Machinery industry – Page 35 – CNC Machining & Turning, Milling, Metal parts

Operation process and precautions of CNC milling machine

1、 Purpose

In order to improve the company’s efficiency and ensure the delivery time of parts processing, this document is hereby formulated in a unified and standardized way of operation.

2、 Scope of application

It is suitable for company computer gong operator.

3、 Responsibilities and authorities

1. Daily cleaning and maintenance work, training for users, correct operation of computer gongs and machine tools.

Job content:

2. Clamping method and tool use standard before processing:

1) Press strip, vise, magnetic table, fixture, select the best clamping method according to the applicability of the workpiece.

2) Bead: pay attention to the cleaning of the burr and iron chips on the plane of the machine and the adjustment of the height of the bead, so as to avoid the collision between the knife arm and the bead.

3) Vise: pay attention to the cleaning and clamping force of the fixed and movable surfaces of the vise.

4) Magnetic table: when using the magnetic table, it is necessary to consider whether the bottom of the workpiece is flat, whether the adsorption surface is large enough, and whether the workpiece edge processing pad is blocked. In order to ensure that the process will not be loose.

2. Inspection standard before processing:

1) After the completion of each division, first copy the work coordinates, and then recheck whether the distance from the center to both sides is the same after clearing, to ensure that the division and reading are correct.

2) Select, install, set and read the coordinates of Z axis. Select the appropriate tool according to the programming list, clean the tool head and the nozzle thoroughly before installing the tool, and check whether the tool is skewed with the calibration table after installing the tool. Check again after reading the knife to avoid the wrong knife, which will cause great loss to the company.

3) transmit program and start processing: use single section execution before cutting tool, transfer speed and feed speed to slowest, slow down knife, watch machine tool display Z axis margin, check abnormal, if abnormal, press the pause button immediately, find out cause, solve abnormal, confirm all normal, adjust to suitable speed to start processing.

4) In the process of machining, always pay attention to observe whether there is abnormal machining, whether the cutter is worn or not. If the cutter is seriously worn, pause the grinding to ensure the normal machining.

3. Processing standard of core

1) After getting the drawing and workpiece, first check whether the drawing and workpiece mold number are consistent.

2) Measure the actual size of the workpiece with a measuring tool.

3) Check whether the direction of water transportation and reference angle on the 2D drawing is consistent with that on the programming list.

4) Use 400 × oilstone to clean the burr at the bottom and around of the workpiece, and use cloth chips to clean the workpiece.

5) Place the workpiece on the clamping tool of the machine platform, level the plane and perpendicularity of the workpiece with the parallelism, and the perpendicularity tolerance is within ± 0.015. Then fix the workpiece firmly and start the centring. According to the position indicated on the programming list, divide the centring and z-axis collision number. (pay attention to whether the edge finder collides with the workpiece during the split) input the data of the mechanical coordinates x, y and Z into the corresponding coordinates.

6) Transfer all the programs into the computer according to the programming list, use the tool path simulation software to simulate, check the processing area and the maximum and minimum depth of processing, and determine the clamping direction, clamping reservation position and tool length of the workpiece.

7) Install the corresponding tool according to the programming list, and input the tool parameters automatically with the method of automatic tool setting.

8) Transfer the program to the machine for processing.

4. Copper processing standard

1) After getting the program sheet, find the appropriate copper material by comparing the mold number on the program sheet with the size and quantity of copper material.

2) According to the requirements of the programming list, process the rough and the young. (to avoid common mistakes of coarse and young materials, the copper material is marked with a code, “a” for young male, “B” for coarse male.

4) Check if the tool on the program sheet matches the tool on the machine magazine. The program is simulated with the tool path simulation software, and the machining area, the maximum and minimum machining depth are observed to determine the clamping direction, reserved position and the length of the tool.

5) Transfer the program to the machine for processing. In the process of workpiece processing, the next workpiece to be machined must be prepared to reduce the above preparation time.

