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In 2008, the wind turbine equipment manufacturer's reducer factory completed a total of 1,000 sets of 1.5MW wind power increasers. Although there are many factors such as insufficient processing capacity in the manufacturing process, and severely restricting the completion of the 1000 targets for the whole year, the reducer factory continuously improves the production efficiency and continuously improves the production efficiency by using advanced processing concepts. The plan goals proposed at the beginning of the year and laid the foundation for continued substantial increase in production in 2009.
Throughout the production process throughout the year, how to improve production efficiency in the case of equipment conditions has been a serious problem in front of the company's process and production personnel. As a tool supplier, how to effectively help users improve production efficiency is an important issue. Kenner Feishuo Metal Co., Ltd., together with the Dalian International Industry and Trade Company, which is responsible for the distribution of the unit, has developed a complete and effective service plan and implemented it effectively, ensuring that the user can continuously improve production efficiency and strengthen its technical processing capability. .
The technical service team consisting of Kenner and distributors will appear on the user's processing site every day, together with the process technicians and field operators of the wind turbine manufacturer's reducer, to solve every problem that occurs during production and processing. And through the engineering and technical training center in Shanghai headquarters to provide technical training to the relevant technical and technical personnel of the user, and at the same time continue to give technical lectures and training to the user on-site operators, explain the skills and methods of various tool applications, and help the operator on site. The processing parameters are adjusted and relevant processing suggestions are provided to optimize the on-site tool application under the user's existing equipment conditions and to fully utilize the equipment capabilities. Constantly challenge the tool limit, and continuously improve the processing efficiency under the premise of ensuring product quality and equipment capability, thus indirectly ensuring the achievement of the user's annual production target. Among them, there are several cases to illustrate the efficiency improvement of processing:
1. Machining of large ring gear workpiece connecting holes
For parts with more porous parts, the machining of the holes is the most influential factor to the machining efficiency. For machining with a diameter of more than 5 times the diameter of the medium borehole, high-speed steel drill bits or shovel drills are generally used for machining.
The cutting speed of high-speed steel drills is generally not more than 20m/min, the feed rate is 0.1mm/r, the processing time of 40 ф32×200 holes on the processing large ring gear is 402min; the cutting speed with shovel is generally 30m. /min, the feed amount is 0.3mm/r, and the processing time of 40 ф32×200 holes on the processing large ring gear is 89.36min;
Kennametal's unique KSEM drill bit is the industry's leading hole machining tool. It uses Kennametal's unique drill tip structure to mount an efficient drill tip in the front section of a steel toolholder with a cutting speed of 80m/ Min, the feed rate is 0.6mm/r, and the machining time of 40 ф32×200 holes on the large ring gear is 16.75min, which is 24 times and 5.3 times higher than the traditional processing method.
2. Input shaft connection hole processing
For the processing of 48 ф39×150 holes on the input shaft connection hole, the original machining plan is completed by the machine clamp shallow hole machine clamp (U-drill), the cutting speed is 120m/min, and the feed rate is 0.13mm/r. The total cutting time is 56.55min.
Kenneth's KSEM modular drill bit: cutting speed of 90m/min, feed rate of 0.4mm/r, total machining time of 24.5min; Kenneth's KSEM-PLUS machine clamp modular drill: cutting speed of 160m /min, the feed rate is 0.32mm/r, the total machining time is 17.23min, which is about 3.3 times higher than the machine clamp (U-drill) efficiency and 1.4 times higher than the KSEM drill.
3. Turning of steel parts
Since its inception, Kennametal has been advancing with advanced materials for machining steel turning tools and has been a leader in this field. The latest Beyond turning series is the latest generation of Kennametal's upgraded product. A complete platform for a new high-performance Kennametal turning product, the complete product line includes 11 new materials and 40 new geometry geometries for turning applications in steel, stainless steel and cast iron. Due to its high material removal rate and long tool life, the Beyond range can increase productivity by at least 30% to 300% for users in many metalworking industries.
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Galvanized Steel Wire: Galvanized steel wire refers to a type of steel wire that has undergone the galvanizing process. It is made from carbon steel wire that has been coated with a layer of zinc to protect it from corrosion. Galvanized steel wire is widely used in various applications, including fencing, construction, electrical wiring, and manufacturing. The galvanized coating provides excellent rust resistance, making the wire suitable for both indoor and outdoor environments.
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