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Cutting tools let the new energy industry fly high

2019-03-11

The development of the energy industry has always attracted people's attention. In addition to the traditional energy industry, emerging clean energy such as wind power, nuclear power, solar energy and tidal energy are receiving more and more attention. The rapid development of the energy industry is also related to its manufacturing industry. Higher requirements are put forward. Among them, the tool is one of the most critical factors. Under the premise of ensuring the processing quality and production efficiency, for the energy industry, especially the new energy industry, how to choose the tool that suits you is our concern. of.

Use deduction and induction to get the most suitable products
The choice of tools is a very logical job. Every new project is like a reasoning problem. You need to use deductive and induction to get the most suitable product. In short, it is a process of continuous dismantling and integration. The customer's parts are very specific. You must disassemble this thing into small, detailed attributes. Each attribute has an impact on the design of the tool. After summing up these effects, you can get the products you need. .

For example, turbine blade processing, fan blade mold, a 5MW fan, the blade can reach 60m long, 5m wide, the corresponding mold is also a big guy: geometrically, large size requires rapid removal of the margin In the Isa products, there are products that can work in the high-speed feed condition of the FeedMill series of tools and the rapid metal cutting of the plunge-cutting cutter; the large length may cause the tool to hang large; in the case of long overhang Quickly remove the residual, it is necessary to reduce the cutting resistance; in the case of long overhang, it is easy to generate vibration, and the cutting edge is required to have strong impact resistance and good toughness; if there are spatial curved surfaces on the blade, the arc element needs to be present in the tool. In combination, the following results can be obtained: FeedMill rapid face milling, cavity roughing, MillShred for deep cavity profiling, and rounding of the cavity with a round insert.

For example, the blades of a steam turbine turbine are made of a high-temperature alloy at the high-temperature and high-pressure inlet end of the steam turbine of a thermal power station. The strength of the material itself is high, the toughness is large, and the surface plastic deformation during processing causes severe work hardening, which makes the chip strong. Tough, so the cutting force is large and the cutting temperature is high. The cutting resistance is reflected in the tool design. It is necessary to reduce the cutting force by increasing the rake angle and the back angle of the tool; to suppress the influence of the cutting temperature, the relevant results can be obtained through the knowledge of the tool coating, and the coating is suppressed from the cutting area to The heat transfer of the blade (tool) slows down the temperature shock and acts like a layer of thermal insulation because it has a much lower thermal conductivity than the tool base and workpiece material. For superalloys, Iskar's SPS82C and IC380 are PVD and titanium oxynitride coatings designed for this difficult-to-machine material.

A common feature of the shape of the energy industry is the large size. The material of the workpiece is characterized by the processing of steel, stainless steel and superalloy. Iska proposed the concept of fast metal cutting in FMR (fastmetalworkremoval) very early. And a complete product line to meet the processing of large workpieces.

Since 2009, Iska has an upgrade of HeliDo for milling products. Simply speaking, it is double-sided of the blade. The direct result is that the number of cutting edges can be doubled on one blade. If you study it carefully, you will find At the same time as the double insert, the dovetail type positioning groove, the larger cutting front angle, and the small negative chamfer of the cutting edge, we can increase the life of the blade well, and the HeliDo product will be the main direction in the future. In terms of coating improvement, in addition to SPS82C and IC380, which are special products for superalloys, all coatings have the corresponding SUMO upgrade, which is a recoating technology. On the basis of ordinary PVD and CVD coatings, a layer of alumina is added to make the surface of the cutting edge smoother, reduce the formation of built-up edge and increase the tool life.

From the beginning of research and development to the actual sales, for conventional metal processing, the life of the beam magic coating tool in the comparison with Isa's own old products, the life expectancy increased by 10% to 30%. For non-metallic materials in the wind power industry, such as composite materials such as fiberglass, carbon fiber and synthetic resin, Iskar's polycrystalline diamond tools (we call it "PCDLine"), and the practical use of small wave-edge cutting tools abroad. It has been proven to be effective in preventing scaling, breakage, and smashing. These tools have common keywords: sharp edges, large rake angles, rake face polishing, high-speed cutting, and fine chips.

