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As a major construction machinery manufacturing country in the world, China's construction machinery production and sales has ranked first in the world for many years. Famous engineering machinery companies such as Sany, Xugong, Zoomlion and Shantui have all ranked among the best in the world. Its high-end product manufacturing level and production capacity are strong support for recognition. At the production sites of these companies, there are a large number of world-leading machine tools and tool products, which guarantee the production quality and processing efficiency of enterprise parts. Walter, one of the leading brands of tool suppliers, is one of them. The tool products provided by Walter show great advantages in the processing of key parts of construction machinery. Not only that, but the solutions they provide make engineering machinery companies better in the competition.
Shantui Tracked Chassis Division has always been the largest construction machinery crawler chassis manufacturer in China, and has a strong say in the processing of high-hardness special steel crawler chassis.
Breaking through the processing predicament of high-hardness special steel materials
Different from general mechanical manufacturing, engineering machinery equipment parts often have some special processing requirements, such as crawler chassis parts, which is a typical representative. The construction machinery equipment uses a large number of crawler chassis to ensure the mechanical stability during the movement and to facilitate the movement of the work.
In actual use, the track undercarriage is a typical consumable, and it must be replaced in time to wear to a certain extent. Therefore, the crawler chassis products usually need to be produced in large quantities. Moreover, as the walking device of the construction machinery, the working environment of the crawler chassis is bad and the wear is serious. Therefore, the materials used are all special steels with excellent wear resistance. These special steel materials generally need heat treatment, and the hardness reaches about HRC60. Therefore, how to finish the finishing of high-hardness special steel crawler chassis with higher quality and higher efficiency has become a key part of the core competitiveness of the production enterprises. Here, not only high-quality processing equipment but also higher requirements for cutting tools are proposed. The wear resistance and long service life in mass production become the prerequisite for the tool supplier to be selected.
Yin Yanming, Vice Minister of Process Technology, is a witness to the application of various advanced equipment, technologies and processes to the processing of crawler chassis parts.
“Because of the high hardness of the special steel after heat treatment, it is easy to cause the wear of the tool during the cutting process. In addition, the sealing parts such as the hole and the shaft have high requirements for precision, and the special steel material after processing these heat treatments For the workpiece, high-end carbide coated tools are required.†Yin Yanming, Vice Minister of Process Technology Department of Shantui Construction Machinery Co., Ltd. (hereinafter referred to as “Shanxi Tracked Chassis Divisionâ€) clearly pointed out that the tool supplier The requirements, in his view, must be the correct choice of efficient tools to solve the efficiency and quality problems in processing. As the leader in this field, Shantui Tracks Chassis has a voice in the processing of high-hardness special steel crawler chassis.
After in-depth comparative analysis, in the boring and drilling process of the processing track chain section, the Shantui crawler chassis division finally selected Walter's cutting tool products. In the boring process, Walter technicians tailored the non-standard compound boring tool to the business unit in combination with the processing object and process requirements, and the processing efficiency is extremely high. In the drilling process, the division uses Walter's standard 3-fold Xtra·tec? indexable shallow hole drill with Walter's famous tiger blade and PM5 grooved cutting edge for outstanding processing performance. .
Walter tiger knives are used in the boring and drilling process. The high processing stability and long service life ensure the efficiency and quality of the track undercarriage of the track chassis.
It turns out that this decision has benefited them a lot. Generally, in the drilling process, the loss of the tool is extremely large, and the service life is only about 1000 pieces. This degree becomes an important issue affecting the production progress of the business department, and the arrival of the Walter Xtra·tec? indexable shallow hole drill bit allows This problem is solved, its amazing 2000-piece service life has won the recognition of all employees, high processing stability and long service life ensure the efficiency and quality of the track chassis rail hole hole processing.
The insert has a blade geometry of the Walter PM5, and its grooved edge is very distinctive. “It has many successful cases around the world, and the PM5 grooved edge has a 0.10mm protection chamfer. Even in the harsh working conditions, the edge protection can be realized. The 12° front rake angle ensures the sharp performance of the blade, making the special steel processing more brisk and efficient. In the chain drive hole processing of the Shantui crawler chassis division Play a huge role and become another masterpiece of it.†Walter Product Manager Zhang Shiguang said.
In the use of Walter products, another technique that makes Yin Yanming admire is Walter's tiger knife coating. "I think Walter's unique coating technology is its core competitiveness, which makes the tool wear resistant. The perfect combination of sex and toughness. The black rake face of the Walter Tiger Blade is a layer of alumina coating with excellent thermal and oxidation resistance against crater wear on the rake face. Good wear resistance It allows it to work efficiently at higher wire cutting speeds. The gold rear blade uses a TiN coating to resist wear on the rear blade, while also making it easy for the user to identify the amount of wear and determine if the blade has been used. According to the amount of wear, it is determined whether the blade has reached the service life." Yin Yanming has already made a lot of characteristics for Walter cutters.
The updated Silver Tiger Blade, with its high temperature wear resistance and toughness, will once again increase processing efficiency and quality with amazing tool life, helping Shantui continue to lead the crawler chassis market.
