September 2020 – Page 40 – CNC Machining & Turning, Milling, Metal parts

Modernization process of CNC machining center with aluminum cavity

With the rapid development of modernization, CNC machining of aluminum cavity is paid more and more attention. People gradually begin to change the traditional ideas. People put forward various new requirements on the surface performance and appearance of aluminum cavity CNC machining. For example, when large area electroplating is used on the related products of aluminum cavity CNC processing, because people do not like the color of light, like another color, so they develop a new type of aluminum cavity CNC machining Aluminum cavity CNC processing products.

The modernization process of aluminum cavity CNC machining is tortuous and long. We all know how important the CNC machining of aluminum cavity is for industrial production. With the development of modern science and technology, the equipment industry is moving towards the extreme manufacturing direction: on the one hand, the equipment is becoming more and more tall, on the other hand, the products processed are more and more sophisticated, the processing technology is also more and more complex, and the integration of production technology is also higher and higher.

CNC machining of aluminum plate with aluminum cavity

In order to meet the demand of future products, many enterprises in the industry have begun to replace the traditional CNC machining center with aluminum cavity CNC machining center. Different from the traditional CNC machining center, the aluminum cavity CNC machining center is generally divided into grades according to the number of shafts. Those below the three axis CNC machining center are low-grade, the three to five axis CNC machining center are medium and high-grade, and those above five axis CNC machining center are high-grade.

After years of development and generations of hard work, China’s aluminum cavity CNC machining center industry has made a major breakthrough in the production of traditional CNC machining center. At present, it has become the third largest production country of aluminum cavity CNC machining center in the world. This is the result of a strong country, which is the credit of all the people working in the front line and the hard work of everyone. We are worthy of being powerful and have strong technology, which has changed the modernization process of CNC machining center for aluminum cavity in China.

With the rapid development of the modernization process of CNC machining center for aluminum cavity, more and more mechanical manufacturing equipment are constantly changing to high-speed, high-precision, high-efficiency and high-intelligence, and the demand for high-speed CNC machine tools in various industries is increasing day by day. In the design and manufacture of high-speed CNC machine tools, CNC machining of aluminum cavity is particularly critical.

In CNC machining of aluminum cavity, selecting reasonable cutting parameters is the most economical and effective machining method. The operator should select the cutting speed according to the material to be processed, hardness, cutting state, material type, feed rate, cutting depth, etc. The most suitable processing conditions are selected on the basis of these factors. Regular and stable wear is the ideal condition for service life.

How to determine CNC processing route

Operation technicians need to make preparations when using CNC aluminum plate machining center. Of course, each operator has his own set of skills. Here, the author would like to say that both novice and experienced personnel should be prepared for use. What are the specific contents?

CNC machining of aluminum plate

The tool used in the inspection should be consistent with the specification allowed by the machine tool. The maximum tool length, maximum tool weight and total tool weight of CNC machining center for aluminum plate are determined.

Check whether the tool used is worn or damaged, sometimes it should be replaced immediately. Check for obstructions around machinery and control systems.

Some moving parts are lubricated with grease. Before working, check whether the machine tool has reached the time specified on the lubrication indicator plate, and supplement it in time.

Safety awareness must have, check whether the control system is closed. Whether the control switches are in good condition. Whether someone is in the mechanical danger area.

How does the operator determine the CNC processing route when using the aluminum plate CNC machining center? I would like to share with you:

CNC machining of aluminum plate

First of all, we need to understand what CNC processing route means? It refers to the path that the turning tool moves from the tool setting point (or the fixed origin of the machine tool) until it returns to the point and ends the processing program. It includes the path of cutting and the path of non cutting empty stroke such as cutting in and cutting out. In order to determine the CNC processing route, the following principles must be followed:

1. Shorten the processing time and reduce the processing time.

2. Ensure the accuracy and surface roughness of the workpiece to be processed.

3. For some repeated programs, subroutines should be used to simplify the workload of numerical calculation and the processing program.

