Yancheng Industrial Vocational and Technical College: School-enterprise cooperation to overcome precision tool processing problems
What has long troubled many manufacturing companies are the measurement and adjustment problems associated with tool processing. Yancheng Industrial Vocational and Technical College and the Jingxin Technology Team recently reached an industry-university-research cooperation contract. Both parties will work together to promote the research, development and application of high-speed intelligent processing technology for precision tools. This technology resolves many pain points in traditional processing and brings new possibilities to intelligent manufacturing.
Three core technologies break through processing bottlenecks
The first highlight of the entire system is the three-point measurement process. In traditional machining, workers rely on visual inspection to determine the tool shape, which not only results in huge errors, but also easily causes the tool to be scrapped. The new technology accurately outlines the shape and structure of the tool through three measurement points. The system completes the grinding work on its own based on actual data, without the need for repeated manual adjustments.
One problem was solved through the adaptive adjustment of the six-way tailstock. There are various differences in the shape of the tool. As long as the height difference between the tailstock and the spindle is slightly wrong, it will affect the machining accuracy. The six-way tailstock developed by the Jingxin Technology Team can automatically adjust the position according to the specific characteristics of the tool and with the support of an expert experience database to ensure that every machining is stable and reliable.
What has a protective effect is the dynamic sensing technology of the center frame pressure. In the process of precision grinding processing , the grinding pressure is constantly changing. If the pressure is abnormal and not handled in time, the tool will be extremely easy to be destroyed. This technology can monitor the pressure data in real time. Once an abnormality is detected, an alarm signal will be sent out immediately, so that the operator can take corresponding measures immediately.
Traditional processing pain points finally have solutions
In the laboratory of Yancheng Industrial Vocational and Technical College, engineers have conducted a large number of tests. The data shows that the scrap rate due to inaccurate measurement during traditional tool processing is about 8%. Workers have to make repeated measurements and adjustments. Even skilled masters can only process dozens of tools a day.
Engineers in the Jingcheng Technology Team stated in interviews that in the past, when tool processing, problems such as inaccurate visual force and improper adjustment of the tailstock were often encountered. As a result, the quality of the tools produced was unstable, and the processing efficiency was difficult to improve. Nowadays, with the help of high-speed intelligent molding technology of precision tools, such problems can generally be solved.
There is a company engaged in tool production in Yancheng. The person in charge of the company made some calculations and came up with an account situation. After using the new technology, the processing time required for each individual tool was reduced from the previous fifteen minutes to six minutes, and the proportion of scraps was reduced to less than 2%. Just one workshop can save more than 300,000 yuan in material costs every year.
School-enterprise cooperation takes a new path
The cooperation signing was held at Yancheng Industrial Vocational and Technical College. Representatives of the school and the leader of the Jingcheng Technology Team attended the signing ceremony. The two parties conducted in-depth exchanges on school-enterprise cooperation and the integration of industry and education. The school provided technical research and development talents and experimental equipment, and the company provided industrialization capabilities and market channels.
Yancheng Industrial Vocational and Technical College has many years of experience in the research and development of precision machining technology. The school has a dedicated intelligent manufacturing laboratory equipped with advanced equipment such as five-axis machining centers and high-precision grinders. In the past three years, the school has undertaken four scientific research projects at or above the provincial level and published more than 20 related papers.
Eight invention patents have been applied for by the Jingxin Technology team on this technology. The team leader revealed that they have established a pilot base in Suzhou and completed more than 300 batches of actual processing tests. The test results show that the processing accuracy of the cutting tools using the new technology has been improved to the micron level, and the surface roughness has been reduced by 40%.
Combining industry and education to promote technology implementation
Industry-university-research cooperation is not as simple as signing an agreement. According to the cooperation agreement signed by both parties, the Jingcheng Technology Team will provide the school with three sets of intelligent processing devices for teaching and research and development. The school will select two associate professors and six graduate students to work in the company to participate in technical optimization and process improvement.
The two parties are also preparing to jointly build a precision tool processing technology joint laboratory. The laboratory will be located on the campus of Yancheng Industrial Vocational and Technical College. The company invests 500,000 yuan in operating expenses every year. This laboratory will be open to the outside world and will provide technical consultation and sample trial production services to surrounding small and medium-sized manufacturing companies.
This cooperation model solves two problems. One problem is that the school obtains real production scenarios and data, allowing students to have access to the latest technology. The other problem is that the company has continuous technical support and talent reserves, so there is no need to build a R&D team from scratch. Both parties stated at the signing ceremony that precision grinding processing technology , this kind of cooperation will continue in the long term.
Smart manufacturing needs more breakthroughs like this
Precision tools belong to the category of basic tools in the manufacturing industry. A high-quality tool can increase processing efficiency by more than 30%. Currently, the domestic high-end tool market still relies on imports. The annual import quota exceeds 20 billion yuan. The situation of domestic tools is that there is a gap in accuracy and life. The main reason is that processing technology has not kept up with the pace.
It is this gap that the cooperation between Yancheng Industrial Vocational and Technical College and the Jingcheng Technology Team is targeting. Three-point measurement is a precision grinding processing technology , including six-directional tailstock adjustment and pressure dynamic sensing. These three technologies are combined to form a complete solution. The system can automatically complete the entire process from measurement to grinding, reducing the interference of human factors.
This technology has been trial-run at three tool manufacturing companies. The data presented in the trial run shows that the dimensional accuracy of the tools can be stabilized within the range of two microns, the service life of the tools has been increased by an average of 25%, the number of operators has been reduced from three to one, and labor intensity has been significantly reduced.
There is still more room for imagination in the future
The cooperation between the two parties will not stop here. At the symposium held after the signing ceremony, school representatives expressed the need to expand this technology to more application scenarios. For example, forming tools used in automotive parts processing and high-temperature alloy tools used in aerospace can all be processed using this system.
The carefully built technology team has already begun the development of second-generation products. The new product will introduce edge computing technology to migrate the experience database owned by experts from locally configured servers to the cloud. The processing data owned by different companies can be shared after desensitization. The system will become more intelligent with continued use, and the recommendation of processing parameters will become more and more accurate.
The local government has supported this cooperation in Yancheng. The Yancheng Economic and Technological Development Zone has provided a start-up capital of 300,000 yuan for the project, and has also promised to assist the company in applying for the first set of provincial-level major equipment. The relevant person in charge of the development zone stated that precision machining is a key industry development direction in Yancheng, and such industry-university-research cooperation is worthy of strong support.
Don’t you think where are the links in precision tool machining technology that can be further optimized? You are sincerely welcome to share your personal opinions in the comment area, and don't forget to like and forward this article, so that more peers can see this technological breakthrough.
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