Dry processing

Dry processing

Precision CNC machining parts The machining quality mainly is refers to the work piece the processing precision and the surface quality (including surface roughness, residual stress and superficial hardening).Along with the technical progress, the machining quality enhances unceasingly.The 18th century later periods, the machining precision counts by the millimeter; At the beginning of 20th century, machining precision Gao Yida 0.01 millimeter; To the 50's, the machining precision has reached a micron level; The 70's, the machining precision enhances to 0.1 micron.

The influence machining quality primary factor has aspects and so on engine bed, cutting tool, jig, work piece semifinished materials, technique and processing environment.Must improve the machining quality, must take the suitable measure to the above various aspects, like reduces the engine bed work error, selects the cutting tool correctly, improves the semifinished materials quality, the reasonable arrangement craft, the improvement environmental condition and so on.

Precision CNC machining parts Enhances the cutting specifications to enhance the material excision rate, is enhances the machining efficiency the essential way.The commonly used highly effective machining method has the high-speed cutting, the force cutting, the plasma arc heating cuts and vibrates the cutting and so on.

The grinding speed is called the high-speed grinding in 45 meters/second above es the high-speed cutting (or grinding) both may enhance the efficiency, and may reduce the surface roughness.The high-speed cutting (or grinding) requests the engine bed to have the high speed, the high rigidity, the high efficiency and the vibration-proof good craft system; Requests the cutting tool to have the reasonable geometry parameter and the convenience tight way, but also must consider the safe reliable chip breaking method.

Precision CNC machining parts The force cutting refers to the roughing feed or cuts the deep machining greatly, uses in the turning and the grinding generally.The force turning main characteristic is the lathe tool besides the main cutting edge, but also some is parallel in the work piece has processed superficial the vice-cutting edge simultaneously to participate in the cutting, therefore may enhance to feed quantity compared to the general turning several times of even several http://www.wendangku.net/doc/90cc2c195ef7ba0d4b733b53.html pares with the high-speed cutting, the force cutting cutting temperature is low, the cutting tool life is long, the cutting efficiency is high; The shortcoming is processes the surface to be rough.When force cutting, the radial direction cutting force death of a parent is not suitable for to process the tall and slender work piece very much.

The vibration cutting is along the cutting tool direction of feed, the attachment low frequency or the high frequency vibration machining, may enhance the cutting efficiency.The low frequency vibration cutting has the very good chip breaking effect, but does not use the chip breaking equipment, makes the knife edge intensity to increase, time the cutting total power dissipation compared to has the chip breaking installment ordinary cutting to reduce about 40%.The high frequency vibration cutting also called the ultrasonic wave vibration cutting, is helpful in reduces between the cutting tool and the work piece friction, reduces the cutting temperature, reduces the cutting tool the coherence attrition, thus the enhancement cutting efficiency and the processing surface quality, the cutting tool life may enhance 40% approximately.

To lumber, plastic, rubber, glass, marble, granite and so on nonmetallic material machining, although is similar with the metal material cutting, but uses the cutting tool, the equipment and the cutting specifications and so on has the characteristic respectively.

The lumber product machining mainly carries in each kind of joiner's bench, its method mainly has: The saw cuts, digs cuts, the turning, the milling, drills truncates with the polishing and so on.

The plastic rigidity is worse than the metal, the easy bending strain, the thermoplastic thermal conductivity to be in particular bad, easy to elevate temperature the conditioning.When cutting plastic, suitably with the high-speed steel or the hard alloy tools, selects the small to feed quantity and the high cutting speed, and uses compressed air cooling.If the cutting tool is sharp, the angle is appropriate, may produce the belt-shaped scrap, easy to carry off the quantity of heat.

Glass (including semiconducting material and so on germanium, silicon) but degree of hardness high brittleness is big.To methods and so on glass machining commonly used cutting, drill hole, attrition and polishing.To thickness in three millimeters following glass plates, the simple cutting method is with the diamond or other hard materials, in glass surface manual scoring, the use scratch place stress concentration, then uses the hand to break off.

To the marble, the granite and the concrete and so on the hard material processing, mainly uses methods and so on cutting, turning, drill hole, shaping, attrition and polishing.When cutting the available circular saw blade adds the grinding compound and the water; The outer annulus and the end surface may use the negative rake the hard alloy lathe tool, by 10~30 meter/minute cutting speed turning; Drills a hole the available hard alloy drill bit; The big stone material plane available hard alloy planing tool or rolls cuts planing tool shaping; The precise smooth surface, available three mutually for the datum to the method which grinds, or the grinding and the polishing method obtains.

Cutting tool in hot strong alloy application

The aviation processing also changes rapidly. For example, nickel base heat-resisting alloy like several years ago the most people had not heard Rene88 now occupies to the aircraft engine manufacture uses the total metal quantity 10~25%. Has very good showing and the commercial reason regarding this. For example, these heat strong alloy will be able to increase the engine endurance moreover to permit the small engine work on the big airplane, that will enhance the combustion efficiency and reduces the operation cost. These tough good materials also present the expense on the cutting tool. Their thermal stability causes on the knife point the temperature to be higher, thus reduced the cutting tool life. Similarly, in these alloy carbide pellet remarkably increased the friction, thus reduces the cutting tool life.

As a result of changes in these conditions, can be very pleased to have processed many titanium alloys and nickel-based alloy materials C-2 hard metal alloys, in the application to today's cutting edge of blade to the crushing and cutting depth of the trench lines badly worn. But using the latest high-temperature processing of small particles hard metal alloys to be effective, cutlery life improved, but more importantly to enhance the reliability of applications in high-temperature alloys. Small particles hard metal than traditional hard metal materials higher compression strength and hardness, only a small increase in the resilience of the cost. And resulted in high temperature alloy processing than traditional hard metal resistance common failure mode more effective.