In a word, in order to ensure the aluminum plate finish machining, we must do the preparatory work, and ensure that the aluminum plate CNC machining center processing route is correct.

How to prevent parts deformation in computer gong processing

As we all know, computer gongs processing is an automatic numerical control machinery, now many processing enterprises need this kind of mechanical equipment, but due to the fierce market competition, computer gongs processing chaos. The author suggests that before purchasing computer gong equipment, we must have a detailed understanding and investigation of the manufacturer.

Computer gong processing in the process of use will encounter some common faults, such as computer gongs can not return to zero, computer gongs positive and negative hard limit alarm, so what are the causes of these failures?

1、 Cause analysis of computer gong can not return to zero

1. The contact of the origin switch is stuck and cannot act; 2. The origin stop cannot hold the origin switch to the action position of the switch; 3. The water in the origin switch causes the contact of the switch to rust; 4. The line of the origin switch is disconnected or the input signal source is faulty; 5. The PLC input point is burnt out.

2、 Cause analysis of positive and negative hard limit alarm of computer gong

Computer gong processing under normal circumstances will not appear this alarm, but what is the cause of this situation?

1. The contact of the travel switch is pressed and stuck (over travel); 2. The travel switch is damaged; 3. The circuit of the travel switch is open circuit, short circuit and no signal source; 4. The limit block cannot hold the switch contact to the action position; 5. The PLC input point is burnt out.

Most of the time, due to the improper use of technical personnel, or work handover is not in place, computer gong processing will cause some problems, how should we prevent the deformation of parts in the process of computer gong processing?

Computer gong processing

In order to meet the requirements of ultra-high speed machining, the combination of spindle motor and machine tool spindle is adopted in computer gong machining, which realizes the integration of variable frequency motor and machine tool spindle. The bearing of spindle motor is in the form of magnetic levitation bearing, liquid dynamic and static pressure bearing or ceramic rolling bearing. Deformation often occurs in the process of processing, how to prevent it?

1、 In order to reduce the influence of cutting force and cutting heat, the deformation caused by rough machining can be corrected in finish machining.

2、 To reduce the influence of clamping force, the following measures should be taken to reduce the influence of clamping force:

1. When using radial clamping, the clamping force should not be concentrated on a certain radial section of the workpiece, and the operator should make it distributed over a large area to reduce the clamping force on the unit area of the workpiece.

2. The position of clamping force should be selected at the part with strong rigidity to improve the deformation of thin-walled parts under the action of clamping force.

3. The direction of clamping force is changed from radial clamping to axial clamping.

4. As we all know, computer gong is a kind of automatic numerical control machinery. Now many processing enterprises need this kind of mechanical equipment, but due to the fierce market competition, computer gong processing is chaotic. The author suggests that before purchasing computer gong equipment, we must have a detailed understanding and investigation of the manufacturer. In order to reduce the clamping deformation, special claws are used to clamp the workpiece, and the convex edge is cut off at the end of processing.

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How to adjust workpiece coordinate system in CNC machining

CNC machining process needs to be adjusted in many aspects. Due to the difference of machining parts, some adjustments need to be made before operation. Let’s take a look at how CNC machining adjusts the workpiece coordinate system?

CNC machining of aluminum parts

When adjusting the workpiece coordinate system, the reference point should be set outside the physical (geometric) length of all tools, at least on the tool location of the longest tool.

For the workpiece coordinate system on the workpiece installation drawing, the operator obtains it by setting the machine coordinate system offset on the machine tool. In other words, the operator sets a reference point on the machine tool, finds the dimension between the reference point and the zero point of the workpiece coordinate system set by the programmer, and sets this dimension as the offset of the workpiece coordinate system.

