC tools is very low. Often prefer to spend heavily on imports rather than risk saving money to buy domestic knives. After all, hundreds of thousands or even tens of millions of CNC machine tools cost tens of yuan to several hundred dollars compared with the cost of tool purchase, if you do not have full control, you would rather choose imported tools. Automotive manufacturers and aerospace companies are typical examples. Today, when domestically produced tools are not mature enough, they will hardly provide opportunities for domestic tools to be tested on CNC production lines. 
4Customer bidding ability threatens to join the WTO, global procurement will make a large number of reasonable prices, mature cutting tools continue to flood into the Chinese market, allowing customers to have greater choice and bidding capacity, so that the domestic CNC tool manufacturer market Development is more difficult. 
5 The own industrial chain is incomplete, the supplier relies on the risk. The domestic CNC tool enterprises are too small in production and operation. They do not form a close joint of their own cutting tool industry chain. In particular, the tool system manufacturers do not produce blades, and the blade manufacturers do not. Production tools are almost entirely dependent on suppliers; there is no real industry alliance within the industry. 
6 Professional technical talents are scarce CNC cutting tools are technology-intensive, knowledge-intensive, talent-intensive industries, and their development is highly dependent on talents, especially when the company's production and operation scale is small. Domestic CNC tooling technical talents, management talents, marketing talents, and CNC machine tool operators are all scarce. The general training period is 3 to 5 years. However, colleges and universities do not have the responsibility to train CNC CNC machining and CNC tooling professionals. They all rely on the company to spend a long time to train, often with half the effort, and may not be able to retain. 
7 The industry level is low and lacks core competitiveness The overall comprehensive strength of China's tool industry is far from the developed countries. 
2. China's CNC tool development countermeasures
(1) To build a management and employee team with realistic and innovative spirit and learning ability. The members of this team must have the know-how of CNC tooling, management experience, and the belief that CNC tools are dedicated to their careers.
(2) High investment and high starting point, rapid development. Accelerate product research and development, build core competitiveness of enterprises, and implement differentiated strategies. In terms of product quality, we must either do it or do it first. Choose your own core products, pursue quality products, narrow the gap with imported tools; product pricing adheres to the principle of high quality and good price, does not fight price war and low cost strategy; technology development imitation plus innovation, self-contained system, has its own original characteristics; focus on packaging And corporate CI planning, enhance corporate image and create a high-quality tool brand. 
(3) Technical service is the pioneer, providing users with CNC machining solutions. Taking advantage of its own technology and low cost of service, compared with the service quality and speed of imported tool manufacturers, we will fight for the market with service; first of all, we must recognize the gap between us and the world's advanced tools, and use our own advanced CNC tool technology and information at home and abroad. Integrate the characteristics of advanced tools at home and abroad, and provide technical and tooling services for different users, and provide users with the option of selecting knives, using knives, reducing costs, and ensuring quality and efficiency. With high-quality technical services and rapid response capabilities to make up for the temporary shortcomings in their tool manufacturing and learn from them. 
(4) Systematic thinking, seeking industrialization alliance and international cooperation, standing on the shoulders of giants to seek their own development. China's tool industry has been developing very early. As early as more than a decade ago, multinational tool manufacturers enjoyed national treatment in advance. There is no access system, and import tariffs are only about 8%. In addition, a large number of smuggling tools and blades impact the occupation of China's CNC. More than 90% of the tool market. In the past few years, the disordered market competition in the tool industry, the pressure of survival forced many tool companies to show their last card - price war, killing you and killing, so that the original profitable tool companies are so badly hurt, unable to do technological transformation and Cultivate talents, use talents and retain talents. The danger of the domestic tool industry is overwhelming. It is not alarmist. 
When China wants to become a manufacturing powerhouse, when CNC manufacturing systems are the mainstream in today's metal cutting industry, when tools and metal cutting machine tools play a very important role in machining, when facing the entire tool industry and the world cutting With the huge gap in the tool industry, China's CNC tool companies should calmly think about differences, quality, brand creation, service, implementation of quality strategy and talent strategy, and actively seek domestic and international alliances to make China's tool industry re-emerge.

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