模塊化刀具系統(tǒng)在銑削聋亡、車削和鉆削加工領(lǐng)域一直都是最先進的工具。其經(jīng)驗證的優(yōu)勢主要包括：可對不同的刀具組件進行快速喜鼓、靈活的配置副砍，從而制造出必要精密的刀具，減少了刀具庫存和設(shè)備的二次加工時間庄岖。

Modular tool systems have Long been state ofthe art in the fields of milling, turning and drilling. Their proven advantages primarily include the fast and flexible configuration of different tool components to create the necessary precision tools. This can reduce both the secondary processing times of the machine and the tools that need to be kept instock.

然而豁翎，對于內(nèi)螺紋加工，尤其是攻絲和螺紋成型加工而言隅忿，市場上一直沒有可用的模塊化刀具心剥。直到幾年前，藍幟金工的研發(fā)專家在LMT Fette公司開發(fā)出了模塊化螺紋成型刀具背桐，HPF(高性能擠壓絲錐)以及后來的XChange模塊化切削絲錐优烧。

For internal thread production, however, particularly for tapping and thread forming, modular tools have not been readily available onthe market. Only a few years ago the research experts of LMT TOOLS at the LMT Fette site created a modular thread former, the HPF (High Performance Forming),and then also a modular tap , the XChange.

除了上面提到的優(yōu)點之外，這些突破性的創(chuàng)新還結(jié)合使用了兩種切削材料的強度優(yōu)勢：硬質(zhì)合金的耐磨性和高速鋼的韌性链峭。這使得這種具有加工可靠性的方法能夠適用于新維度的性能：更為有利的刀桿扭轉(zhuǎn)特性可以實現(xiàn)更快的切銷速度畦娄，同時，還延長了刀具的使用壽命弊仪。通過內(nèi)部冷卻劑和采用同步攻絲刀柄（如：Bilz）熙卡，使刀具系統(tǒng)的性能得到進一步提升。

Apart from the advantages already mentioned above, these groundbreaking innovations combine the strengths of two cutting materials: The wear resistance of the carbide and the toughness of the high speed steel. This allowed a process-reliable approach to new dimensions of performance: More favorable torsion characteristics allow much higher cutting speeds and, at thesame time, increase the tool life. The performance of the tool systems is furthermore improved by an internal coolant supply and through the use of asynchro-chuck, for example by Bilz.

XChange攻絲鉆：結(jié)合使用硬質(zhì)合金和高速鋼（HSS）

XChange tap : Carbide side by side with HSS

絲錐中高速鋼材料仍然占有90%左右冠八。高速鋼是一種切削材料选曼，在反轉(zhuǎn)進給過程中尤其需要利用這種材料的韌性底靴。另一方面，即使采用最高牌號的硬質(zhì)合金制造的整體硬質(zhì)合金絲錐失傍，也不能滿足系列化生產(chǎn)中不斷提高的可靠性要求贝崎。

Taps still consist of approx. 90% high speed steel, a cutting material that exhibits a toughness that is especially required during the return feed. VHM tap drills made of finest grade carbide, on the other hand, still do not fulfill the requirements of increased process reliability inseries production.

新型XChange絲錐的配方的成功之處在于結(jié)合使用了耐磨性硬質(zhì)合金螺紋絲錐頭和具有高韌性的鋼制刀桿，二者均有獨立的接頭咒祠。在刀具壽命結(jié)束時智复，只需更換絲錐頭便可繼續(xù)使用捺再。此外萌琉，定制的藍色“北極星”（Polaris）涂層的應用，能夠進一步延長使用產(chǎn)品的使用壽命（圖1）糜隶。

The recipe for success of the new XChange tap drill is its combination of a wear-resistant carbide threaded head and a tough steel shaft that form a separable joint. At the end of the tool life only the threaded head needs to be exchanged. The tailor-made blue Polaris coating increases the lifetime even more (Figure 1).

帶藍色“北極星”涂層的XChange模塊化絲錐

Modular tap drill, XChange, with blue Polaris coating

新型XChange的主要優(yōu)勢是切削速度快咧饭，這樣既可以縮短加工周期和時間，又能大幅度降低每條螺紋的設(shè)備和/或加工成本会激。通過大量的實際應用證明栏渺，與HSS普通高速鋼絲錐相比，該產(chǎn)品將切削速度提升了一倍锐涯。

The main advantage of the new XChange is the high cutting speed it allows combined with the short cycle and process times and the resulting tremendous reduction of machine costs and/or production costs per thread. In numerous practical applications the cutting speed could be more than doubled compared to HSS tap drills.

