BALINIT 新涂层助力齿轮加工 15 th July 2016 金敏
Company Overview Four core competencies 公司概况 四大核心竞争力 Segment Surface Solutions 表面处理事业板块 Segment Manmade Fibers 化学纤维事业板块 Segment Drive Systems 传动系统事业板块 Segment Vacuum 真空技术事业板块 Gaining strength for the next level. 助力前行 We are a leading global supplier of PVD coatings and other surface technologies for precision components as well as metalworking and plastics processing tools. Together with Oerlikon Metco we are about to become the world technology leader in surface solutions. With our combined strengths we will provide even better solutions to our customer s demands in the future. A wide spectrum of industries will benefit from new possibilities created from the combined product and solution portfolio. 我们是世界领先的 PVD 涂层 和其它用于精密零部件 金属和塑料加工工具的表面技术供应商 与欧瑞康美科携手后, 我们将成为表面处理领域的全球领军企业 未来, 通过优势结合将会提供更好的解决方案以满足客户的需求 新的产品和解 决方案的组合将惠及更加广泛的行业领域 Page 2 Oerlikon Balzers, February 2015
Close to you Anywhere in the world 靠近您 我们在您身边 24 Centres 24 个涂层中心 46 Centres 46 个涂层中心 36Centres 36 个涂层中心 Americas 美洲 Argentina 阿根廷 Brazil 巴西 Canada 加拿大 Mexico 墨西哥 USA 美国 Page 3 Oerlikon Balzers, February2015 Europe 欧洲 Austria 奥地利 Belgium 比利时 Czech Rep. 捷克 Finland 芬兰 France 法国 Germany 德国 Hungary 匈牙利 Italy 意大利 Liechtenstein 列支敦士登 Luxembourg 卢森堡 Netherlands 荷兰 Poland 波兰 Portugal 葡萄牙 Romania 罗马尼亚 Russia 俄罗斯 Spain 西班牙 Sweden 瑞典 Switzerland 瑞士 Turkey 土耳其 United Kingdom 英国 Asia 亚洲 China 中国 India 印度 Indonesia 印度尼西亚 Japan 日本 Malaysia 马来西亚 Philippines 菲律宾 Singapore 新加坡 South Korea 韩国 Thailand 泰国
Close to you Wherever you are 在您身边 无论您在何处 Number of coating centres (as of February 2015) 涂层中心数量 ( 截止 2015 年 2 月 ) 106 73 78 81 85 83 84 87 90 93 94 47 47 56 61 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Page 4 Oerlikon Balzers, February 2015
Locations and market regions in China 在中国的地址和市场区域 Changchun Heilongjiang Cutting Tools Forming Tools Components Low pressure nitriding epd PPD Reconditioning Liaoning Xinjiang Inner Mongolia Beijing Tianjin Qinghai Xi an Shiyan Jinan Xizang Hanzhong Henan Shiyan Wuhan Suzhou Shanghai Chengdu Chongqing Jiangxi Wenling Fujian Taiwan 11 coating centers in China No. of employees :399 在中国共有 12 个涂层中心员工数量 :399 Dongguan Page 5 Oerlikon Balzers, Febraury2014 Hainan As of Dec.2015 截止 2015 年 12 月
Key statements in gear cutting application 齿轮加工应用中的关键陈述 Market is strongly enduser driven (Automotive companies) 市场由强大的终端用户驱使 ( 汽车公司 ) First to adapt new coatings 最先采用新涂层 Trend to dry machining 干式加工的趋势 Reliability of products 产品的可靠性 Productivity is most important criterion 生产率是最重要的准则 Page 6
Productivity is the key 生产率是关键 50% increase in tool life reduces costs per piece by 1 % 刀具寿命提高 50%, 产品单件成本下降 1% 30% reduction in tool costs reduces costs per piece by 1 % 刀具价格下降 30%, 产品成本减少 1% Picture: http://www.star-su.com 20% increase in cutting parameters (depth of cut, cutting speed) reduces costs per piece up to 15% 提高 20% 的切削参数 ( 切深, 切削速度 ), 单件成本减少 15% Page 7
