The leading role of advanced tools in reducing costs
In the cost statistics of the automobile industry, the tool cost only accounts for 3% to 5% of the total cost of the powertrain, but it can affect 20% to 30% of the total cost. This is mainly due to the increase in production efficiency brought about by advanced tools, which leads to a decline in the production cost of the production line. Advanced tools not only directly reduce the tooling cost of the powertrain, but also indirectly lead to a significant reduction in production costs, in line with the "lean production" principle - to maximize economic benefits with minimal investment. The leading role of advanced tools in reducing the cost of powertrains is mainly reflected in reducing equipment investment, reducing the cost of parts and tools, and reducing production costs.
Advanced tools can reduce equipment investment in the powertrain production line during project planning. The requirement to reduce costs in production begins throughout the engine project from the beginning of the engine production line and is consistent. Active application of advanced processing tools has the effect of reducing equipment investment and winning the most economic benefits. For example, in the process analysis in Figure 1, the advanced tooling solution will reduce the investment of one machine tool compared with the traditional tooling solution. If the entire project uses advanced tools and minimizes the investment in machine tool equipment, it can achieve the minimum investment. The purpose of maximum economic benefit. Another example is the machining of the starting motor surface of the cylinder (see Figure 4). Since the machined surface is parallel to the CNC machine tool spindle, the traditional solution is to use a special machine for processing, the cost is about one million RMB, and the equipment flexibility is poor. It is now possible to use the angle head for milling, which can be used directly on standard CNC machines, with an investment of about 100,000 RMB, and the equipment is flexible. Obviously, under the premise of meeting the same process requirements, the decline in equipment investment is very considerable.
Figure 4 Processing of the starting motor face of the cylinder block
Reduce the cost per part of the tool
Advanced tools also have a good performance in reducing the cost of parts and tools. The price of advanced tools is often relatively expensive, but the performance of advanced tools can be greatly improved compared to traditional knives, and the cost of tooling for integrated parts is generally significantly reduced. For example, the same size specifications of carbide reamer and PCD reamer on the engine aluminum alloy parts processing, the price of PCD reamer is generally 3 to 5 times that of cemented carbide reamer, tool life on PCD reamer It is 10 times more than a cemented metal reamer, and with a PCD reamer, the cost of a single piece of tool can generally be reduced by 50% or more. For existing production lines, the continuous development of tool technology enables tool costs to continue to decline while their performance is fully utilized. The new materials and new coatings of advanced tools are often 10% to 30% longer than the original ones, and the prices are generally comparable.
Reduce production costs
Advanced tools can continuously reduce production costs in production. Dry machining of advanced tools and MQL have gradually become the direction of future processing. By using and using a small amount of coolant, it can generally save 15% of manufacturing costs. In addition, it can reduce the unit processing time of parts, reduce tool loss and increase Machine start-up rates, reduced tool management costs, and extended tool life reduce tool inventory costs to reduce production costs. According to reports, some companies have purchased a large number of imported high-performance machine tools, but they use traditional low-performance high-speed steel tools. The performance of the machine tools only plays 10% to 20%. Due to the short tool life, the machine tools frequently stop and change tools. On the surface, the cost of the tool may be relatively low, but in terms of the production cost of the part, the cost of the part is bound to increase significantly as the depreciation cost of the device is spread over fewer parts. Therefore, the sensible choice should be to apply advanced tools to maximize the machine's unit time output, thus reducing production costs as much as possible.
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