Inspire unlimited wind energy
In the development of new energy industry, wind energy as a clean renewable energy has been paid more and more attention by all countries in the world. European countries, the United States and China have given great support and promotion in their national energy planning.

In the development of new energy industry, wind energy as a clean renewable energy has been paid more and more attention by all countries in the world. European countries, the United States and China have given great support and promotion in their national energy planning. As a leader in the wind power industry, Seco Tools not only provides high-quality tools, professional processing technology, but also always focuses on providing a total solution for metal cutting needs. In the long-term cooperation with the famous wind turbine parts manufacturers in the world, Seco has accumulated rich experience and strictly meets the demanding processing requirements of wind power component manufacturers.

The wind unit has a harsh working environment and has extremely high requirements for many factors such as fatigue resistance, reliability and vibration absorption. For wind turbines, gearboxes, wind turbine hubs, wind turbine bearings (slewing bearings and gears), fan spindles, and wind turbine seats are all extremely important operating components. At the same time, they are also parts that are difficult to process, require high precision, and have a large amount of processing. Seco offers a range of process solutions to help wind power industry users stand out in the fierce market competition.

The wind turbine gearbox is one of the important components of the wind turbine. Because the operating conditions of the wind turbine installation site are complex, reliability and service life requirements, the gearbox body must have sufficient rigidity, suitable support structure and wall thickness to meet the complex force requirements. Commonly used materials are ductile iron and other high-strength cast iron. The mechanical structure of the gearbox is complex and large in size, requiring hundreds of hours of precision machining. More parts are processed using a high-precision double-table horizontal boring and milling machining center.

Machining types for wind turbine gearboxes include milling (corn milling cutters and three-sided blades), drilling (Perfomax series) and boring (bridge decking). It is worth mentioning that the diameter of the gearbox connection hole exceeds 2m and the tolerance is H7. This processing is quite difficult. Seco's Graflex bridge slabs cover standard sizes from 204 to 2155 mm in diameter; jumbo (JUMBO) slabs with a maximum diameter of 3,200 mm. They are made of high-strength aluminum alloy (Fortal) and steel interface, which combines flexibility, tool body weight and rigidity. In the fine boring, the precision requirements of up to IT5 and Ra0.6 can be reached, and the size adjustment is also very convenient, which can be directly completed on the machine tool. At the same time, the modular design can also meet the needs of large diameter outer round sets and backs. For example, the A731001Jumbo bridge plate type boring tool is roughened by the TCMT16T308-F2TK2000 blade. The cutting line speed Vc is 150m/min, the feed speed Vf is 25mm/min, and the cutting depth ap is 5~6mm. The precision is CCMT09T304-F2TK1000, the cutting line speed Vc is 120m/min, and the cutting depth is ap0.3mm. These high-performance cutting parameters ensure the customer's extremely high part accuracy and greatly reduce the customer's production cycle.

The hub is also one of the important components of the wind turbine. Its structure and force deformation are complex, which will directly affect the normal operation and service life of the wind turbine. Therefore, it has the characteristics of high strength, good reliability, long fatigue life and strong vibration absorption to meet the working conditions of -20 °C ~ 40 °C. Common materials are as-cast, low-temperature, high-impact ductile ductile iron. The main machining types of the hub are milling and drilling.

Wind turbine hubs are bulky and generally have a long machining cycle. A customer has encountered such a processing problem: although all of its machines are running at full capacity, production tasks cannot be completed on time. In order to help customers tide over the difficulties, Seco designed a non-standard indexable forming tool with a diameter of 360mm and R85mm, supplemented by 335.19-1207EN2R85-D09, F40M inserts, cutting line speed Vc up to 200m/min, feed per tooth. The quantity fz0.14mm, the cutting depth ap1~2mm, the production efficiency is greatly improved, the production cycle of this wheel hub is shortened from the original 30h to less than 16h. The customer was able to deliver smoothly and avoided significant losses.

Seco's DoubleOctomill double octagonal R220.48 face Milling Cutter is ideal for wheel milling. The double-edged face milling cutters feature a positive rake angle design with 16 cutting edges per insert. The same milling cutter is designed for rough, precision machining applications with unmatched economy and versatility.