On the lathe, the reference point can be set at the tool carrier rotation center, the reference tool tip or other positions. If there is no additional movement, the zero of the programmer’s instruction is that the reference point of the tool rest (machine tool) moves to the zero position of the offset. At this time, if the reference point is set at the rotating center of the turret, the turret must collide with the workpiece. In order to ensure that there is no collision, the reference point on the machine tool should not only be set outside the tool holder, but also outside all the cutting tools. In this way, even if the tool holder is equipped with a tool, the reference point will not collide with the workpiece.

On the milling machine, the datum points of X and Y axes are on the axis line of the main shaft. However, the reference point of the Z axis can be set at the spindle end or at a point outside the spindle end. If at the spindle end, when the command is zero, the spindle end will reach the zero position specified in the coordinate system. At this time, the end key of the spindle end will collide with the workpiece: if the spindle is equipped with a tool, it will collide with the workpiece. In order to ensure no collision, the reference point on Z axis should be set outside all tool lengths. Even if no other motion is added, the reference point will not hit the workpiece.

CNC machining adjusting workpiece coordinate system is only a part, so what about CNC machining process?

(1) The technical preparation process includes market investigation, prediction, new product identification, process design, standardization review, etc.

(2) The technological process refers to the process of directly changing the size, shape, mutual position of surface, surface roughness or performance of semi-finished raw materials into finished products. For example, liquid forming, plastic forming, welding, powder forming, cutting, heat treatment, surface treatment, assembly and so on are all process processes. The reasonable process is written into a technical document to guide production, which is called process specification.

(3) Auxiliary production process refers to the auxiliary production activities necessary to ensure the normal operation of the basic production process.

(4) Production service process refers to the organization, transportation, storage, supply, packaging and sales of raw materials.

Difficulties in processing computer gongs

There are three common processing methods of computer gongs: vertical, horizontal and multi axis linkage. What is the difference between them? Let’s talk about it briefly.

1、 Vertical

Familiar with computer gongs processing friends all know that, due to the processing center spindle and worktable relative position is different, so the computer gong processing method is also different, so for operators, what are the common processing methods? Center: it refers to the machining center with the spindle axis perpendicular to the worktable. It is mainly used for processing complex parts such as plates, plates, molds and small shells.

2、 Horizontal computer gong machining center: it refers to the machining center with the spindle axis parallel to the worktable, which is mainly suitable for processing box type parts.

3、 Multi axis linkage type computer gong machining center: it refers to the machining center which can control the linkage change of the spindle axis and the rotary axis of the worktable to complete the machining of complex space curved surface. It is suitable for the processing of impeller rotor, mold, cutting tools and other workpieces with complex spatial surface.

Familiar with the three ways of computer gong processing, but there will be some problems and difficulties in the process of computer gong processing. The author learned from a master who has been engaged in computer gong processing for many years. I hope the following contents can help you.

1. In the process of processing products, when the size of height direction changes greatly, do not adjust the depth of wear tool compensation. First, check whether there is aluminum slag in the tool handle and spindle, and then add wear cutter compensation after confirming that there is no slag.

2. A knife flicks around the corner. When it is found that there is a spring knife at the corner of the product, the size of the corner of the product is analyzed first, and the tool smaller than the R angle of the corner is used. It can also be solved by reducing the spindle speed.

3. When CNC machining deep holes with accuracy requirements, taper is easy to appear, especially when the hole depth is longer, it is difficult to ensure the upper and lower to the next. It can be rough first and leave a small amount of allowance before boring.

4. When using the jaw to clamp the products, the thickness is different, the outer dimension is thinner and the inner dimension is thicker. This is the external jaw clamping to jack up the product. Pay attention to whether the movable part of the jaw is too loose. After locking it, the problem of different product thickness can be solved.