PVD (physical gas phase deposition) coating also by certificate effective processing heat-resisting alloy. TiN (titanium nitrides) the PVD coating was uses and still was most early most receives welcome. Recently, TiAlN (nitrogen calorization titanium) and TiCN (carbon titanium nitrides) the coating also could very good use. In the past the TiAlN coating application scope and TiN compared the limit to be more. But after the cutting speed enhances them is a very good choice, enhances the productivity in these applications to reach 40%. On the other hand, is decided under the low cutting speed in coating superficial operating mode TiAlN can cause to accumulate the filings lump afterwards, micro collapses with the trench attrition.

Recently, used in the heat-resisting alloy application material quality already developing, these coating but became by several combinations. The massive laboratories and the scene test has already proven this kind of combination and other any kind of sole coating compares in time the very wide scope application is very effective. Therefore aims at the heat-resisting alloy application the PVD compound coating possibly to become the focal point which the hard alloy new material quality research and development continues. With the MTCVD coating, the coating ceramics gather in the same place, they hopefully become a more effective processing to research and develop newly are more difficult to process the work piece material the main impact strength.

Dry processing

Including the refrigerant question is technical and the commercial expansion industrial production tendency another domain which the cutting tool makes. North America and the European strict refrigerant management request and the biggest three automobile manufacturer forces them the core supplier to obtain the ISO14000 authentication (the ISO9000 environment management edition), this causes the refrigerant processing cost rise. To the car company and their core supplier said obviously one of responses which welcome is in the specific processing application avoids completely the refrigerant the use. This kind did the processing the new world to propose a series of challenges for the cutting tool supplier.

Recently, already appeared some to concern this topic to promulgate the speed, to enter for, the coating chemical composition and other parameters very substantial comprehensive nature very strong useful technical papers. Wants to concentrate the elaboration in here me "does the processing viewpoint" in the operation and commercial meaning automobile manufacturer new.

The metal working jobholders can the very good understanding related refrigerant use question, but majority cannot understand concerns except the technical challenge (for example row of filings) beside does the processing question in the cutting tool - work piece contact face between. Usually may observe to the refrigerant disperser scrap which flows out, but the pressure surpasses 3,000 pounds/An inch 2 high speed refrigerant also can help to break the filings, specially soft also the continual scrap can cause in the cutting tool - work piece contact face trouble.

Uses does the cutting craft the components result is the engine bed uses the wet type processing components to be hotter than. Whether before you do allow them to survey in the open-air natural cooling? If processes newly the hot components put frequently to the turnover box, elevates the environment temperature, whether components full cooling and just right enough permission precision examination? Also has the handling side several dozens on hundred components to be able to operate the worker to increase the extra burden.

With many cutting tools/The work piece technical question same place, these latent questions need to state whether dryly adds the ability line. Luckily, has very many ways to elaborate these questions. For example, the compressed air was proven row of filings becomes the question in very many applications the situation to have the successful echo.

Another plan is called MQL (minimum lubrication) a technology, it replaces the traditional refrigerant by the application the quite few oil mists constitution. This is a recognition compromise plan, this kind of minimum technology can large scale reduce the refrigerant the headache matter, moreover the smooth finish which processes in many applications very is also good. This domain still had very many research to do, moreover the cutting tool company positively participated in such research was absolutely essential. If they will not do fall behind the competitor, will be at the disadvantageous position.

In the factory the special details design other perhaps better plan according to the world in. The manufacturing industry jobholders possibly still could ask why they do have to use recent development the technology to replace the refrigerant method diligently which the tradition already an experience number generation of person improved enhances, because implemented especially does the experiment and the defeat which the processing or the subarid processing produced possibly causes the higher short-term cutting tool cost. The concise answer is when the bit probably accounts for the model processing components cost 3%, the refrigerant cost (from purchases to maintenance, storage, processing) can account for the components cost 15%.

Perhaps does the dry processing is not all suits to each application, but above discusses likely other processing questions are same, needs from a wider operation, the environment and the commercial angle appraises. Will be able to help the cutting tool company which the customer will do this to have the competitive advantage, but these will not be able to provide unceasingly is in the passive position.

Cutting tool and nanotechnology

Can fiercely change the cutting tool industry the enchanting new domain is the miniature manufacture, or the processing small granule forms the product which needs. Must refer to is its here does not have about the cutting tool miniature manufacture first matter; Second must say the matter is it is not remote.

Why the miniature manufacture and are the cutting tool related. Because most main is the particle size smaller, the hard alloy toughness of material better also is more wear-resisting. (Some experts define with the nanometer level pellet for are smaller than 0.2 mu m, but other people persisted a nanometer pellet had to be smaller than the hard alloy tools prototype which 0.1 mu m) made already to complete and the test,It is said that wear resistant theatrically increase. The question is the nanometer level hard alloy pellet cannot depend on the smashing big material formation, they are certain through the smaller material constitution, but processes the molecular level granule is not easy and the economical matter.

  

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Efficient tool and modules

  Precision CNC machining parts Efficient tool  To improve production efficiency, double-sided, four and more than clamping fixture of more and more products. Work piece in order to reduce the installation time, all kinds of auto-centering clamping, precision flat clamp, clamping levers, cam clamp, such as pneumatic and hydraulic clamping, rapid clamping new features constantly. New type of electronically controlled permanent magnet fixture, step up and release the work piece only 1~2 seconds, simplifying the fixture structure for the machine to carry out stage, faceted and processing to create the condition. American JERGENS the company's ball lock clamping system,1 minutes, will be able to locate and lock fixture in the machine tool table, the ball lock clamping system of flexible production line for the replacement of fixtures, played reduce downtime and increase the role of productivity.

Precision CNC machining parts   Modular components of modular fixture is the basis of the realization of portfolio. Take advantage of the modular design of serialization, standardization fixture elements, quickly assembled into a variety of fixtures, has become a fixture technology development basis points.Save labor, time, materials, energy-saving, being reflected in a variety of advanced fixture system innovation. The modular design laid the foundation for the the fixture computer-aided design and assembly. Application of CAD technology to create a component library the typical fixture library, standard and user archive fixture optimization design, assembly fixtures for users dimensional solid. Cutting process simulation tool, both to provide users with the correct fixtures and components supporting the program, but also the accumulation of experience, understand the market demand, and continue to improve and perfect the fixture system.    