The processing of wind power components also includes fan main shaft, fan base, connecting flange, fan tower, planet carrier, fan blades and so on. For the machining of these parts, Seco has complete solutions for turning, milling and hole machining. Based on the philosophy of “becoming a strategic partner of customers”, Seco Tools is committed to improving processing efficiency and competitiveness for its customers.

"High energy rate processing" has become the focus
The remarkable development of the Chinese economy is continuing, and it is not an exaggeration to describe it in short supply. The power supply required for the rapid development of the railway network and building construction is definitely in an insufficient state. However, the investment cost will be very large when a large number of imported machinery and equipment are introduced. Recently, customers have increasingly demanded "high-energy production" and "high-efficiency production" with existing equipment.

Since the temperature of the generator blades is very high during operation, the materials are often made of heat-resistant alloys. Moreover, due to its complex shape, not only turning tools, but also various types of tools such as drills and end mills are used in the machining process. Sumitomo Electric Hard Alloy has a material for machining the AC500 series of difficult-to-cut materials in the turning insert. The drill has a multi-purpose drill MD for difficult-to-cut materials, and the GS milling cutter for hard-to-cut processing in the End Mill. Available in stock, the corresponding size is also quite rich, fully able to meet the complex processing requirements of customers. All of the above-mentioned tools are developed for the processing of difficult-to-cut materials, so they are excellent in wear resistance and chipping resistance.

The remarkable development of the Chinese economy is continuing, and it is not an exaggeration to describe it in short supply. The power supply required for the rapid development of the railway network and building construction is definitely in an insufficient state. However, the investment cost will be very large when a large number of imported machinery and equipment are introduced. Recently, customers have increasingly demanded "high-energy production" and "high-efficiency production" with existing equipment. Therefore, Sumitomo Electric Cement's recommended solution is the following products with the keyword "high energy rate processing".

Turning: For the ultra-high feed machining of more than f=0.5mm/r, it is recommended to use the chip-processed high-energy chipbreaker series SE type and GE type. When the feed requirement is higher (~0.8mm/r), it is recommended to use the wiper type LUW type and GUW type.

Milling: It is recommended to use the high-feed milling cutter MS1400, although the depth of cut cannot be greater than 1.5mm, but the feed can correspond to 2mm/blade.

Drilling: The newly developed J-type transverse blade has improved chip handling and a special chip flute shape for excellent chip discharge during high feed machining. In addition, due to the use of the latest PVD coating and DEX coating, long life has been achieved. The carbide versatile drill GS/HGS type is recommended here. When the hole diameter exceeds 12.5 mm, it is recommended to use the cutter head replaceable drill SMD type.

High hardness material processing
For high-speed/high-energy processing of high-hardness materials, there are four kinds of coated CBN materials depending on the application. BNC100 is recommended for high speed/continuous machining, BNC160 is recommended for weak intermittent machining, BNC200 is recommended for high energy rate machining, and BNC300 is recommended for strong intermittent machining. In addition, the high-feed machining or high-precision machining is recommended for the wiper series.

The slewing ring is a relatively representative hard-to-cut part of wind power components. Depending on the capacity (size) of the wind turbine, its size is also varied, and slewing rings with a diameter of more than 2 m are particularly difficult to machine. In particular, when the bearing surface is machined after quenching (hard car), the machining accuracy is strict, the tool life is short, and there are many mounting holes.

The first recommendation for HardTurning after bearing surface quenching is the BNC160 which is excellent in wear resistance and can be processed for large workpieces. The BNC100 is recommended for high speed machining. The company has prepared three kinds of cutting edges for various CBN materials, and can select the most suitable cutting edge treatment according to the degree of damage of the tool and the required surface roughness.

Mounting hole processing
The mounting hole of the slewing ring is generally about φ25 mm and the hole depth is about 100 mm. The WDX type shown on the right is recommended when machining these holes. Each blade has 4 corners for economical efficiency, and the most suitable blade chipbreaker also has good chip discharge when processing deep holes of L/D=5. However, if the hole accuracy requirement is less than ±0.15 mm, the aforementioned SMD type is recommended.

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Jen Li

Ms. Jen Li

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