How to improve tool management level in flexible processing production line

With the rapid development of the domestic automobile manufacturing industry, the machining level of engine parts has been continuously improved. In order to adapt to the fierce market competition, the flexible processing production line (FMS) came into being.

The purpose of establishing FMS is to solve the problems of low production efficiency, long development cycle and fast product change of multi-variety, medium and small batch products. For FMS to achieve automated machining, all kinds of CNC machining center machines are indispensable. High-efficiency, high-speed advanced cutting technology emerges in an endless stream, new tool structures, new tool materials, new tool coating technology and blades with new cutting edge geometry. It has also been continuously researched and developed: new tool holders for CNC machine tools and high-speed machining, such as HSK tool holders, hot-sleeve holders, and hydraulic tool holders, have been widely used; to improve production efficiency and reduce tool change. Time, more and more use of a variety of composite tools in the processing of automotive parts, such as drill collar composite, drill hinge composite, drilling and attack composite and other tools and complex expansion tools.

In order to ensure that the production line can get the required, sufficient quantity and excellent cost performance tool in time, it is necessary to effectively control the maintenance and maintenance of the tool, pre-adjustment and detection, tool life, etc. When the machining problem or tool problem occurs, the production line Get fast response and support, quickly analyze and resolve problems so that production goes smoothly and minimize losses.

Faced with the challenge of modern automobile manufacturing industry to be flexible and efficient production, in the face of increasingly fierce market competition and pressure to continuously reduce manufacturing costs, the level of tool management is directly related to the cost control of tools, and tool management needs to ensure The production line can get the required tools in time, and keep the quantity of inventory tools at the minimum necessary level, so that the liquidity occupation and the financial expenses caused by it are minimized; and can be made when the tool is abnormally consumed. Timely and fast response to ensure normal production. Therefore, tool management has become a hot spot of concern for various automobile manufacturers.
When the FMS is running, the tool is in a dynamic process, so tool management is necessary. How to improve the level of tool management, we need to start from the following aspects:
1. Optimized configuration of the tool

In the face of the current fierce market competition, all mechanical manufacturing enterprises, especially automobile manufacturing companies, regard improving efficiency and reducing costs as one of the most important tasks and objectives. Since cutting is a complex system problem, processes, machine tools, fixtures, Changes in cutting fluid and cutting parameters have an effect on the life of the tool, which causes changes in the structure of the tool itself, tool material, surface coating, and the like.

The use of high-speed, high-efficiency processing, in theory, should improve production efficiency, but for the automotive industry that implements the production of water, to truly improve production efficiency, it is necessary to rationally plan the tool and optimize the tool configuration. The following aspects of work:
(1) Attach great importance to the work of tool planning and investment stage: In recent years, work practices at home and abroad have shown that the unreasonable tool processing method may affect the efficiency of a multi-million-yuan equipment and the design of tools in the process planning stage. The selection determines the manufacturing cost and tooling cost in the production stage to a large extent, and should deal with the relationship between disposable equipment, tool investment and long-term tool consumption. Some projects save equipment investment during project planning, use expensive tools or unreasonable cutting parameters, resulting in short tool life and long-term cost of tool consumption, which brings many unfavorable factors to tool management.
(2) Formulating reasonable cutting and processing parameters: The speed of processing and tempo directly affects the purchase price of the tool and the manufacturing cost of the parts.
(3) Properly determine the tool life: the durability of the tool and the frequency of the tool change, the length of the tool change directly affects the machine start rate.
(4) Formulating a reasonable processing route: A reasonable processing route is the key to ensuring balanced production of various equipment on the production line.
(5) Improve the pre-adjustment and detection level of high-speed machining tools, and ensure the pass rate of the adjustment tool.

(6) Strengthen the prevention and control of abnormal tool consumption, and try to control the blank quality of the workpiece, the stable running capacity of the machine tool, the concentration ratio of the cutting fluid, and the stability and consistency of the tool coating quality.