Precision CNC machining parts   Economic fixture versatility direct impact on the economy. Modules, modular fixture system, a one-time investment is relatively large, the only fixture system reconfigurable and scalability features a wide range of applications, common good, fixture utilization, faster recovery of investment to reflect the economic good.

  

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The material properties

The material properties can be classified into three major headings:

(i) Physical,

(ii) Chemical,

 (iii) Mechanical. Physical properties

   Precision CNC machining parts Density or specific gravity, moisture content, etc., can be classified under  this category. Chemical properties

  Precision CNC machining parts Many chemical properties come under this category. These include acidity or alkalinity, reactivity and corrosion. The most important of these is corrosion which can be explained in layman’s terms as the  resistance of the material to decay while in continuous use in a particular atmosphere.

  Precision CNC machining parts Mechanical properties  Mechanical  properties include the strength properties like tensile, compression, shear,  torsion, impact, fatigue and creep. The tensile strength of a material is obtained by dividing the maximum load, which the specimen bears by the area of cross-section of the pecimen. This is a curve  plotted between the stress along the Y-axis(ordinate) and the strain along the X-axis(abscissa) in a tensile test. A material tends to change or changes its dimensions when it is loaded, depending upon the magnitude of the load. When the load is removed it can be seen that the deformation disappear s. For many materials this occurs up to a certain value of the stress called the elastic limit. This is depicted by the straight line relationship and a small deviation thereafter, in the stress-strain curve.

 

veral examples

veral examples 

 transforms the X53 milling machine with SIEMENS 810M  

   In 1998, the company invested 200,000 Yuan, Cnc machining with German Simens the 810M numerical control system, the 611A exchange servo drive system sds was the X53 milling machine carries on X, Y, the Z three axle numerical control transformation to a company's model; Retained the original main axle system and the cooling system; The transformation three axle has used the roller lead screw and the gear drive organization on the machinery. The entire transformation work including the machine design, the electrical design, the PLC procedure establishment and the debugging, the engine bed overhaul, finally is the entire machine installment and the debugging. After the milling machine transforms, processing effective stroke X/Y/The Z axis respectively is 88.0/270/28 billion mm; Maximum speed X/Y/The Z axis respectively is 5000/1500/800 mm/Min; Manual speed X/Y/The Z axis respectively is 3000/1000/500 mm/Min; The engine bed processing precision achieves ±0.001mm. The engine bed three coordinates linkage may complete each kind of complex curve or the curved surface processing

Ransforms the C6140 lathe with GSK980T and the exchange servo drive system sds 

  In 2000, Cnc machining with Guangzhou numerical control plant production GSK980T numerical control system, the DA98 exchange servo unit and 4 locations automatic tool rests to an electrical machinery branch factory C6140 lathe X, the Z two axes carries on the numerical control

 transformation Retained the original main axle system and the cooling system; The transformation two axes have used the roller lead screw and with the ambulacrum transmission system on the machinery. Entire transformation work including machine design, electrical design, engine bed overhaul and entire machine installment and debugging. After the lathe transforms, processing effective stroke X/The Z axis respectively is 3.90/73 million mm; Maximum speed X/The Z axis respectively is 120.0/3 million mm/Min; The manual speed is 400mm/Min; Manual is fast is X/The Z axis respectively is 120.0/3 million mm/Min; The engine bed smallest migration unit is 0.001mm

Ransforms the X53 milling machine with SIEMENS 802S  

   In 2000, the company invests 120,000 Yuan, with German Simens the 802S numerical control system, step-by-steps the actuation system is the X53 milling machine carries on X, Y, the Z three axle numerical control transformation to company's another model; Retained the original main axle system and the cooling system; The transformation three axle has used the roller lead screw and the gear drive organization on the machinery. Cnc machining The entire transformation work including the machine design, the electrical design, the engine bed overhaul, finally is the entire machine installment and the debugging. After the milling machine transforms, processing effective stroke X/Y/The Z axis respectively is 63.0/240/28 billion mm; Maximum speed X/Y/The Z axis respectively is 3000/1000/600 mm/Min; Manual enters for speed X/Y/The Z axis respectively is 200.0/800/5 billion mm/Min; The smallest motion unit is 0.001mm.

Robot's adhibition 2

    Robot's adhibition 2

Manual operation of a simulation of the automatic machinery, ,Precision CNC machining parts it can be a fixed program draws ﹑ handling objects or perform household tools to accomplish certain specific actions. Application of robot can replace the people engaged in monotonous ﹑ repetitive or heavy manual labor, the mechanization and automation of production, instead of people in hazardous environments manual operation, improving working conditions and ensure personal safety. The late 20th century, 40, the United States atomic energy experiments, the first use of radioactive material handling robot, human robot in a safe room to manipulate various operations and experimentation. 50 years later, manipulator and gradually extended to industrial production sector, for the temperatures, polluted areas, and loading and unloading to take place the work piece material, but also as an auxiliary device in automatic machine tools, machine tools, automatic production lines and processing center applications, the completion of the upper and lower material, or From the library take place knife knife and so on according to fixed procedures for the replacement operation. Robot body mainly by the hand and sports institutions. Agencies with the use of hands and operation of objects of different occasions, often there are clamping ﹑ support and adsorption type of care. Movement organs are generally hydraulic pneumatic ﹑ electrical device drivers.

  Precision CNC machining parts  Manipulator can be achieved independently retractable ﹑ rotation and lifting movements, generally 2 to 3 degrees of freedom. Robots are widely used in metallurgical industry, machinery manufacture, light industry and atomic energy sectors.