5. The chamfering has burr. When there are burrs after chamfering, first check whether the tool is worn. If the tool is intact, then check the depth and range of chamfering. Generally, these two aspects can solve the problem of chamfering burr

How to determine the tool setting point of CNC machining center

Tool setting means that after the workpiece is aligned and tightened on the CNC machining center, the machine coordinate of the origin of the workpiece coordinate (programming coordinate) is determined (the value of X, y, Z of g54 is determined). Because a complete machining process of a workpiece may involve several or even dozens of cutting tools, because the trial cutting method is relatively primitive and the accuracy of tool setting is poor, it is rarely used. So how to determine the tool point of CNC machining center? After the center is aligned and tightened, determine the machine coordinate of the origin of the workpiece coordinate (programming coordinate) (determine the value of X, y, Z of g54). Because a complete machining process of a workpiece may involve several or even dozens of cutting tools, because the trial cutting method is relatively primitive and the accuracy of tool setting is poor, it is rarely used. So how to determine the tool point of CNC machining center?

CNC machining of aluminum parts

Tool setting point is the reference point used to determine the position of workpiece coordinate system in the machine coordinate system after the workpiece is aligned and clamped on the machine tool. The tool setting point can be selected on the workpiece or clamping positioning element, but there must be an accurate, reasonable and simple position corresponding relationship between the tool setting point and the workpiece coordinate point, so as to facilitate the calculation of the position of the workpiece coordinate point on the machine tool (the machine coordinate of the workpiece coordinate point). The tool setting point should coincide with the workpiece coordinate point.

The common tool setting methods of CNC machining center mainly include automatic tool setting method, tool setting instrument tool setting method, etc. How to realize the two common methods?

1. Automatic tool setting

The automatic tool setting is realized by using the tool detection function configured by the CNC machining center. This device can automatically and accurately measure the length of each tool in each coordinate direction, and can automatically correct the tool error value. The whole detection and correction process can be realized on the basis of the normal operation of the machine tool. This tool setting method is completely realized by electronic control device, which eliminates the error of manual tool setting, so the accuracy and efficiency of tool setting are higher.

2. Tool setting method of tool setting instrument

Tool setting instrument is the main tool setting method for CNC machining center because of its high economy. There are two kinds of tool setting instruments: inside and outside. The tool setting of the external tool setting instrument needs to be calibrated outside the machine tool in advance, and then the tool can be used after being installed on the machine tool; the tool setting of the internal tool setting instrument is a method to directly install the tool on a fixed position of the machine tool for measurement.

How to check the performance of CNC machining spindle

CNC machining center is an automatic processing equipment developed from CNC milling machine. The powerful processing ability of CNC machining center can bring higher work efficiency for enterprises. What environmental requirements do processing enterprises need to consider when installing CNC machining centers?

1. Location requirements

It should be far away from the vibration source and direct sunlight. If there is a seismic source nearby, an earthquake proof trench should be set up.

2. Temperature and humidity

The optimal processing temperature of CNC machining center is below 30 ℃. If the ambient temperature and humidity are too high, the service life of the control system components may be reduced. If the ambient humidity is too high, it may lead to the short circuit and fault of the integrated circuit board.

3. Voltage and current control

There are many processing equipment in the workshop, which will cause excessive fluctuation of the power grid. We need to control the voltage and current within the allowable range of the machining center and keep it stable, otherwise the work of the system may be affected. The power supply shall be 380V ± 10%, three-phase AC.

As we all know, after the installation of CNC machining center, the acceptance still needs to be done, because the acceptance of CNC machining center directly affects the equipment put into use of the manufacturer. The general factory acceptance standard is to directly carry out the workpiece processing test. In fact, after the workpiece processing test, it can be basically determined that the key parts of the machining center meet the standards, and in the case of normal use There is no problem. About CNC machining center spindle performance inspection is what?

1. Select low, medium and high speed. The main shaft starts 5 times in a row, then stops the operation to check the flexibility and reliability of its action. At the same time, check whether the power display on the load meter meets the requirements.

2. It can input data manually, so that the spindle gradually increases from low speed to the maximum allowable speed. Check whether the speed is normal, the general allowable error should not exceed ± 10%. While checking the spindle speed. Observe whether the noise, vibration and temperature rise of the spindle are normal. The temperature rise of the spindle is 15 “C after running at high speed for 2 h.