Reduction of manufacturing costs 制造成本的减少 Example Gear Cutting 齿轮加工案列 Tool costs 刀具价格 (80x200) v c = 150 m / min (module 模数 1.75) 800 (PM HSS hob 粉末冶金高速钢滚刀 ) v c = 350 m / min (module 模数 1.75) 1600 (Carbide hob 硬质合金滚刀 ) Coating costs 涂层费用 50 (low end 低端 ) 100 (high end 高端 ) Tool life / tooth 刀具寿命 / 齿 5 m 5 m Number of recoatings 重涂次数 15 15 Workpiece / hour 工件 / 小时 103 143 Costs / workpiece 成本 / 工件 0.80 0.63 25% reduced production costs, by increased cutting speed! 25% 的生产成本下降, 来源于切削速度的提高 Page 8
The acceleration of gear cutting speeds in the last 35 years 在过去 35 年齿轮加工速度的提升 Cutting speed (m/min) 350 300 BALINIT A (TiN) BALINIT FUTURA (TiN/TiAN) BALINIT ALCRONA PRO (AlCrN) BALINIT FUTURA NANO (TiAlN) BALINIT ALCRONA (AlCrN)? 250 BALINIT B (TiCN) 200 150 100 50 0 1978 1989 1996 2001 2004 2010 2015 Page 9
BALINIT ALCRONA PRO Facts and figures 事实和数据 Structure 结构 AlCrN Monolayer Hardness 硬度 HV 0.05 3200 Residual stress 残余应力 [GPa] - 3.0 3 µm Service temperature 工作温度 [ C] max. 1100 Coefficient of friction 摩擦系数 0.35 BALINIT ALCRONA PRO is particularly suitable for: Operations such as 应用于 Milling 铣削 Gear cutting 齿轮加工 Tapping 丝锥 Punching / fine blanking 冲头 / 精冲 Sheet metal forming / extrusion 成型 Forging 锻造 Materials 工件材料 Steel up to 52 HRC 硬度不超过 52HRC Stainless steel 不锈钢 Cast iron 铸铁 Page 10
BALINIT ALCRONA PRO is impressive in hobbing BALINIT ALCRONA PRO 应用于滚刀 No. of parts produced [pcs] 5,000 4,000 3,000 2,000 1,000 +122% Tool PM-HSS hob Workpiece Steel 1.7131(~AISI 5115) Cutting parameters v c = 200 m/min VB ~ 0.3 mm Machining Dry Source Automaker 0 Page 11 AITiN BALINIT ALCRONA PRO
Faster hobbing with BALINIT ALCRONA PRO 采用 BALINIT ALCRONA PRO 实现更快的滚齿 No. of parts produced [pcs] 2,500 2,000 Machining time: 0.8 min Tool PM-HSS hob Ø 90 mm S390 Workpiece Steel 1.6526 (~ AISI 8620) 1,500 1,000 500 Machining time: 1.4 min Cutting parameters f z;tiain = 3 mm f z;alcrona PRO = 4 mm v c;tiain = 110 m/min v c;alcrona PRO = 146 m/min Machining With oil Source Auto parts supplier, Sweden 0 Page 12 TiAIN BALINIT ALCRONA PRO
Hobbing at top speeds 最高速的滚齿加工 Parts produced 3,000 2,500 2,000 1,500 1,000 500 Tool Carbide hob Workpiece Planetary gear Steel 1.7131 (~ AISI 5115) Cutting parameters Cut 1: v c = 500 m/min Cut 2: v c = 650 m/min Dry Source Auto parts supplier, Germany 0 Page 13 BALINIT ALCRONA BALINIT ALCRONA PRO
Bevel gear cutting at top speeds 最高速的加工螺旋伞齿 Relative service life [%] 140 120 100 80 60 40 20 Tool Stick blade 刀条 (carbide) Workpiece confidential Cutting parameters confidential Machining Dry Source: Klingelnberg Source Auto parts supplier / transmissions Germany 0 Page 14 BALINIT FUTURA NANO BALINIT ALCRONA PRO
Manufacturing costs: 生产成本 biggest leverage point is cutting speed 最大的影响是切削速度 30% Machining Costs 生产成本 34% Cutting Costs Savings 节省 Reduced machining costs by increasing cutting speed 节省生产成本来源于提高切削速度 26% Other costs 其它成本 26% Other costs 其它成本 24% Setup costs 设定成本 24% Setup costs 设定成本 12% Cooling 冷却液 8% Tool Costs 刀具成本 12% Cooling 冷却液 8% Tool Costs 刀具成本 Page 15
Shift up a gear with BALINIT ALTENSA! 采用 BALINIT ALTENSA 提高齿轮加工速度 Cutting speed (m/min) 350 BALINIT ALTENSA 300 250 200 150 100 50 0 1978 1989 1996 2001 2004 2010 2015 Page 16