 ,Precision CNC machining parts Can mimic some of the staff and arm motor function, a fixed procedure for the capture, handling objects or operating tools, automatic operation device. It can replace human labor in order to achieve the production of heavy mechanization and automation that can operate in hazardous environments to protect the personal safety, which is widely used in machinery manufacturing, metallurgy, electronics, light industry and nuclear power sectors.

  Mechanical hand tools or other equipment commonly used for additional devices, such as the automatic machines or automatic production line handling and transmission of the workpiece, the replacement of cuttingtools in machining centers, etc. generally do not have a separate control device. Some operating devices require direct manipulation by humans; such as the atomic energy sector performs household hazardous materials used in the master-slave manipulator is also often referred to as mechanical hand. 

 Precision CNC machining partsManipulator mainly by hand and sports institutions. Task of hand is holding the workpiece (or tool) components, according to grasping objects by shape, size, weight, material and operational requirements of a variety of structural forms, such as clamp type, type and  adsorption-based care such as holding. Sports organizations, so that the completion of a variety of hand rotation (swing), mobile or compound movements to achieve the required action, to change the location of objects by grasping and posture. Robot is the automated production of a kind used in the process of crawling and moving piece features automatic device, which is mechanized and automated production process developed a new type of device. In recent years, as electronic technology, especially computer extensive use of robot development and production of high-tech fields has become a rapidly developed a new technology, which further promoted the development of robot, allowing robot to better achieved with the combination of mechanization and automation. Robot can replace humans completed the risk of duplication of boring work, to reduce human labor intensity and improve labor productivity. Manipulator has been applied more and more widely, in the machinery industry, it can be used for parts assembly, work piece handling, loading and unloading, particularly in the automation of CNC machine tools, modular machine tools more

commonly used. At present, the robot has developed into a FMS flexible manufacturing systems and flexible manufacturing cell in an important component of the FMC. The machine tool equipment and machinery in hand together constitute a flexible manufacturing system or a flexible manufacturing cell, it was adapted to small and medium volume production, you can save a huge amount of the work piece conveyor device, compact, and adaptable. When the work piece changes, flexible production system is very easy to change will help enterprises to continuously update the marketable variety, improve product quality, and better adapt to market competition. At present, China's industrial robot technology and its engineering application level and comparable to foreign countries there is a certain distance, application and industrialization of the size of the low level of robot research and development of a direct impact on raising the level of automation in China, from the economy, technical considerations are very necessary. Therefore, the study of mechanical hand design is very meaningful.

  

Precision CNC machining parts

The basic requirements for clamping device

The basic requirements for clamping device

   Precision CNC machining parts Without damaging the work piece positioning accuracy and quality assurance process under the premise of clamping devices should be enabled to:   

  1. The size of the appropriate clamping force. It is necessary to ensure that the work piece in the whole process of its stable position vibration small but also so that the work piece does not produce excessive clamping deformation.   

  2. Technology is good. Precision CNC machining parts The complexity of the clamping device should be suited to the production of the Program to ensure production efficiency its structure should be kept simple easy to manufacture and maintenance. 

    3. Good use. The operation of clamping device should be convenient safe and labor-saving.

 Third the basic Clamp

   The original force into a clamping force through the clamping body to achieve.Among the many institutions in the clamping wedge oblique spiral and by their eccentric combination of the most common application of clamping.  

  (A) Wedge Clamp   

  Wedge used as components or transmission of the clamping device clamping body known as the Wedge Clamp.    

  Precision CNC machining parts Wedge clamping directly the oblique wedge of the self-locking conditions are:Wedge angle smaller than the work piece Wedge Wedge and folders between the concrete and the friction angle.

  Namely: a f1+f2  

   In order to ensure a reliable self-locking manual clamping generally take a =6 °~ 8 °. Using pneumatic or hydraulic device drivers do not need the self-locking oblique wedge it is desirable to a =15 ° ~35 °. 

    Wedge clamp is simple in structure than by large self-locking features such as performance it is widely available.

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 In the past, Dongguan CNC machining plant needed an additional operation on a milling machine or broaching machine to process serrations on parts. In this way, it needs to be set separately on additional machine tools, resulting in additional labor costs (for milling machine or broaching machine operators), of course, additional handling, movement and possible temporary parts storage between processes. In addition, parts may require intermediate cleaning operations before serration.

If Dongguan CNC machining plant regards sawtooth machining as one of the companies operating alone, you will be glad to learn that there is a sawtooth machining razor, which can be used to carry out sawtooth machining on CNC lathe, just like another process. Sawtooth razors are manufactured by schwanog and sold in the United States by GST Tools Co., Ltd. (Roselle, Illinois). The tool is composed of replaceable blade and supporting tool holder. The high-speed steel blade with tin coating consists of a 1 / 4 circle with six teeth. Only the first or guide teeth have a complete (finished) tooth profile. On the other five teeth, the tooth profile is a decreasing profile.
If you take the sawtooth machining of parts as a secondary operation, you can simply use this sawtooth razor as another process on the CNC lathe.
At the beginning of sawtooth machining in Dongguan NC machining plant, the main shaft remains stationary, while the turret goes three times on the Z axis to form the first five teeth and the fully formed sixth teeth in the form of progressive stage.
The tool is mounted on the turret of the lathe and forms sawtooth along the part through continuous z-axis stroke. At the beginning of the process, the spindle remains stationary and the tool runs three times to form the first five teeth and the full shape sixth teeth in a progressive stage. Then the spindle is indexed to the next tooth position (a c-axis is required), in which the first five teeth are formed incrementally and the last tooth is completed. Each time when the spindle is indexed to the next tooth position and the turret completes the part stroke, the machining of one tooth is completed. The process continues until the whole circle is indexed and the sawtooth is completely formed.
Once the first tooth of Dongguan NC machining plant is fully formed, the spindle divides the part to the next tooth position, and the turret goes another way to complete the tooth processing. Every time the spindle is indexed, a complete tooth is formed. The indexing cycle continues until the part is completely machined to the required sawtooth shape.
Dongguan CNC processing factory thinks the process is simple and fast. For example, the sawtooth machining of 1045 steel parts can be completed in less than 7 seconds on an ordinary CNC lathe with c-axis function. Combining the sawtooth machining operation into one lathe process can simplify the processing of parts: the operation does not have to be carried out on additional machine tools, avoiding the cleaning of parts between different processes, the setting and operation cost of additional machine tools, and the additional part handling process. The most important point is that the part is fully machined when leaving the lathe and ready for cleaning and sending to the customer. GST reported that the blade for sawtooth machining can be sharpened by the end user, but facilities for tool re centering must be provided. The removal of the blade is fast and simple because it is fixed with a single screw. Since the tool holder is only an adhesive tool, the tool for sawtooth machining can be used on both multi spindle machine tools with c-axis function and single spindle machine tools.