5. Formwork processing standard

1) After the workpiece is processed, check whether the shape of the workpiece is consistent with the shape of the 3D drawing before dismounting, and then check whether the workpiece has the position of missing processing, over cutting and smooth connection at the junction.

2) According to the data marked on the programming list, use the calibration table or depth gauge to measure the accurate number, and use the needle gauge or plug gauge to measure some matching positions and positioning positions.

3) Measuring parting surface: according to the data provided by the drawing or programming personnel, check the coordinates of several points (x, y, z) on the parting surface, and check whether the parting surface has been machined to the number.

4) Measure whether the depth of all horizontal positions reaches the number. For some positions that need to be connected, first improve the processing, and then paint the color on the connected positions and then slowly connect them.

5） Check the position data of all other requirements for CNC machining accuracy, and confirm that it is OK before getting off the machine.

6. Precautions:

1) Take extra care when removing the tool from the tool holder to avoid scratching your fingers.

2) When using the numerical control program that has not been tried out, the machine cannot be operated fully automatically.

3) When the shaft is still rotating, use extreme care to adjust the coolant flow direction.

4) In case of emergency, press the red emergency switch on the controller.

What is two color injection molding

Double injection molding is mainly used to produce two-color products by two material tubes of double color molding machine and two sets of molds.

Compared with traditional injection molding, dual material co injection molding process has the following advantages:

1. The core material can use low viscosity material to reduce the injection pressure.

2. In consideration of environmental protection, the recycled secondary materials can be used as the core materials.

3. According to different use characteristics, for example, soft material is used for thick finished leather material, hard material is used for core material or foamed plastic can be used for core material to reduce weight.

4. Lower quality core materials can be used to reduce costs.

5. Coating material or core material can be used with high price and special surface properties, such as anti electromagnetic interference, high conductivity and other materials to increase product performance.

6. The proper combination of the core material and the cortex material can reduce the residual stress of the products, increase the mechanical strength or the surface properties of the products.

7. Products that produce lines like marble.

From the characteristics and application of multi-color injection molding and dual material co injection molding, it can be seen that there is a trend to gradually replace the traditional injection molding process in the future. The innovative injection molding technology not only improves the precision of the injection molding process, provides the high difficulty process technology, but also opens up the scope of the injection molding process field. The innovative injection equipment and process are enough to meet the more diverse, high-quality and high value-added product demand.

Two color injection molding has been widely used in electronic products, electric tools, medical products, home appliances, toys and almost all plastic fields. The production and molding of two color mold, the research and development of two color multi-color injection molding machine and two color injection raw materials have also made rapid development.

Structure of plastic mould

The utility model mainly includes a die with a variable cavity composed of a die combination base plate, a die assembly and a die combination card plate, and a die with a variable core composed of a die combination base plate, a die assembly, a die combination card plate, a cavity cutting assembly and a side cutting combination plate. Coordinate change of punch, die and auxiliary forming system. It can process series plastic parts of different shapes and sizes.

In order to improve the properties of plastics, it is necessary to add a variety of auxiliary materials, such as fillers, plasticizers, lubricants, stabilizers, colorants, etc., in order to become plastics with good properties.

1. Synthetic resin is the most important component of plastics, its content in plastics is generally 40% – 100%. Because of its high content and the properties of resin often determine the properties of plastics, people often regard resin as a synonym of plastics. For example, PVC resin and PVC plastic, phenolic resin and phenolic plastic are confused. In fact, resin and plastic are two different concepts. Resin is a kind of raw polymer, which is not only used to make plastics, but also used as raw materials for coatings, adhesives and synthetic fibers. In addition to a very small part of plastics containing 100% resin, the vast majority of plastics, in addition to the main component resin, also need to add other substances.

