Optimize treatment metre to realize efficient treatment

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Optimize workpiece to machine working procedure, produce actually what use OEE opposite to produce equipment can produce with theory can rate undertakes monitoring, master the bottleneck that produces a course, it is a kind of implementation the beneficial exploration that component of efficient, low cost machines. Cylinder body is the important part of engine, fundamental form is more complex: The wall is thin, present case model, much cavity and aperture are. Normally the circumstance falls, the treatment characteristic of cylinder body product line is: First the aperture after the face; Advanced travel is easy the working procedure that discovers flaw of spare parts interior; Finish deep Kong Jia to be versed in first, shun precision work of the foreword after greater internal stress is affected; Correct and reasonable arrangement is sealed experiment, press fitting, clean wait for auxiliary working procedure. In home the cylinder body product line of some car company is optimized in, technical personnel used the method that metre optimizes, use OEE management method, rose to produce can, reduced manufacturing cost. Optimize cylinder body to machine metre to be with product line of cylinder body of L4 gasoline engine exemple, product line is comprised by homebred 4 horizontal machining center and 4 vertical machining center, workpiece uses manual outfit to place, deferent use without dynamical roller; Subsidiary engine (clean, try leakage, press fitting) use private plane; Positional dimension uses 3 coordinate to measure machine detect, aperture of bore diameter, hole depth, whorl adopt special measure; Cutting tool is given priority to with cutting tool of homebred hard alloy, pivotal cutting tool introduces foreign famous brand; The design is produced can 80 ／ day. The route system that analyses this product line above all is led evenly, the balance state that makes the work person of product line body go up in the time in exercise element namely. Route system leads = evenly (× of the sum of metre of all working procedure 100% ) / (personnel of × of metre of bottleneck working procedure) assume every machining center configures a handlers, can calculate a rate of equilibrium of system of this line line for 43.

4% , loss 56.

6 ％ . Normally the manufacturing metre of product line is by time of the production in entire line the longest equipment is decided. Analyse through undertaking to the technological process of cylinder body and metre (watch 1) , the treatment metre that can see OP60 is the longest, it is OP30, OP100 next. It is OK to optimize a process cent is optimized for simple working procedure and entire line metre is balanced. 1, simple working procedure is optimized (1) optimize workpiece clamping apparatus this product line is machining center composition is flexible treatment line, because this chooses appropriate equipment parameter,be very important. Current, the fast and floating rate of high speed machining center can amount to 80m/min, each mobile axis acceleration maintains 10m/s2, the time that change a knife (knife - knife) 3s, 16000r/min of main shaft rotate speed. To machining center, the commonly used method of managing and auxiliary handling time is to use double workbench and duplex operation undertake machining. The graph shows the duplex operation that takes gas side to machine some crock of lid 1 times clamping apparatus, use the machining center of structure of vertical of double pallet changer, treatment content enters air cover and installing hole of bolt of the face that take energy of life for mill of thick, essence, this working procedure shares 5 kinds of cutting tool, the time changing a knife of every cutting tool is 9s, pallet changer time is 8s. When the odd clamping apparatus that uses convention is machined, whole treatment metre is 161s; Should use duplex operation when clamping apparatus is machined, treatment metre is 135s. This method suffers length of the size range of pipe bent of equipment, cutting tool, especially of workbench the biggest bearinged tie, when the design need undertakes serious school nucleus, additional, must consider the time that hold clip when using manual outfit to place, when using machining center of double pallet changer, must make sure handling time is more than artificial outfit to place the time of workpiece. Graph sketch map of 1 pair of clamping apparatus (2) cutting tool uses optimize □ to optimize treatment method to use optimize a design to machine cutting tool to choose reasonable cutting tool for the face athletic contrail; Machine cutting tool to aperture, should reduce cutting tool to approach a distance. □ optimizes technique to be in milling treatment, instead of much knife treatment one knife is machined, use compound cutting tool more, be like compound auger, step getting; Bore hole and much blade treatment is used more when milling is planar. □ uses high speed to machine cutting tool to use high speed to machine cutting tool, can reduce pure handling time effectively. For example, thick on machining center of CICINNATI four-axle vertical boring some engine crock aperture, bit of adoption hard alloy boring, cut deeply 1.

5mm, v=180 M/min, fz=0.