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 To improve the milling fixture installed in the machine tool stability, Precision CNC machining parts  reduce its intermittent cutting may be caused by vibration, not only in the specific folder have sufficient stiffness and strength, their height and width ratio should also beappropriate, a general H / B ≤ 1 ~ 1.25, in order to reduce the fixture center of gravity, so that as close as possible to the workpiece surface countertops.

Precision CNC machining parts In addition, we must set a reasonable and ear blocks to strengthen the tendons.   If the folder specific wide, can be set up in the same side of two T-slot milling machine table equidistant between the ears Block; of heavy-duty milling fixtures, specific folders should also be set up at both ends of the rings, such as lifting holes or to carry.   In the milling process, the often installed in the milling fixture table, together with the jig with the workpiece feed table for movement.In the milling process, the often installed in the milling fixture table, together with the jig with the workpiece feed table for movement. According to the workpiece feed means of general milling fixture can be divided into the following two types:    

  1. Linear feed-type milling fixture 。In the milling process, the often installed in the milling fixture table, together with the jig with the workpiece feed table for movement.

2. Circle feed milling fixture.Such fixtures are commonly used in the milling machine with rotary table, the workpiece table, together with the fixture with the continuous, slow movement of the rotary feed, no parking will be loading and unloading the workpiece. According to the processing requirements of the two cutter head can also be rough at the same time, finishing  

  Precision CNC machining parts Milling is a flat, keyway, gear and a variety of forming surface processing methods commonly used. Processing the workpiece in the milling machine, the general adoption of the following types of clamping methods:   

   (1) directly in the milling machine table clamping a large workpiece clamping often directly in the table, with stud, plate compactor, which need to dial indicator methods, tools such as zoned to find the needle surface and the cutter is processing relative position.      

 (2) vice flat tool used for clamping the workpiece in the shape of a simple, small parts, general machine tools can be used in clamping vice in the mouth, the need to ensure that when used in machine vice the correct position.

  (3) dividing head with the workpiece clamping, the need for indexing of the workpiece, the general direct clamping head in the sub-degrees. In addition, indexing of the workpiece without dividing head with clamping processing is also very convenient.

 (4) with V-shaped frame workpiece clamping method is generally applicable to.

Grinding technology development trend

Grinding technology development trend

 Precision CNC machining parts Grinding machining is important processing technology in mechanical manufacturing. With precision mechanical products, the requirement of increasing the reliability and service life, high hardness, high strength, high wear resistance, high functional new materials application increased, for grinding processing and put forward many new problems, such as material of grinding machining and surface integrity, super precision grinding and high efficiency grinding and grinding automation, etc. Problems to be solved.At present, the grinding technology is moving toward using super hard abrasives, development of precision and ultra precision grinding, high speed, high efficiency grinding technology and the development of high precision, high stiffness of the grinding machine automation direction. 

 One.   In-depth development of grinding theory and technology research

 Precision CNC machining parts Grinding theory research is the basis for the development of grinding technology, the grinding technology and the development of practice and research provides the opportunity for grinding theory, requirement and new topic, in recent ten years, professionals engaged in the work of grinding, grinding technology and phenomenon many factors for a lot of in-depth research and achieved fruitful results.

 Two.  Unit grinding machine high speed, high precision components manufacturing technology 

 Precision CNC machining parts High precision grinding machine spindle unit, feeding unit, bearing unit and auxiliary unit is the key parts and components. Spindle unit including spindle power, shaft, bearing, and frame sections, she affects the precision of the machining system, stability and application scope, its dynamic performance and stability of high performance precision ultra-precision grinding, play a key role. Feed unit including the position detection unit, Demand of feed units, therefore, flexible operation, high resolution, high positioning accuracy, not crawl and large movement range, both to have larger acceleration, and large enough thrust, high stiffness, quick dynamic response, high positioning accuracy. Machine tools supporting technology mainly refers to the supporting member of design and manufacturing technology. Auxiliary unit technology including fast clamping workpiece, high efficiency grinding fluid filtration system, machine safety devices, chip removal and the workpiece cleaning technology, spindle and grinding wheel dynamic balance technology, etc.

cutting speed

cutting speed, precision metal parts feed rate is an important parameter in the CNC machine tool cutting parameters, mainly based on the machining accuracy and surface roughness and the tool, workpiece material properties, select the maximum feed rate, machine tool stiffness and feeding system performance limitations., near the corner of contouring feed rate should be appropriately reduced in order to overcome the inertia or process systems is caused by deformation in the contour around the corner "overtravel" or "under process" phenomenon. to determine the principles of the feed rate : When the workpiece quality requirements can be guaranteed, in order to improve production efficiency, can choose a higher feed rate generally selected in the range of 100 ~ 200mm/min. processing in high-speed steel cutting tools, cutting, machining deep hole or should choose a lower feed rate, generally 20 ~ 50mm/min select range of .3 when machining accuracy, surface roughness, the feed rate should be selected smaller, generally in the 20 ~ 50mm/min range within selected .4 tool air travel, especially long-distance back to zero, you can select the CNC system given the maximum feed rate.

  precision metal parts back to eat the knife amount (or side knife to eat the amount determined under the premise of ensuring the quality of the machined surface, the back of cut (ap) should be determined according to the stiffness of the machine tool, workpiece and tool under the conditions allowed by stiffness, should as much as possible so that the back of cut allowance equal to the workpiece, thus reducing the number of tool path, and increase productivity.

   precision metal partss machining centers with axial and neck power head, to achieve the linkage of the three coordinates. Polar coordinate interpolation instruction and cylindrical interpolation instruction program optimization and development, and the machining station repeated positioning error of the effective compensation, the initial fast and reliable precision milling on the side of the rotary to improve the machining accuracy and surface finish quality.