BALINIT ALTENSA Benefits at a glance BALINIT ALTENSA 优势一瞥 Improved hot hardness 改善热硬性 > Reduced wear at high cutting speed 高速加工时减少磨损 Increased abrasive wear resistance 提高耐磨损能力 > Lower thermal conductivity 低的热传导率 > Optimised oxidation resistance 优化抗氧化能力 > Reduced flank wear at moderate and high cutting speed 在中速和高速加工下减少后刀面磨损 Reduced thermal impact on tool substrate (especially for PM-HSS) 在刀具基体上减少热影响 ( 特别是 PM-HSS) Longer tool life at dry cutting conditions and high cutting speed 长的刀具寿命在干式和高速加工 Improved tool life at moderate cutting speed 在中速加工时提高刀具寿命 Significant improvement for highest cutting speed conditions for all substrate materials (PM-HSS, MC90, carbide) 有效改善各种刀具材料的最高的切削速度 (PM-HSS,MC90, 硬质合金 ) Enables higher cutting speeds and increase in productivity Page 更高的切削速度和提高生产率 17
BALINIT ALTENSA impresses in various high-end gear-cutting applications BALINIT ALTENSA 应用于各种高端齿轮加工 Bevel gear cutting Hobbing Gear shaping Page 18
Lab tests: convincing results at high-speed cutting 实验室测试 : 在高速加工中令人信服的结果 Tool life (m/tooth) 22 +60% 20 18 16 14 12 10 8 6 4 Tool: PM-HSS hob (S390) Workpiece: Steel 1.7131 (AlSI 5115) Cutting data: v c = 260 m/min m n = 2.56 f a = 4.8 mm H cu,max = 0.25 mm dry Benefit: +60% tool life at high cutting speed 2 0 BALINIT ALCRONA PRO BALINIT ALTENSA Source: Oerlikon Balzers WZL Aachen Page 19
Customer test 1: 30% increase in cutting speed results in 20% longer tool life 客户测试 1: 切削速度提高 30%, 结果提高 20% 刀具寿命 Tool life (no. of gears) 2,200 2,000 1,800 1,600 1,400 1,200 1,000 800 600 400 V c = 200 m/min +22% V c = 260 m/mi n Tool: PM-HSS hob (S390) D = 90 mm Workpiece: Steel 1.7131 (AlSI 5115) Cutting data: v c = 200 v c = 260 m n = 1.62 f a = 6.0 mm dry Gearbox for passenger car Benefit: +30% cutting speed and > 20% longer tool life 200 0 BALINIT ALCRONA PRO BALINIT ALTENSA Source: Automotive Enduser Page 20
Speeding up to 300m/min results in 20% savings in machine costs 速度提高到 300 米 / 分钟的结果节省了 20% 的生产成本 Machine costs for 1,800 gears ( ) BALINIT ALCRONA PRO BALINIT ALTENSA 288 savings with BALINIT ALTENSA Page 21
PM-HSS hob: Confirmed results at high speed PM-HSS 滚刀 : 在高速加工下验证的结果 Tool life (no. of gears) 4,500 4,000 3,500 +70% Tool: PM-HSS hob (S390) D = 70 mm Workpiece: Steel 1.7131 (AlSI 5115) 3,000 2,500 2,000 1,500 1,000 Cutting data: Cut 1: v c = 200 Cut 2: v c = 320 m n = 1.52 dry Gearbox for passenger car Benefit: +70% tool life 500 0 BALINIT ALCRONA PRO BALINIT ALTENSA Source: Automotive Enduser Page 22
Stick blades: 70% increase in tool life at moderate cutting speed 刀条 : 在中速加工时提高 70% 的刀具寿命 Tool life (no. of gears) 2,100 +67% Tool: Carbide stick blades 1,800 1,500 Workpiece: Steel 1.7131 (AlSI 5115) 1,200 900 Cutting data: v c = 148 m/min dry 600 Benefit: +70% tool life 300 0 BALINIT ALCRONA PRO BALINIT ALTENSA Source: Automotive supplier Page 23
Shaper cutter: promising first results 插齿刀 : 有前景的第一次结果 Tool life (no. of gears) 1,400 Tool: PM-HSS shaper cutter, D=130 1,200 1,000 +140% Workpiece: Steel 1.7131 (AlSI 5115) 800 600 Cutting data: m = 1.56 wet 400 Benefit: + 140% longer tool life 200 0 BALINIT ALCRONA PRO BALINIT ALTENSA Source: Automotive Supplier / France Page 24
Thank you! 谢谢! Time for questions and answers 提问回答时间 Page 25