According to Zhang Shiguang, in the Shantui Tracks Division, the updated Silver Tiger Blade is about to replace the existing Tiger Blade. Tiger ® tec Silver is Walter's new generation of CVD coated cutting material, named after the silver flank of the new TiCN indicator coating. It has excellent toughness, which is the most essential difference from existing CVD coating materials, and is also very suitable for wet processing. “Compared to the tiger blade, Silver Tiger technology has taken another step forward: the material's own resistance to cracking and abrasion has been greatly improved, and such improvements have no negative impact on its otherwise excellent high temperature wear resistance. It also has excellent anti-wear properties at high temperatures, which was previously impossible for all PVD coating materials.†Zhang Shiguang believes that high temperature wear resistance and excellent toughness will once again increase production at the processing site with amazing tool life. Efficiency and quality have helped Shantui continue to lead the crawler chassis market.
Trust comes from solving problems at critical moments
Because of the continuous innovation of its products and technologies, Walter and his technicians have always been recognized as “experts in problem solving†by the Shantui Chassis Chassis Division. This understanding actually goes back to a new trial production in 2007.
Competition in the construction machinery market has always been fierce and cruel. Sometimes, the timely launch of a new product can even turn the tide. In 2007, in the trial production process of the new products of the track assembly, the existing equipment and tools could not guarantee the smooth progress of the trial production. Therefore, the division selected two German STAMA MC534 twin-spindle double-station vertical machining centers from a variety of alternative processing equipment, mainly for the drilling of drill collars with more difficult track links. machining. The drilling and boring of the chain section is also the most demanding process for the tool. Through the layer selection, the Walter tool finally becomes the original knives, which solves the problem of Shantui at the critical moment of the new product trial and has been used. to date.
Walter Xtra · tec ® indexable shallow hole drills solved the problem using the production schedule, which surprisingly won the recognition of the service life of 2000 all employees
The introduction of Walter carbide coated tools has enabled the performance of machine tools and tools to be fully utilized. The STAMA MC534 twin-spindle double-station vertical machining center is equipped with a 2x32 large-capacity tool magazine and adopts a patented tool change technology. The fastest chip-to-chip tool change time is only 3.3s. The speed can reach up to 10000r/min and the fast-forward speed can reach 60m/min. These technical parameters were world-leading at that time. “The trial production process of the new track assembly was very smooth, no abnormalities occurred, all the aperture processing dimensions were qualified, and the accuracy met the requirements of the drawings. At that time, we felt that the choice of the dual-spindle double-station vertical machining center and the Walter tool was not only It has brought great convenience to the development of our new products, and has provided efficiency and quality assurance for our future production. It has been proved that the rapid mass production of new products has further established the market leading position of Shantui crawler chassis. The tone of the extended memories is still full of excitement.
Today, the Shantui Track Undercarriage Division consists of three professional manufacturing plants for forging, crawler and wheel trains. It has an advanced production line for crawler chassis parts, including 13 chain link processing lines and 12 chain rail assembly press production lines. 6 wheel train assembly line, 5 chain rail sections, track shoe heat treatment production line and 4 wheel heat treatment production lines, etc., with a total of 175 advanced CNC equipment, machining centers and special planes. Today, in many processing equipment, the combination of Yin Yanming and his colleagues' choice of the dual-spindle duplex vertical machining center and Walter tool is still considered to be one of the best combinations.
"The fierce competition makes us always keep the word 'innovation' in mind, pay more attention to the overall R&D level and production capacity of the business unit. We hope to draw nutrients from our partners, or more frankly, we need suppliers to provide Comprehensive and timely training is not only the grant of application knowledge, but also the inheritance of various advanced processing technologies and concepts. Walter's approach is exemplary. “It is the development needs of Shantui’s chassis division. Yin Yanming focuses on closer interaction with partners.
In the years of cooperation, in addition to regular training, Shantui crawler chassis division will receive a regular return visit from Walter. Walter engineers will help Shantui crawler chassis division to solve technical problems in processing. This is Yin. Yan Ming and his colleagues are most in need. "Of course, we will take the initiative to seek help when we encounter difficulties. The Shantui Tracks Division and Walter have always maintained close cooperation. In addition to selecting tools and testing knives, we must continue to make existing tools and processes. Optimization and improvement. In the Shantui Track Chassis Division, the main task of the relevant technicians is to study how to better utilize the processing advantages of these advanced tools and promote the improvement of production efficiency and manufacturing quality.†Walter's comprehensive service makes Shantui The Track Chassis Division continues to benefit from the development process.
In the long-term cooperation process, Walter's cooperation with Shantui's crawler chassis division can be said to be mutually successful. "The customers of Shantui Chassis Division are our ideal customers, and their requirements can just make Walter's The core competitiveness is fully implemented. Walter's practical experience accumulated around the world, solutions to various processing difficulties, and the latest technological innovation trends have become topics we share and discuss. In turn, we can further understand To the development needs of the business department, lay the foundation for the next step of cooperation." Manager Zhang Shiguang said.
Background introduction:
Shantui Construction Machinery Co., Ltd. is a well-known construction machinery enterprise group in China. Its crawler chassis division is a professional enterprise engaged in research, development, production and sales of construction machinery crawler chassis parts. It is Shantui, Volvo, Komatsu, Liugong and Xugong. The track chassis suppliers of more than 30 well-known construction machinery companies at home and abroad, mainly producing crawler and wheel train products for 3.5T～100T excavators, 70～520 horsepower bulldozers and other crawler construction machinery, annual production With a capacity of 18 million forgings, 180,000 track chain assemblies and 1.4 million wheel trains, it has been the largest construction machinery track chassis manufacturer in China for many years.