    

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As a result of milling and cutting force cutting more and more intermittent cutting edge, easy processing of vibration, so they should pay attention to the design of milling machine fixture: clamping force to be sufficient self-locking and anti-stroke; fixture installation to be accurate and reliable , that is, when the processing installation and the proper use of directional keys on the knife device; precision turned parts specific folder have sufficient stiffness and stability, the structure must be reasonable. 

 precision turned parts As a result of milling and cutting force cutting more and more intermittent cutting edge, easy processing of vibration, so they should pay attention to the design of milling machine fixture: clamping force to be sufficient self-locking and anti-stroke;fixture installation to be accurate and reliable , that is, when the processing installation and the proper use of directional keys on the knife device; specific folder have sufficient stiffness and stability, the structure must be reasonable. 

1. Directional keys

 Directional key position, also known as keys, installed on the bottom of the vertical slot fixture, generally with two, an in a straight line, the farther the distance, the higher the precision-oriented, with screw fastening in the specific folder.   Directional keys work with the milling machine with table-shaped slot in the machine tool fixture to determine the correct position; can absorb part of the cutting torque, reducing the load on clamping bolt to increase the stability of the fixture, so flat and some special drilling jig boring machine fixture is also frequently used.  Directional keys are rectangular and round two.

 2. Of the knife device

   precision turned parts precision turned partsDevices on the knife block and knife by the side of the foot of the fixture and tool used to determine the relative position. The structure of the form of a knife depends on the shape of the surface processing.

  Directional high-precision fixture should not be used or heavy directional keys, but in the specific folder on one elongated side processing as a base to look for is the installation location calibration fixture.Knife block on the pin and screw fastener commonly used in the specific folder, its location should be easy-to-use plug-foot on the knife, without prejudice to the workpiece loading and unloading. On the knife when the knife cutter block with a plug in between the feet with the knife tool to avoid direct contact block or cause damage to the knife blade block premature wear. Cypriot Cypriot feet are flat feet and two-foot cylindrical plug, the thickness and diameter of 3 ~ 5mm, manufacturing tolerance h6.

  Side of the knife block and feet have been standardized (the design can be found in the relevant manual), use the total fixture Sedat map scale should be marked on the knife block size and the work surface and positioning the location between the components. Devices should be installed on the blade of the knife and is easy to cut one end of the workpiece.

  

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The application of industrial manipulator 

 Manipulator is in the process of mechanization, automation production, developed a kind of new type of device. In recent years, cnc machining parts with electronic technology, especially the wide application of electronic computer, the robot's development and production has become a high technology developed rapidly in the field of an emerging technology, it promoted the development of the manipulator, make the manipulator can achieve better with the combination of mechanization and automation.

 Manipulator although it is not as flexible as manpower, but it can have repeated work and labor, do not know fatigue, is not afraid of danger, cnc machining parts snatch heavy weights strength characteristics such as larger than man, as a result, the manipulator has been brought to the attention of the many departments, and have been applied more and more widely.

 (1) Machine tools machining the workpiece loading and unloading, especially in automatic lathe, use common combination machine tools.

(2) Widely used in the assembly operation, it can be used to assemble printed circuit board in the electronics industry, it can be in the machinery industry to assemble parts.

 (3) Can be in working conditions is poor, repetitive easy fatigue of the work environment, to instead of human Labour.

(4) The development of the universe and the ocean.

(5) Military engineering and biomedical research and test. 

   Application of robots can replace people in dull, repetitive or heavy  manual work, to realize mechanization and automation of production, instead of human in harmful environment of manual operation, improve labor condition, ensure the personal safety. In the late 1940 s, the United States in the nuclear experiments, firstly adopts manipulator handling radioactive materials, people in the security room to manipulate manipulator for various operation and experiment. After the '50 s, robots gradually extended to industrial production department, for use in high temperature, serious pollution of local leave work pieces and the loading and unloading materials, as auxiliary device in the machine tool automatic machine, automatic production line and processing center in the application, complete the material up and down or from libraries take put the knives and replace tool operations such as fixed procedure. Manipulator is mainly composed of hand and motion mechanism. Hand mechanism varies according to the usage situation and operation object, the common are holding, hold and the adsorption type etc. Motion mechanism usually driven by hydraulic, pneumatic, electric devices. Manipulator can be achieved independently of scaling, rotation and lifting movement, generally speaking, there are 2 ~ 3 degrees of freedom. Robots are widely used in machinery manufacturing, metallurgy, light industry and atomic energy etc.   

 Manipulator is used in the production process automation with grab and move the workpiece is a kind of automatic device, it is in the process of mechanization, automation production, developed a new type of device. In recent years, with electronic technology, especially the wide application of electronic computer, the robot's development and production has become a high technology developed rapidly in the field of an emerging technology, it promoted the development of the manipulator, make the manipulator can achieve better with the combination of mechanization and automation. Robots can replace humans do dangerous, repeat the boring work, reduce human labor intensity and improve labor productivity. Manipulator have been applied more and more widely, it can be used for parts assembled in the machinery industry, processing the workpiece handling, loading and unloading, especially on the automatic CNC machine, combination machine tools more common use. At present, the manipulator has developed into a flexible manufacturing system of FMS and flexible manufacturing cell is an important component of FMC. The machine tool equipment and manipulator of a flexible manufacturing system or flexible manufacturing unit, it is suitable for medium and small batch production, can save a large workpiece delivery device,cnc machining parts structure is compact, but also has a strong adaptability. When the workpiece changes, flexible production system is easy to change, is advantageous to the enterprise continuously updated marketable varieties, improve product quality, better adapt to the needs of the market competition. But at present our country's industrial robot technology and its engineering application level and foreign than there is a certain distance, scale and industrialization level is low, research and development of the manipulator has direct influence on raising the automation level of production in our country, from the consideration on the economic and technology is very necessary.

