Zhang Chao, the Head of the Tool Management Department, has over seven years of experience in the cutting tool industry. His work primarily involves Volkswagen engine cylinder head hoods and BMW cylinder heads, using tools made from cemented carbide and PCD (polycrystalline diamond). The brands used in his department include Marpa, Changzhou COSCO, and Shanghai Weishi. Annual tool expenditures reach several million yuan. He has worked with both imported and domestic tools, frequently attending training sessions and product launches. Major tool manufacturers he collaborates with include Sandvik Coromant, Kennametal, ISCAR, Walter, Seco, Gaomet, Mapa, and Cobalt. In this article, he shares insights on tool selection, process understanding, and views on tool localization.
Tool Selection
Choosing the right tool material is crucial for effective machining. Common materials include high-speed steel, hard alloys, PCD (diamond), CBN, and ceramics. Each material is selected based on the part's material and machining conditions. For example, PCD is ideal for aluminum alloy parts but not suitable for cast iron due to its poor thermal stability at high temperatures. Heat generated during the process can cause rapid wear on PCD tools when machining cast iron.
Other factors influencing tool choice include the machine’s capabilities, such as internal cooling, cutting fluid concentration, pressure, and tool holder type. Even for similar tasks, different manufacturers offer varied modular solutions that meet the same requirements. A complete tool system includes both cutting tools and auxiliary components like shanks, inserts, and coolant tubes.
Challenges in the Domestic Tool Market
The current domestic tool market is highly imitative, leading to issues like mislabeling and reconditioned blades. Standardization is lacking, and many companies prioritize profit over quality. Popular domestic brands today include Zhuzhou Diamond, Zhengzhou Diamond, Shenzhen Zhongtian, Sichuan Sentai Yingge, and Zigong Tools. Despite growth, there are still significant gaps compared to imported tools, especially in precision and consistency.
Common Issues in Tool Usage
Many companies face challenges in tool usage, often due to poor setup or lack of expertise. Small enterprises typically use low-cost tools without dedicated tool specialists, leading to improper handling and increased failure rates. For instance, mismatched tap and drill sizes can result in broken tools, increasing costs and downtime.
Deep hole drilling is another challenge, especially when dealing with small-diameter, deep holes. These require careful planning, often starting with a pilot tool before using a deep-hole drill. However, breakage remains a common issue. Some solutions involve milling a surface first, but practical improvements are limited.
Localization Challenges and Suggestions
Domestic PCD tools have reached a level where their performance is comparable to imported ones. Localization is becoming a trend in large-scale engine production due to lower costs and faster delivery times. This presents both opportunities and challenges for local manufacturers.
However, domestic tools still struggle with consistency and innovation. Many focus on imitation rather than R&D, leading to weaknesses in precision and process control. While 3D manufacturing is advancing, it cannot replace traditional methods in the short term. A complementary approach may be more effective.
In conclusion, domestic tool manufacturers should invest in R&D, improve quality, and provide better customer support. Building strong brands through innovation will help them compete globally and contribute to the development of China’s manufacturing sector.