When 17mm/r, use odd blade boring and 4 blade boring respectively, treatment metre differs 169s (watch 2) . 2, entire line metre rectifies line metre evenly is to raise cylinder body evenly flexible a when machine product line efficiency necessary step. In particular technology staff procedure, because used the principle that craft centers, because this craft designs staff,the content cent that can machine every working procedure is two kinds: One kind is requirement of basis product precision and craft order, the content that must finish in same way working procedure, for example, aperture of crankshaft of cylinder body of boring of essence of life and end panel of finish machining around, because need to assure the verticality of around end panel and crankshaft aperture, it is reasonable that so this content is finished in same way working procedure. Besides other treatment content belongs to the 2nd kind, for example, the bore of aperture of the aperture of water pump bolt of around end panel, oil pump bolt and tap, did not secure must finish in some working procedure, have certain adjustability however. Accordingly, metre balance suits in content of the 2nd kind of treatment. The cost component that the metal machines is cutting tool cost, raw material cost, personnel cost, facility cost and other cost, the proportion that they have respectively in totle drilling cost is occupied for cutting tool about 3% , raw material is occupied 22% , personnel cost, facility cost and other cost are occupied in all 75% . (1) cutting tool cost drops 20% , totle drilling cost can drop only 0.

6% . 3% × of ＝ of totle drilling cost (22% ＋ of 1-20%) ＋ 75% ＝ 99.

4% (2) cutting tool life increases 2 times, totle drilling cost can drop only 1.

5% . 22% ＋ of ＝ of 3%/2 of ＝ of totle drilling cost 75% ＝ 98.

5% (3) manufacturing efficiency rises 20% , totle drilling cost drops 15% . 3% ＋ of ＝ of totle drilling cost 75% × of 22% ＋ (1 - 20%) ＝ can see clearly in the 85% program that reduce manufacturing cost 3 kinds from above, improving manufacturing efficiency is very effective to reducing finished cost. Accordingly, show example of melt into of actor of OP10 working procedure in order to express 1, after the change machines cutting tool parameter, machine pitch time from 1446s (24.

1min) turn into 750s, if express,3 are shown. The integral train of thought that this line working procedure optimizes has at 2 o'clock, the first it is underside of will thick mill decompose semifinished product supplier to be in rough machining, the 2nd it is to raise cutting tool reasonably parameter and optimize cutting tool to approach a distance. What the bit that uses in this line working procedure uses is homebred hard alloy (V=60 ～ 90m/min, fz=0.

18 ～ 0.

22mm/r) , what milling cutter uses is coating hard alloy (V=150 ～ 220m/min, fz=0.

10 ～ 0.

22mm/r) , reamer (V=40m/min, f=0.

10mm/r) , tap (V=6 ～ 12m/min) . Through be opposite other of each working procedure optimize and after metre is balanced, this product line machines metre to shorten not only, reduced 2 operations staff at the same time, rate of route system equilibrium is achieved 82.

6% , produce also can achieve day to produce 80 cylinder body. Use OEE government tool to raise high yield can as a result of various reasons, after classics of metre of the production that make a line is optimized, produce can cannot reach theoretical value instantly normally. The measurement that OEE is an independence tool, with will measure produce actually can produce with theory can 3 crucial essential factor that index of rate, usable rate, expression and quality index are OEE. OEE= can behave index of exponential × quality with rate × for example: OP100 equipment working hours is 24h, the plan before the class stops machine 20min, real trouble stops stage 180min, manufacturing metre is 14.

1min, produced 83 when the class, without reject, its OEE is 82 ％ . Usable rate = handles time / plan working hours, with the loss that brings at evaluating shutdown place. Usable rate = (24 × 60 - 180) ÷ (24 × 60 - 20) = of index of = 89% expression produces metre / (total operation time / total output) , use at evaluating the loss on manufacturing rate. Behave exponential =14.

83 ÷ of 1 × (24 × 60 - 180) eligible product of = of index of = 93% quality / total output, use at evaluating the loss of quality. Quality index =100% passes pair of this product line to undertake an analysis, from production organization, content shedding deserves to send, quality assures, many sided of equipment maintenance, cutting tool management undertakes analyse and was makinged rectifying and reform with precautionary measures, through the promotion of a month, the yield of this product line can realize above of 80 ／ day smoothly, equipment OEE value is stable also achieve 80 ％ above. The last word falls this synergism is the objective that the enterprise pursues hard, improving manufacturing efficiency is to raise cutting tool parameter not just, answer to adjust craft parameter and craft plan in time according to machining conditional change, make technology program more sound. Use OEE tool for a long time in actual production, the enterprise finds an influence easily to produce the bottleneck of efficiency, hand-in-hand travel is improved and dog, in order to improve manufacturing efficiency. CNC Milling