Therefore, carries on the research design of the manipulator is very meaningful.

Manipulator

Manipulator

  Robot developed in  Precision CNC machining parts recent decades as high-tech automated production equipment. Industrial robot is an important branch of industrial robots.

 It features can be programmed to perform tasks in a variety of expectations, in both structure and performance advantages of their Precision CNC machining parts own people and machines, in particular, reflects the people's intelligence and adaptability. The accuracy of robot operations and a variety of environments the ability to complete the work in the field of national economy and there are broad prospects for development.

 Precision CNC machining parts With the development of industrial automation, there has been CNC machining center, it is in reducing labor intensity, while greatly improved labor productivity. However, the upper and lower common in CNC machining processes material, usually still use manual or traditional  relay-controlled semi-automatic device. The former time-consuming and labor intensive, inefficient; the latter due to design complexity, require more relays, wiring complexity, vulnerability to body vibration interference, while the existence of poor reliability, fault more maintenance problems and other issues. Programmable Logic Controller PLC-controlled robot control system for materials up and down movement is simple, circuit design is reasonable, with a strong anti-jamming capability, ensuring the system's reliability, reduced maintenance rate, and improve work efficiency.

 Robot technology related to mechanics, mechanics, electrical hydraulic technology, automatic control technology, sensor technology and computer technology and other fields of science, is a cross-disciplinary integrated technology.

Numerical control system choice

Numerical control system choice 

  When the numerical control system mainly has three kind of types, the transformation, should act according to the special details to carry on the choice

Step-by-steps the open system which the electrical machinery drives   

   This system servo drive mainly is step-by-steps the electrical machinery, the power step-by-steps the electrical machinery, Cncmachining the battery solution pulse motor and so on. Entering sends out which by the numerical control system for instruction pulse, after the actuation electric circuit control and the power enlargement, causes to step-by-step the electrical machinery rotation, through gear vice- and ball bearing guide screw vice- actuation executive component. So long as the control command pulse quantity, the frequency as well as the circular telegram order, then may control the executive component movement the displacement quantity, the speed and the heading. This kind of system does not need the physical location and the velocity feedback which obtains to the input end, therefore called it the open system, this system displacement precision mainly decided in step-by-steps the electrical machinery angular displacement precision, transmission part and so on gear guide screw pitches the precision, therefore the system displacement precision is low.  

  This system structure simple, debugging service convenient, work reliable, cost low, is easy to reequip successfully

 The asynchronous motor or the direct current machine drive, diffraction grating survey feedback closed loop numerical control system 

  This system and the open system difference is: Cncmachining  Physical location feedback signal which by position detector set and so on the diffraction grating, induction synchromesh obtains, carries on the comparison as necessary with the given value, two interpolations enlargements and the transformation, the actuation implementing agency, by the speed which assigns turns towards the elimination deviation the direction movement, until assigns the position and the feedback physical location interpolation is equal to the zero. The closed loop enters for the system  Enters for the system complex in the structure compared to the split-ring, the cost is also high, requests strictly to the environment room temperature. The design and the debugging is all more difficult than the open system. But may obtain compared to the split-ring enters for a system higher precision, quicker speed, actuation power bigger characteristic target. May act according to the product specification, decided whether uses this kind of system

 The direct current servo electrical machinery drives, encoder feedback semi-closure link numerical control system

 Half closed-loop system examination part installs in among passes in the moving parts, indirectly surveys the executive component the position. It only can compensate a system ring circuit interior part of part the error, therefore, its precision compared to closed-loop system precision low, but its structure and the debugging all compares the closed-loop system to be simple. In makes the angular displacement examination part and the speed examination part and the servo electrical machinery time a whole then does not need to consider the position detector set installs the question

  The current production numerical control system Cncmachining  company factory quite are many, overseas famous company like German SIEMENS Corporation,

 Japanese FANUC Corporation; Native corporation like China Mount Everest Corporation, Beijing astronautics engine bed numerical control system group company, Central China numerical control company and Shenyang upscale numerical control country engineering research center. 

  When choice numerical control system mainly is each kind of precision which the engine bed must achieve after the numerical control transformation, actuates the electrical machinery the power and user's request.

The numerical control transformation superiorly lacks

The numerical control transformation superiorly lacks

 Reduced investment costs, the date of delivery are short 

  With purchases the new engine bed to compare, may save 60% ~ 80% expense generally, the transformation expense is low. Large-scale, the special engine bed especially is specially obvious. The common large-scale engine bed transforms, Cnc machining only spends the new engine bed purchase

 expense 1/3, the date of delivery is short. But some peculiar circumstances, like the high speed main axle, the tray automatic switching unit manufacture and the installment too requires a lot of work, costs a great deal of money, often transforms the cost to enhance 2 ~ 3 times, with purchases the new engine bed to compare, only can economical invest about 50%.

   Machine capability stable are reliable, the structure is limited

   Uses foundation and so on lathe bed, column all is heavy but the firm casting component, but is not that kind of welding component, after the transformation engine bed performance high, the quality is good, may take the new equipment continues to use many years. But receives the original mechanism the limit, not suitably makes the unprecedented transformation.

