AI + turning and milling are reshaping the workshop: future manufacturing will be really different
All processes can be completed with one clamping operation
The key highlight of the AI turning-milling compound machine tool launched by Shandong Dahan Intelligent Manufacturing is that it integrates many processes such as turning, milling, drilling and tapping into one piece of equipment. In the traditional machining process, for a relatively complex part, four or five machine tools are usually required to be connected with each other to complete it. And every time the machine tool is replaced, the clamping operation must be performed again. As a result, the accuracy is prone to deviations. However, this machine can complete all process operations with only one clamping, and the time spent is reduced from the original several hours to dozens of minutes.
Last year, a precision parts factory in Shandong introduced this equipment. Since then, the processing time of a single piece has been reduced from the original 45 minutes to 12 minutes. At the same time, the yield rate increased from 85% to 97%. The factory director said that in the past, three masters worked on three machine tools all day long, but now it is just an ordinary operator who works on one machine, but the output has doubled.
AI smart panel turns novices into masters
What really separates this machine tool is the AI intelligent operation panel it is equipped with. When debugging traditional machine tools, senior technicians are required to repeatedly perform test cuts, measurements, and parameter adjustments. It takes about three years for a novice to learn how to debug the machine independently. However, the AI panel can automatically match the optimal processing parameters and optimize the cutting path in real time, turning the technology that was accumulated based on experience into something that the machine itself can calculate.
There is an auto parts factory in Qingdao that could not recruit a sufficient number of skilled workers. After replacing two old-fashioned CNC lathes with Dahan's AI turning and milling compound machine tools, the training cycle was shortened from three months to just one week. New employees operate according to AI prompts, but the accuracy of the parts processed is more stable than that of older employees. The workshop director said that this machine is equivalent to having an invisible master.
Predict tool wear and machining risks in advance
The most worrying thing during the machining process is that the tool suddenly breaks or the workpiece is scrapped. AI machine tools can monitor tool status in real time and predict the remaining tool life by analyzing cutting force, vibration, temperature and other data. Once an abnormality is detected, the system will automatically adjust the feed speed or remind the tool to be replaced to prevent batch scrapping.
There was once a mold factory located in Weifang. At that time, a batch of parts worth 200,000 yuan was scrapped because it failed to detect the wear of the tools in time. Later, it was replaced with Dahan's AI machine tool. When the system detected that only 10% of the tool life was left, it issued an early warning message . The operator promptly replaced the tool based on this early warning, and there has never been a similar accident since then. After some calculations, the owner of the mold factory only considered reducing scrapped parts, and the result was that he could save 120,000 yuan a year.
Data cloud management no longer relies on experience
Each AI machine tool is connected to the Internet, and production capacity, energy consumption, equipment status and processing quantity are uploaded to the cloud in real time. Managers can see the operating status of the entire workshop on their mobile phones or computers, and know which machines are inefficient, which processes consume high power, and which orders are behind schedule. Production decisions have shifted from making decisions based on feelings to making judgments based on data.
A machinery manufacturing company located in Jinan, after using Dahan's cloud management platform, discovered that three machine tools had 2 hours of non-processing time every day. After adjusting the production schedule, the equipment utilization rate increased from 72% to 91%, and monthly output increased by nearly 30%. The production director said that in the past, the workshop was like a black box, but now every machine is telling the truth.
More flexible to handle small batch and multi-variety orders
A key challenge in the manufacturing industry at this time is the increase in the number of small batch orders, the increase in the number of multi-variety orders, and the increase in the number of orders with fast delivery times. When replacing products in a traditional production line, it is necessary to re-adjust the machine and replace the fixture. Usually, the time required for debugging is longer than the time required for processing. The AI turning-milling compound machine tool has the ability to quickly switch processes. It can automatically match the processing plan of new products with the help of a built-in process database.
In Linyi, there is a factory engaged in the production of agricultural machinery parts. It needs to switch dozens of parts of different specifications every month. In the past, whenever a production change was performed, the machine had to stop for half a day to adjust parameters. However, now with the help of AI, the parameters can be automatically calculated and the time required for production change has been shortened to 40 minutes. As a result, the factory was able to accept more urgent and small orders, and customer satisfaction was significantly improved. Compared with before, the order volume increased by 40% year-on-year.
Shandong localized services make upgrades more practical
As a local enterprise in Shandong, Dahan Intelligent Manufacturing provides not only equipment, but also a complete set of services covering process consulting, installation and commissioning, and after-sales training. Compared with imported machine tools with high prices, expensive accessories and slow after-sales response, Dahan's AI turning and milling compound machine tools are more cost-effective, and technicians can arrive at the site in two hours.
The boss of a valve factory in Texas compared three imported brands and the local Dahan, and finally made a choice based on the development trend of turn-milling combined processing technology , and chose Dahan. He said that although the imported machines were good, there was only one glitch and it took three days for engineers to fly over, which delayed production. Dahan's equipment has been used for more than half a year and has never had any problems. The local service in Shandong responds quickly, which makes people feel at ease.
As for you, in your opinion, the development trend of turning and milling combined processing technology , when AI machine tools are fully popularized, will the workshop still need master craftsmen? You are welcome to leave your comments in the comment area for discussion, and like and forward this behavior so that more peers can see it.
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