Jingwei Textile Machinery Engineer talks about advanced tool application experience

I work for a state-owned large-scale textile machinery manufacturer that has been in operation for over 60 years. Our company has developed and produced a wide range of machinery, especially spinning machines, which have enjoyed a strong reputation both domestically and internationally. As the saying goes, "A craftsman must sharpen his tools before he can do good work." The key to improving production efficiency, product precision, and meeting diverse processing needs lies in the effective use of advanced cutting tools.

Every year, our company invests more than two million yuan on tools. We have selected high-quality brands such as Sandvik Coromant from Sweden, Kenner from the U.S., NIKKEN and Mitsubishi from Japan, and Zhuzhou Diamond from China, based on cost-effectiveness and applicability. In addition, we also use specialized tools from other brands like PLANSEE aluminum cutters from Austria, Isca tools, OSG drills from Japan, and mountain high-speed end mills from Sweden, along with domestic taps, all of which have shown excellent performance in our production processes.

Industry experts agree that the cost of tools accounts for only 3% to 5% of the total manufacturing cost of parts. Even if tool prices drop by 30%, the overall cost savings are just about 1%. However, if we can improve cutting efficiency by 20% through better tool selection—such as using new material grades—the cost savings could reach up to 15%. This is because higher cutting efficiency reduces energy consumption, machine downtime, labor costs, and ultimately lowers the average production cost per unit.

So, how can we further enhance the application of advanced tools? Let me share some of our experiences here.

We focus on increasing the use of indexable and coated tools, as well as solid carbide tools. Since the introduction of the first Italian CNC machining center in the 1980s, we've continuously explored and improved our tool application. Today, indexable and coated tools make up 80% of our metal cutting operations. These tools offer high-speed, high-precision, and high-efficiency machining capabilities. Coated tools, on the other hand, provide high surface hardness, wear resistance, and stability under harsh conditions. Their effective use has laid a solid foundation for our success in producing fine textile machinery.

We started using carbide drills early on. Previously, it was believed that drilling required low feed rates and cutting speeds, but this view was outdated when using conventional twist drills. With the introduction of cemented carbide drill bits, the concept of drilling has evolved. Properly selecting the right carbide drill can significantly boost productivity and reduce the cost per hole.

Depending on the processing conditions, we use three main types of carbide drills: solid carbide drills, indexable carbide inserts, and welded carbide drills. Each type is optimized for specific applications and offers unique advantages.

Solid carbide drills not only improve production efficiency and reduce machine time but also lower manufacturing costs. Additionally, their long service life and excellent wear resistance help reduce tool costs. In recent years, we’ve also seen great results from using solid carbide end mills.

New tool material grades are essential for adapting to different workpiece materials and cutting conditions. Modern manufacturing involves a wide range of materials, including steel, non-ferrous metals, heat-resistant alloys, and synthetic materials. Each material has different machinability characteristics, even within the same category. For example, ferritic and austenitic stainless steels, though both classified as stainless, behave differently during machining. Therefore, choosing the right material grade is crucial to achieving optimal results.

Typically, new material grades are developed to increase cutting efficiency by over 20%. It's important for us to stay updated and apply these new grades to replace older ones, ensuring continuous improvement in cutting efficiency.

Collaborating closely with tool manufacturers helps us enhance tool application and processing efficiency. In today’s environment, enterprises need more support from tool suppliers. Modern tool companies possess extensive cutting technology knowledge and resources, and they aim to help users improve their cutting efficiency. They are professional teams dedicated to advancing cutting technology. Their research capabilities, investment in development, modern equipment, and management practices have driven progress in the industry.

By working with tool manufacturers, we can improve our tool application level, increase efficiency, and shorten delivery times. This is one of the reasons why foreign users gain a competitive edge, and we should follow suit.

Chinese tool manufacturers should also evolve their business models, leverage their strengths in materials, coatings, and design, and provide better technical support and after-sales services to users. They should become reliable partners for their customers.

Currently, the pace of development in the domestic machinery manufacturing industry is accelerating. It's a challenging yet promising period. Therefore, we must update our thinking and understand the importance of advanced tools in optimizing processing, improving product accuracy, increasing productivity, reducing costs, and shortening delivery times. To accelerate innovation, our company will continue to invest in CNC equipment and advanced tools, driving faster and more sustainable growth.