  Familiar understood the equipment, is advantageous for the operation service  

 When purchases the new equipment, did not understand whether the new equipment can satisfy its processing request. Cnc machiningThe transformation then otherwise, may precisely calculate the engine bed the processing ability; Moreover, because many years use, the operator already understood to the engine bed characteristic, uses and services the aspect to train the time in the operation short, effective is quick. The transformation engine bed as soon as installs, may realize the capacity load revolution.

 May fully use the existing condition

  May fully use the existing ground, Cnc machining does not need to like buys when the new equipment such to have reto construct the ground.

  May use the newest control technology 

 enhances the production equipment the automated level and the efficiency, improves the equipment quality and the scale, alters to the old engine bed now the horizontal engine bed.

Machine design

Machine design

 Precision CNC machining parts Machine design is the art of planning or devising new or improved machines to accomplish specific purposes. In general, a machine will consist of a combination of several different mechanical elements properly designed and arranged to work together, as a whole. During the initial planning of a machine, fundamental decisions must be made concerning loading, type of kinematic elements to be used, and correct utilization of the properties of engineering materials. Economic considerations are usually of prime importance when the design of new machinery is undertaken. In general, the lowest over-all costs are designed.

Precision CNC machining parts  Consideration should be given not only to the cost of design, manufacture the necessary safety features and be of pleasing external appearance. The objective is to produce a machine which is not only sufficiently rugged to function properly for a reasonable life, but is at the same time cheap enough to be economically feasible.

  Precision CNC machining parts The engineer in charge of the design of a machine should not only have adequate technical training, but must be a man of sound judgment and wide experience, qualities which are usually acquired only after considerable time has been spent in actual professional work.

The material's elastic limit

The material's elastic limit

Precisionmetal parts Within the elastic  range, the limiting value of the stress up to which the stress and strain are proportional, is called the limit of proportionality. In this region, the metal obeys Hooke’s law, which states

 that the stress is  proportional to strain in the elastic range of loading (the material completely regains its original dimensions after the load is removed). In the actual plotting of the curve, the proportionality limit is obtained at a slightly lower value of the load than the elastic limit. This may be attributed to the time-lag in  the regaining of the original dimensions of the material.

  Precisionmetal parts This effect is very frequently noticed in some no-ferrous metals.  While iron and  nickel exhibit clear ranges of elasticity, copper, zinc, tin, etc, are found to be imperfectly elastic even at relatively low values of stresses. Actually the elastic limit is distinguishable from the proportionality limit more clearly depending upon the sensitivity of the measuring instrument.

 When the load is increased beyond the elastic limit, plastic deformation starts.

 Simultaneously the specimen gets work-hardened. A point is reached when the deformation starts to occur more rapidly than the  increasing load. This point is called the yield point Q. the metal which was  resisting the load till then, starts to deform somewhat rapidly, i. e. , yield. The yield stress is called yield  limit.

Precisionmetal parts The elongation of the specimen continues form Q to S and then to T. the stess-strain relation in this plastic flow period is indicated by the portion QRST of the curve. At T the specimen breaks, and

 this load is called the breaking load. The value of the maximum load S divided by the original  cross-sectional area of the specimen is referred to as the ultimate tensile strength of the metal or simply the  tensile strength. Logically speaking, once the elastic limit is exceeded, the metal should starts to yield, and finally break, without any increase in the value of stress. But the curve records an increased stress even after the elastic limit is exceeded. Two reasons can be given for this behavior:

  1. the strain hardening of the material;

  2. the diminishing cross-sectional area of the  specimen, suffered on account  of  the plastic  deformation

Grinding automation and intellectualization

Grinding automation and intellectualization 

 Precision’s grinding With mechanical manufacturing in FMS (flexible manufacturing system) and CIMS (computer integrated manufacturing system), IMS (intelligent manufacturing system) height automation development direction, the grinding automation requirements are put forward. The development of the CNC grinding machine with CNC lathe, milling machine and so on started late. In the 1980 s and 90 s is a CNC grinding machine for rapid development and entered the popularizing period of practical. In recent years, almost all kinds of grinder CNC products, CNC tool grinding machine from 3 to 10 shaft axis development. Which can realize online measurement, automatic switching of grinding wheel and the emergence of the automatic unloading workpieces milling machining center, mark CNC grinding reached a new level. Grinding CNC system development also have great progress, many special grinding CNC software and systems have been commercialized. In the 1990 s, Japan announced about intelligent grinding results. Use of monitoring information and database, adaptive optimization in grinding condition and the judgment condition of grinding, using computer simulation and virtual technology, establish a realistic virtual grinding environment, to implement the intelligent of the grinding. Continuous track the use of grinding technology, making the grinding technology has made great development. 

 Grinding process monitoring and detection technology   

  Precision’s grinding  Implementation of intelligent computer control of grinding, grinding process is an important problem in the control room. Solve the grinding process, such as the phenomenon of signal identification, signal sampling, signal processing, feedback and compensation, need high sensitive sensor, also need to have expert system or intelligent system and the software design and other technical support.For grinding wheel wear and tear of using acoustic emission monitoring system. Because of the complexity of the grinding process, the grinding process of the monitoring system in theory and practical aspect still has many problems unsolved. Parts after the grinding size, shape and position accuracy, surface quality of the test is divided into offline and online detection.For super precision grinding and free abrasive machining high precision and low surface roughness obtained after detection, high-precision grinding on the surface of the on-line automatic detection are much harder than cars, milling, high sensitivity is the key to development of sensor technology and signal acquisition, recognition and processing technologies.

  Software of grinding technology

  Precision’s grinding  High performance CNC grinding machine should be equipped with a complete software system. Of intelligence information processing and data input of grinding, grinding mode selection and grinding the arrangement of the order, condition of grinding, grinding wheel dressing and grinding automatically selected, the state of the grinding process simulation and virtual detection and compensation, are in software design and development of a reasonable solution.All countries in the development of expert system and intelligent system software. Expert system is a branch of artificial intelligence research, and its essence is a kind of application system. Problem solving ability with expert level in the field of grinding process system, can effectively solve complex problems in the field of grinding.