經(jīng)濟效率

Economic efficiency

這款全新的絲錐是特別針對鑄造材料（GG和GGG）和產(chǎn)生較短切屑的材料設(shè)計的磕诊。它可輕松地加工含硅量在12%以上的鋁合金材料。在工業(yè)方面的應用領(lǐng)域主要包括：批量生產(chǎn)纹腌、汽車行業(yè)（如：發(fā)動機模塊）霎终、齒輪制造、燃油噴射系統(tǒng)升薯、殼體加工（鑄鐵和鋁）以及家用電器（如：洗衣機）的生產(chǎn)莱褒。

This entirely new tap drill was designed in particular for casting materials (GG and GGG) and short-chipping materials. Aluminum alloy materials with more than 12% silicone can easily be processed. Examples for industrial application are, primarily, mass production, the automobile industry(for example engine blocks), gear manufacturing, fuel injection systems,casings (cast iron and aluminum), and household appliances (for example washingmachines).

根據(jù)加工材料的不同，模塊化絲錐在大約更換3次絲錐頭之后（取決于具體材料）便進入收益期涎劈。在大約更換10次絲錐頭之后广凸，就應該更換一個新刀桿。而在大批量生產(chǎn)中蛛枚，絲錐刀桿的成本是可以忽略不計的谅海。

Depending on the material that is being processed a modular tap drill will already pay off after approx. 3 replacements of the threaded head. After approx. 10 replacements a new shaft should be used as well. In large batch production the costs for the shaft, however, are negligible.

根據(jù)成本效率的計算結(jié)果可知，與HSS-E高速鋼絲錐相比蹦浦，使用新型Xchange可將每條螺紋的刀具成本降低50%扭吁，與VHM整體硬質(zhì)合金絲錐相比，可降低20%投篇。

A calculation of the cost-efficiency results in a reduction of tool costs per thread with the XChange by 50% compared to HSS-E and by 20% compared to VHM.

下面的應用示例是一個真實的成功案例：一個汽車行業(yè)的供應商要為貨運卡車生產(chǎn)一批剎車盤欠杀。此外，還必須加工規(guī)格為M 14 x 1.5的螺紋爸备。該供應商一直使用一家中國制造商生產(chǎn)的HSS普通高速鋼絲錐讯策，但是對其性能并不滿意哺里。尤其是那種攻絲鉆的使用壽命很短。此外购烹，由于工件上絲錐在加工過程中的因為出口處的單向受力而會向一側(cè)偏轉(zhuǎn)骄鸽，所以會使刀具發(fā)生故障（圖2）。為了解決這些生產(chǎn)問題底教，客戶開始使用LMT Fette公司生產(chǎn)的Xchange模塊化攻絲鉆铅粉。這種絲錐通過略微地減小了切屑空間，專門改進了絲錐的結(jié)構(gòu)扑澜，從而提升了穩(wěn)定性蓄盘，抵消了有螺紋工件的單側(cè)偏向力。此外鹿响，為了優(yōu)化排屑效果羡微，LMT Fette公司還為這款刀具設(shè)計了螺旋狀入口。

The following application example reads like a true success story: A supplier for the vehicle industry was producing brake disks for trucks. Among other things, M 14 x 1.5 threads had to be produced. The supplier had been using HSS tap drills by a Chinese manufacturer, but he was not satisfied with their performance. Particularly the lifetime of the tap drills was too short. In addition, the tools caused problems because of a one-sided deflection due to the inclination where the thread exits the workpiece (Figure 2). As a solution to these production problems, the customer began using the XChange modular tap drill by LMT Fette.The tap was improved specifically for this application by slightly reducing thechip space, which resulted in an increased stability that counteracted theone-sided forces where the thread exits the workpiece. Moreover, the spiral entry was designed for optimal chip transport.

加工“剎車盤”部件需要絲錐滿足更高的技術(shù)要求惶我。

The component "brake disk"poses high requirements for the tap drill

客戶的要求提出了另一個挑戰(zhàn)：加工流程要全面轉(zhuǎn)換為干式加工妈倔。

The customer requirements included one more challenge: The process was to be converted completely to dry processing.