3. In order to check the flexibility and reliability of the spindle action, the spindle can be stopped accurately and operated continuously for more than 5 times.

How to solve the problem of Tool Collision in CNC machining center

The selection of NC cutting tools and the determination of cutting parameters are important contents in CNC machining process. They not only affect the machining efficiency of CNC machine tools, but also directly affect the processing quality. So how do CNC machining enterprises choose cutting tools?

The tool selection and cutting parameter determination of CNC machining center is completed in the man-machine interaction state, which forms a sharp contrast with the ordinary machine tool processing. At the same time, it also requires the programmer to master the basic principles of tool selection and cutting parameter determination, and fully consider the characteristics of numerical control processing in programming, and be able to correctly select the cutting tools and cutting parameters.

The general principles of tool selection are: easy installation and adjustment, good rigidity, high durability and precision. On the premise of meeting the machining requirements, the shorter toolholder should be selected as far as possible to improve the rigidity of tool processing

Familiar with the importance of cutting tools for CNC machining, it is inevitable that tool collision will occur in the process of use. For example, problems in the origin and coordinate system of CNC machining center will lead to Tool Collision fault. How to solve this problem?

When starting the machine, the origin of the machine tool is not set. If the program is run at this time, it will cause the machine tool to collide with the cutter, because the system does not know the exact position of the machine tool, and the mechanical origin is incorrect. So we should check the CNC machining center coordinate system origin setting before starting.

For the setting of workpiece coordinate system, before machining operation, zero point setting or coordinate system setting of workpiece coordinate system are correct. At this time, CNC machining center will not have the problem of tool collision or incorrect size of workpiece

What is CNC thread milling method

If you want to be a master in the operation of CNC machining center, you must stand the experience of time and constantly improve your working ability. In the CNC machining industry, the programming of CNC machining center should be compiled according to the operation characteristics of machine tools, which is conducive to observation, inspection, measurement and safety. For example, the same parts, the same processing content, vertical processing, and horizontal processing, respectively processing, the program is certainly not the same.

CNC machining parts

Skilled in operating CNC machine tools. This requires 1-2 years of study, the operation is pay attention to the feel, beginners, especially college students, know how to do, but the hands just don’t listen. In this process, we should learn: system operation mode, fixture installation, part reference alignment, tool setting, zero offset setting, tool length compensation, radius compensation, loading and unloading of tool and handle, tool grinding, parts measurement (skilled use of vernier caliper, micrometer card, dial indicator, dial indicator, inner diameter lever gauge).

Can reflect the level of an operator is: horizontal processing, and large gantry (moving beam, top beam) processing. Must have good fixture foundation and measurement technology level. The difficulty of fixture analysis is that it can only be qualitative and difficult to quantify.

In the process of CNC machining, there is a method called thread milling. What is the specific meaning? Thread milling with CNC is a thread milling tool, machining center three axis linkage, namely x, Y axis arc interpolation, Z axis linear feed milling method.

Thread milling is mainly used for machining large hole thread and thread hole of difficult to machine material. It has the following characteristics:

(1) high speed, high efficiency and high precision. The cutting tool material is generally cemented carbide material, and the cutting speed is fast. The manufacturing precision of cutting tool is high, so the precision of thread milling is high.

(2) milling tools are widely used. As long as the pitch is the same, whether it is * * thread or right-hand thread, one tool can be used, which is conducive to reducing the cost of the tool.

(3) milling is easy to chip removal and cooling. Compared with the tap, the cutting condition is better, especially suitable for the screw thread processing of difficult to machine materials such as aluminum, copper, stainless steel, etc,

It is especially suitable for thread processing of large parts and components of valuable materials, which can ensure the quality of thread processing and the safety of workpiece.

(4) because there is no tool front-end guide, it is suitable for machining blind holes with short thread bottom holes and holes without undercut groove.