2. Filler is also called filler. It can improve the strength and heat resistance of plastics, and reduce the cost. For example, adding wood powder to phenolic resin can greatly reduce the cost, make phenolic plastic one of the cheapest plastics, and significantly improve the mechanical strength. Fillers can be divided into organic fillers and inorganic fillers, the former is wood powder, rags, paper and various fabric fibers, the latter is glass fiber, diatomite, asbestos, carbon black, etc.

3、 Plasticizer plasticizer can increase the plasticity and softness of plastics, reduce brittleness, and make plastics easy to process and shape. Plasticizers are generally high boiling point organic compounds that can be miscible with resins, non-toxic, odorless, light and heat stable, and the most commonly used ones are phthalates. For example, in the production of PVC plastics, if more plasticizers are added, soft PVC plastics can be obtained. If no or less plasticizers are added (dosage < 10%), rigid PVC plastics can be obtained.

4. Stabilizer in order to prevent the decomposition and damage of the synthetic resin by light and heat in the process of processing and use, and to extend the service life, stabilizer should be added to the plastic. Commonly used stearate, epoxy resin, etc.

5. Colorant colorant can make plastics have all kinds of bright and beautiful colors. Organic dyes and inorganic pigments are often used as colorants.

6. The function of lubricant is to prevent the plastic from sticking to the metal mold when it is forming, and to make the plastic surface smooth and beautiful. Commonly used lubricants are stearic acid and calcium magnesium salt. In addition to the above auxiliaries, flame retardant, foaming agent and antistatic agent can also be added to the plastic.

Five links of plastic mold

First, effective management of product data management, process data management, drawing document management: effective mold product data management, process data management, drawing document management, can ensure the comprehensiveness of the file, the consistency of the drawing version; so that the drawings can be effectively shared and effectively used for query. It can establish a complete file management computer database to collect and use the design drawings, scattered, previously scattered and isolated information accumulated by the design department, so as to prevent problems caused by the design drawings, 2D and 3D confusion, confusion of original, design change, maintenance version, inconsistency of 3D model and 2D drawing data, and nonstandard and chaotic design of 2D drawings Find out and correct in time, cause the mold to be modified, reworked, even invalid, increase the manufacturing cost of the mold, lengthen the manufacturing and production cycle of the mold, and affect the delivery time.

Second, keep the consistency and integrity of plastic mold drawings, processing technology and physical data: ensure the consistency and integrity of mold drawings, processing technology and physical data through effective, meticulous and strict detection means.

Third, the design and manufacturing cost of each set of plastic mold must be summarized in time: through the effective control of the issuance of the workshop work order, effective management of tool scrap; Through accurate mold structure design, efficient mold parts processing and accurate parts detection, the additional cost of mold due to design change and maintenance will be effectively reduced, so as to obtain the actual cost of each set of mold and effectively control the mold quality.

Fourth, overall planning: organically organize and integrate the planning, design, processing technology, workshop production, human resources and other information, so as to effectively coordinate the planning and production, and effectively ensure the quality of plastic mold and timely delivery.

Fifth, develop a complete and practical plastic mold production management system: develop a complete mold production management system, realize the computer information management system of product data management, process data management, plan management and schedule management of mold production management process, including plastic mold production plan formulation, mold design, process formulation, workshop task assignment and Product inspection, warehouse management, etc., so that mold manufacturing and related auxiliary information from planning to completion delivery can achieve a full range of tracking management.

Precautions for plastic mold

1、 Don’t just focus on product design, ignore plastic mold manufacturing.

Some users in the development of products or trial production of new products, often focus on product development and development at the initial stage, ignoring the communication with the plastic mold production unit. After the product design scheme is preliminarily determined, there are two advantages to contact the mold manufacturer in advance:

1. It can ensure that the designed product has a good forming process, and it will not modify the finalized design because the parts are difficult to process.

2. The mold maker can make design preparation in advance to prevent improper consideration in a hurry and affect the construction period.

3. To make high quality plastic mould, only when the supplier and the demander cooperate closely can the cost be reduced and the cycle be shortened.