The tool configuration scheme is usually handed over from the design department to the production floor in the form of a process document. The advantages and disadvantages of the tool configuration scheme directly affect the improvement of the tool management level. The tool configuration plan should be in the engineering language CAD tool drawing (should include the tool category, tool supplier, tool holder type, tool length diameter, machined part name, fastening) Tool list, actual machining parameters and other related information) to express tool information, tool drawings and technical data should be in digital form, so that tool information can be transferred between computers, to achieve procurement, logistics, adjustment, sharpening, between production lines Networked communication and management.
2. Tool procurement, storage and exchange The tool procurement department checks the inventory according to the CAD tool drawings provided by the process department to generate a tool purchase list.
The storage of the tool should classify the tool, tool assembly (wear or durable), grindable tool or non-repairable tool and store the number to establish inventory management information.
When the tool is exchanged, the warehouse tool backlog and shortage warning information can be known in time.
3. Tool allocation and scheduling

The part programmer can directly call the tool in the tool magazine according to the unique tool number (like the ID number) on the CAD tool drawing. The tool adjuster can pre-adjust the tool according to the CAD tool drawing, and the tool will be sharpened by the manual. The special tool or the purchased standard tool is used to measure the relevant data on the tool setter. After the measurement is completed, assemble it with the standard tool holder, and then input the tool structure parameters and tool code and other related information to the computer.

4. Tool monitoring

The monitoring of the tool is mainly to keep abreast of the changes in the properties of the tool being used due to wear. At present, monitoring is mainly carried out from three aspects: tool life, tool wear monitoring, tool breakage and other forms of tool failure. Tool life refers to the durability of the tool, that is, the total cutting time or the number of workpieces under normal conditions when the wear amount reaches the blunt standard. The tool life value can be calculated by calculation, but it is usually determined experimentally, and the life value of the test is recorded in the file of each tool. After the tool is loaded into the machine, set the number of workpieces or machining time.
5. Tool information management

The contents of the tool information mainly include tool coding information and tool geometry and attribute information. In addition to tool management services, tool information also serves as a source of information for the rational configuration of tools, production scheduling, inventory management, material procurement, tool presetting and maintenance. Since the number and variety of tools required for FMS is very large, a tool database is created. Tool engineers can search the system's internal database for a specific machining task, find the right matching tool, and reduce the redundant redundancy of the tool specifications.

Traditional enterprise management only manages tools as an auxiliary tool. The procurement, logistics, adjustment, sharpening, repair, machining problem solving, tool optimization, cost control and other work related to the tool belong to different enterprises. The departments are managed separately, which often cannot supply high-performance, high-quality tools to the production line in a timely, on-demand, efficient and low-cost manner, and may even affect the normal production of the production, resulting in greater economic losses. With the development and application of the tool management system, the above problems and related services are unified in one system to achieve integrated management, so as to achieve unified command, coordination, rapid response and efficient operation to ensure reliable and strong support for production.

The tool management system is an organic combination of modern management science and high-tech. It has a complete database management function. It can carry out multi-warehouse management for different manufacturers and different types of tools very flexibly and efficiently. The standard inbound and outbound operation and intelligent combination Tool disassembly, rich inventory statistics and other functions, can easily obtain the optimal resource allocation of the tool, effectively reduce the cost of the tool in production, and complete the tool preparation in the shortest time, significantly improving the utilization of the machine.
The basic functions of the tool management system should include:
(1) System management function: It should have user management, operation log, data remote backup, system initialization, system maintenance and so on.
(2) Data maintenance function: It has reference data definition, assembly tool definition, tool package definition and so on.
(3) Tool handle management function: It has the contents of new purchase, storage, report loss management, multi-function inquiry and so on.
(4) Attachment management function: It has the contents of new purchase, storage, storage damage management, multi-function inquiry, etc.
(5) Combined tool management function: with combined tool assembly, lending, modification, disassembly, multi-function inquiry and so on.
(6) Valuable tool management function: with new tools, purchase and delivery, grinding and repair, report damage, maintenance and storage, tool life management and so on.
(7) Gage management function: It has the contents of new purchase, storage, inspection, loss management and multi-function inquiry.
(8) Non-standard tool design function: It has the design, approval, entry and exit, report loss management, multi-function query, etc. of non-standard tools.

(9) Treasury warning function: with multi-warehouse management, new tool automatic coding, tool life management, warehouse tool backlog, shortage warning management, grinding tool management and so on.
(10) Report management function: It has the contents of attachment report module, tool handle report module and valuable tool type report module.

As a technologically advanced advanced manufacturing technology, FMS has now entered the practical stage and achieved good results. In the complete FMS, a tool management system that integrates tool procurement, logistics, adjustment, grinding, tool quality control, tool optimization, etc. must be used as a subsystem of the FMS. The purpose is to timely and accurately specify the machine tool. Applicable tools are available to produce qualified products while maintaining high equipment utilization. Through effective tool management, the tool can be quickly optimized, the performance and life of the tool can be greatly improved, the production efficiency and processing quality can be improved, the manufacturing cost can be significantly reduced, and the enterprise can be in a favorable position in the fierce competition.

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