Xchange絲錐的切削速度為 vc = 31 m/min，使用壽命達：35,000個螺紋孔绸贡。而競爭產(chǎn)品僅加工2,000個螺紋孔的壽命就結(jié)束了盯蝴，相比之下，本產(chǎn)品的使用壽命出乎意料地提高了1,650% （圖3）听怕。

The XChange tap drill was used at a cutting speed of vc =31 m/min and achieved a tool life of 35,000 threads. This was an increase of an incredible 1,650% compared to the competitor's tool which had already reached the end of its lifetime after 2,000 threads (Figure3).

有了Xchange刀具捧挺，可大幅度提高產(chǎn)品性能。

With the XChange, a dramatic increasein performance is possible

適用于批量生產(chǎn)

Fit for mass

適用于批量生產(chǎn)是該產(chǎn)品的另一個優(yōu)勢叉跛。它證實了僅通過很小的應用技術(shù)變更便可以將標準刀具轉(zhuǎn)化為高強度的批量生產(chǎn)刀具松忍。當然，這與刀具制造商的工程專家們擁有的相關(guān)經(jīng)驗以及與用戶的密切合作是緊密相關(guān)的筷厘。

Fit for mass is the message this example conveys. It shows how small application-specific changes can turn standard tools intohigh-capacity mass-production tools. This of course requires the tool producer's engineering expert to have the corresponding experience as well as aclose cooperation with the user.

關(guān)于這一點鸣峭，我們想借此機會簡要介紹一下XChange模塊化絲錐的一個新特點。現(xiàn)在土汽，它還可以配合一根長刀桿來完成加工作業(yè)音虹。長鉆軸可用于加工那些由于邊緣突出或肩測較寬而使鉆頭無法進入的螺紋加工（圖4）。這是在同一個刀具上結(jié)合使用了兩種優(yōu)勢：

In this context, we would like to take the opportunity to briefly present a new feature of the modular tap "XChange". It is now also available with a long shaft which allows the processing of threads that are difficult to access due to projecting edges or broad shoulders (Figure 4). This combines two advantages in a single tool:

· 硬質(zhì)合金的速度和鋼刀桿的韌性奥挑，就像Xchange的標準版產(chǎn)品所具備的特點一樣次新。

· The speed of the carbide and the toughness ofthe steel shaft, just like in the standard version of the XChange.

· 靈活性和長度。無需使用新的絲錐 – 只需換一根絲錐刀桿就足夠了声锤。不必使用價格昂貴的特殊刀具傲枕，僅即時使用標準版產(chǎn)品便可達到特殊加工的目的。

· Flexible shaft length. No new threaded head required - a different shaft is enough. An expensive special tool is not necessary and a just-in-time standard is achieved.

加長刀桿的Xchange刀具是一個解決問題的能手。

The new XChange with long shaft is agreat problem-solver

環(huán)境方面

Environmental aspects

現(xiàn)代化高性能刀具同時滿足經(jīng)濟和生態(tài)要求辩芦。

Modern high performance tools combine economic and ecological requirements.

Xchange模塊化刀具的藍色“北極星（Polaris）”涂層是遵循“藍色能效”倡議的顯著標志嘀拂，達到了節(jié)約能源的目的：

The modular XChange tap drill's blue Polaris coating is a clear indicator that it follows the "Blue Competence" initiative,thus saving resources:

這些刀具長久的使用壽命使刀具的能耗比單支高速鋼絲錐減少了500%，比整體硬質(zhì)合金絲錐減少30%以上遥加。由于加工時間縮短袱蔓，冷卻劑的供應量減少，從而使機器刀具的電驅(qū)動能耗也降低了50%左右观复。干式加工使機油消耗量減少了100%偏序。此外，與整體硬質(zhì)合金絲錐相比胖替，這些模塊化刀具中的硬質(zhì)合金機器原材料鎢和鈷的消耗量也降低了85%左右研儒。

The high lifetime of these tools allows tool consumption tobe reduced by 500% compared to one-piece HSS tap drills and by more than 30% compared to VHM tap drills. Due to the reduced process times and coolant supply the electrical drive energy consumption of the machine tool is also reduced by approx. 50%. Dry processing reduces the consumption of the resource oil by100%. The consumption of carbide and its raw materials wolfram and cobalt is reduced by approx. 85% in these modular tools when compared to VHM tap drills.

在環(huán)境方面的另一個積極作用在于：由于加工時間縮短，設(shè)備成本降低刊殉，同時也減少了生產(chǎn)成本殉摔。

This environmental aspect has another positive effect on production costs on top of the reduced machine cost due to shorter production times.