2、 Don’t just look at the price, but consider the quality, cycle and service in an all-round way.

1. There are many kinds of molds, which can be roughly divided into ten categories. According to different requirements of part material, physical and chemical properties, mechanical strength, dimensional accuracy, surface finish, service life, economy, etc., different types of die forming are selected.

2. The die with high precision needs to be processed by high precision CNC machine, and the die material and forming process are strictly required. CAD / CAE / CAM die technology is also needed to design and analyze.

3. Some parts have special requirements when forming, and the mold also needs to use advanced technology such as hot runner, gas assisted molding, nitrogen cylinder, etc.

4. The manufacturer shall have CNC, EDM, WEDM and CNC profiling milling equipment, high-precision grinder, high-precision three coordinate measuring instrument, computer design and relevant software, etc.

5. Generally, large stamping dies (such as automobile covering dies) should consider whether the machine tool has a blank holder mechanism, even edge lubricant, multi position progressive and so on. In addition to the punching tonnage, the punching times, feeding device, machine tool and die protection device should be considered.

6. The manufacturing means and process of the above mould are not possessed and mastered by every enterprise. When choosing a cooperative manufacturer, we must know its processing ability, not only from hardware equipment, but also from management level, processing experience and technical force.

7. For the same set of mould, there is sometimes a big gap in the quotation of different manufacturers. You should not pay more than the value of the mold, but also should not be less than the cost of the mold. Mold manufacturers, like you, should make reasonable profits in business. Ordering a set of molds with a much lower price will be the beginning of trouble. Users should start from their own requirements and measure them comprehensively.

3、 Avoid multiple cooperation, try to make plastic mold and products processing.

1. With a qualified mold (qualified test piece), it is not necessarily possible to produce a batch of qualified products. This is mainly related to the selection of machining machine tools, forming process (forming temperature, forming time, etc.) and the technical quality of operators.

2. With a good mold, but also have a good forming process, the best is one-stop cooperation, try to avoid multi cooperation. If the conditions are not met, it is necessary to select a party who is fully responsible and write clearly at the same time.

Why do two-color mold products appear gray and black spots?

1. The cycle time is short, that is to say, the residual time of molten material in the barrel is short and the cycle time is prolonged.

2. The barrel temperature in the feeding area is too high, which reduces the barrel temperature in the feeding area.

3. Screw speed is too fast, reduce screw speed.

4. Screw back pressure is too low, increase screw back pressure.

In addition, the reason related to the design of the two-color mold is that the unreasonable screw geometry selects the screw with a long feeding section, and the screw groove of the feeding section is deep.

If the measurement process of the two-color mold injection process starts too early, and the air wrapped in the particles in the screw feeding area does not overflow the feeding port, the air will be squeezed into the melt. However, the pressure in the feeding area is too low to move the air to the rear. The air squeezed into the molten material in the barrel will cause grey black spots in the products. Just like what happens in the compression ignition diesel engine, the coking phenomenon caused by the air squeezed into the barrel is sometimes called “diesel engine effect”. The coking phenomenon can explain the high temperature produced by compression at the junction of the molten material and the extruded bubble, and the fracture of the molten material caused by the oxidation of oxygen in the air. The melting process should be started in the middle of the feeding area when the injection process of the two-color mold is debugged, where the melting pressure is high, forcing the air between the particles to move backward and overflow the material mouth.

The preferred apparent gray black markings may occur near the gate, in the middle of the runner and away from the gate. This phenomenon can only be seen in transparent parts, and is often found in two-color mold injection products made of PMMA, PC and PS materials.

Function characteristics of LED solid crystal machine

1. One machine is applicable to all kinds of LED solid crystal operation

2. Quick change products

3. Double vision positioning system, high crystallizing accuracy

4. Super large material carrier 4 “X8” double slot

5. Standard humanized windows interface design

6. Chinese operation interface, high affinity for operation setting

7. Modular automatic teaching, simple and fast setting

8. Point by point or two-point production diversification

9. The whole plate of support is loaded and unloaded, and the fixture only needs to be replaced for different products

Characteristics of large deep hole drill

1. The whole casting adopts high-quality mihanna cast iron, and after aging treatment, the structure of the casting is uniform and stable, with high rigidity and good stability.

2. The three-axis adopts imported high rigidity and high precision screw rod, which provides more powerful torque and durability during processing.

3. The imported high rigidity, heavy load, high speed and high precision ball linear guide rail is adopted for the three-axis, which ensures the high precision of processing and prolongs the service life of the linear guide rail.

4. The three-axis feed drive adopts Japanese AC servo motor and driver, and is directly connected with the ball screw. The transmission is stable without backlash. At the same time, its good rigidity and optimized shock absorption performance greatly improve the dynamic rigidity of the transmission system, which can realize rapid movement.

5. The spindle adopts imported powerful motor, which can meet the processing requirements of high and low speed, and is equipped with automatic oil cooling system to ensure constant temperature during processing.

6. The operating system adopts Taiwan system, which can be compatible with CAD / CAM software to use more metadata.

Fault analysis of processing large horizontal computer gongs

As a processing industry, especially machining, it is the basic knowledge that every enterprise must know how to analyze and solve its faults. It is also the first step of the processing and maintenance of large horizontal computer gongs. By analyzing the faults, we can quickly find out the causes of the faults and solve them. At the same time, it is also a function of preventing and expanding the machinery. Generally speaking, large horizontal computer The fault analysis of Gong processing has the following aspects:

1. Action analysis method action analysis method is a method to determine the bad part of the action and trace the root cause of the fault by observing and monitoring the actual action of the machine tool. Generally speaking, the hydraulic and pneumatic control parts of Dongguan computer gonging machine tool, such as automatic tool change device, exchange table device, fixture and transmission device, can be determined by action diagnosis.

2. State analysis state analysis method is a method to determine the cause of failure by monitoring the working state of the actuator. This method is most widely used in the maintenance process of Dongguan computer gongs.

3. Conventional analysis conventional analysis is a method to check the mechanical, electrical, hydraulic and other parts of Dongguan computer gong processing machine tool, so as to determine the cause of the failure. The above is a large horizontal computer gongs processing failure analysis methods and solutions, hope to help the majority of users

Classification and application of aluminum plate

According to different processing technology, it can be divided into cold rolling and hot rolling.

According to the different thickness, it can be divided into thin plate and medium thick plate. The aluminum foil with thickness less than 0.2mm specified in GB / t3880-2006 is called aluminum foil. Commonly used brand: pure aluminum plate, strip. Foil. Thick plate, stretch tube. Squeeze the tube. Type. Great. Cold processed bar is mainly used in the situation of high corrosion resistance and formability, but not high strength parts, such as chemical equipment, ship equipment, railway tank car, conductive material, instrument material, welding rod, etc.

3003: plate and strip. Foil. Plate. Stretch the tube. Squeeze the tube. Type. Great. wire rod. Cold working bar, cold working wire, rivet wire, forging, radiator material. It is mainly used for processing parts requiring good molding performance, high corrosion resistance, or weldability, or parts requiring these properties and higher strength than 1 *, such as tanks and tanks for liquid transportation, pressure tanks, storage devices, heat exchangers, chemical equipment, aircraft oil tanks, oil ducts, reflectors, kitchen equipment, washing machine cylinder, rivets, welding Silk. Aluminum clad 3003 alloy: plate, thick plate, stretch tube. Extrusion pipe house partition, top cover, pipeline, etc. 3004: plate, thick plate, tensile pipe. As long as the extruded tube is used for the whole aluminum can body, it requires higher parts than 3003 alloy, chemical product production and storage device, sheet metal processing parts, building baffles, cable ducts, sewers, various lighting parts.

3004 aluminum clad alloy: plate and thick plate are mainly used for building partition, baffle, sewer, roof cover of industrial building 5052: plate, thick plate, foil, tensile pipe, cold processed bar, cold processed wire, rivet wire. This alloy has good forming and processing performance, corrosion resistance, weldability, fatigue strength and medium static strength, and is used for making aircraft oil tank and oil pipe , as well as traffic vehicles, ship’s sheet metal parts, instruments, street lamp brackets and rivet wires, etc. 6061: plate, thick material, tensile pipe. Extrusion pipe, bar, profile, wire, conduit, rolled or extruded structural profile, cold processed bar, cold processed wire, rivet wire, forging. All kinds of industrial structural parts with certain strength, corrosion resistance and high weldability are required, such as pipes, bars and profiles for manufacturing trucks, tower buildings, ships, trams, railway vehicles, furniture, etc.

According to the classification of aluminum plate brand, according to the different metal elements contained in the aluminum plate, we will introduce it gradually.

1. The 2000 series aluminum plate represents 2A16 (Ly16) 2A12 (LY12) 2A06 (LY6) 2000 series aluminum plate, which is characterized by high hardness, of which the copper element content is the highest, about 3-5%. 2000 series aluminum plate belongs to aviation aluminum material, which is not often used in conventional industry at present. At present, there are few manufacturers of 2000 series aluminum plates in China. The quality cannot be compared with that of foreign countries. At present, the imported aluminum plates are mainly provided by Korean and German manufacturers. With the development of China’s aerospace industry, the production technology of 2000 series aluminum plate will be further improved.

In such humid environment, the price is higher than 1000 series, which is a more commonly used alloy series.

2. 5000 series represents 5052.5005.5083.5a05 series. 5000 series aluminum plate belongs to the commonly used alloy aluminum plate series, the main element is magnesium, and the magnesium content is between 3-5%. Also known as aluminum magnesium alloy. It is characterized by low density, high tensile strength and high elongation. In the same area, the weight of aluminum magnesium alloy is lower than other series, so it is often used in aviation, such as aircraft fuel tank. It is also widely used in conventional industry. The processing technology is continuous casting and rolling, belonging to the hot rolling aluminum plate series, so it can do deep oxidation processing. In China, 5000 series aluminum plate belongs to one of the more mature aluminum plate series.

3. 6000 series represents 6061, which mainly contains two elements of magnesium and silicon. Therefore, 6061 is a cold-treated aluminum forging product with the advantages of 4000 series and 5000 series. It is suitable for applications with high requirements of corrosion resistance and oxidation resistance. The utility model has the advantages of good usability, excellent interface characteristics, easy coating and good processability. It can be used on low-pressure weapons and aircraft joints. General features of 6061: excellent interface features, easy coating, high strength, good usability, strong corrosion resistance. Typical uses of 6061 aluminum: aircraft parts, camera parts, couplers, ship accessories and hardware, electronic accessories and joints, decorative or various hardware, hinge head, magnetic head, brake piston, hydraulic piston, electrical accessories, valves and valve parts.

4. The 7000 series represents the 7075 mainly containing zinc. It also belongs to the aviation series. It is an aluminum magnesium zinc copper alloy. It is a heat-treatment alloy. It belongs to super hard aluminum alloy. It has good wear resistance. 7075 aluminum plate is stress relieved and will not deform or warp after processing. All super thick 7075 aluminum plates are detected by ultrasonic, which can ensure no sand holes and impurities. 7075 aluminum plate has high thermal conductivity, can shorten forming time and improve working efficiency.

The main feature is that the hardness of 7075 is a high hardness and high strength aluminum alloy, which is commonly used to manufacture aircraft structures and futures. It requires the manufacture of high stress structural parts and dies with high strength and corrosion resistance. At present, China’s production process still needs to be improved. (a foreign company in our company once proposed that the annealing of 7075 aluminum plate made in China is uneven, and the surface and internal hardness of aluminum plate are inconsistent.).