Grinding technology development trend

Grinding technology development trend

  Grinding machining is important processing technology in mechanical manufacturing.cnc  grinding 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

   Grinding theory research is the basis for the development of grinding technology, cnc  grinding  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

   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, cnc  grinding 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.

Operational safety and environmental protection

Operational safety and environmental protection

 Along with advance in technology and human culture development, the people are more and more high to the working condition improvement and the environmental protection request.Cnc machining  The electric spark forming processing as a result of its own characteristic, can have the driving fluid splash, the smog, the noise, the electromagnetic radiation, the noxious gas inevitably in the processing process and so on the safety factor and the pollution, is noticeable to the operator personal safety and the environment harm. Therefore, for the guarantee electrical finishing industry sustainable development, must act according to “the green manufacture principle”, the realization resources most effective use and the reject threshold produces with the emissions. Should take following measure specifically:

  ①Seal engine bed work area. This is advantageous to the improvement driving fluid, the smog, Cnc machining the electromagnetic radiation and so on to the human body, the engine bed, the working conditions pollution, is advantageous in the operating process prevented receives an electric shock the danger as well as to the noxious gas centralized processing emissions;

 ②Vicarious technical utilization. For example, the environmental pollution which creates for the reduced use driving fluid, may in the guarantee processing efficiency, the processing precision, the processing cost as well as under the processing process stable premise, selects the pollution small driving fluid as far as possible, simultaneously should study, the development vigorously does not use the driving fluid the formed processing technology;

 ③Reject post-processing. The waste liquid, the waste gas produces which after the processing in must pass through processing to be able to discharge. Needs to point out specially, has pollutant reasonable processing to the processing process, not only is advantageous to the enhancement work security, the reduction environmental pollution, but also is advantageous in improves operator's working conditions, causes when the operator work the mood is happy, this regarding

 enhances the electrical finishing industry the social image and the market competitive power also is extremely beneficial.

    The electric spark forming processing technology holds the important status in the manufacturing industry domain, is realizes difficultly to process the material, the complex components precise processing effective method. The researcher should profit from other processing technological development the success experience, enhances strong points and avoid weaknesses, uses the modern science and technology development fully the related achievement, studies the electric spark in the deep person to discharge the mechanism in the foundation, the instruction electric spark forming processing craft theory and the control theory research, improves the engine bed structure and the design method, establishes based on the PC machine open numerical control system, the realization intelligence control technology and the electric spark forming processing technology organic synthesis, Cnc machining simultaneously takes the operational safety and the environmental protection highly, comprehensively impels an electric spark forming processing technology quicker development.

   

Electric spark forming processing craft trend of development

Electric spark forming processing craft trend of development

  Through processes the mechanism to the electric spark forming the research, further promulgates the electric discharge process the inherent laws, and take this as the instruction, impels the electric spark forming processing craft to the high efficiency, Cnc machining the high accuracy, the low loss direction to develop, meanwhile should pay attention to the micro refinement processing aspect the development.

  (1) processing process highly effective

     Not only the processing process highly effective manifests in through the improvement electric spark machining servosystem, the control system, the driving fluid system, the engine bed structure and so on, reduces the above factor to the electric spark forming processing efficiency influence, enhances, the precision work efficiency thickly in under the guarantee processing precision premise, meanwhile should reduce the non-cutting time as far as possible (for example programming time, electrode and work piece localization time, maintenance time and so on), this needs to strengthen the engine bed the automatic programming function, expands the engine bed online backstage programming ability, the improvement and the development suitable electrode and the work piece positioning device.  In the engine bed maintenance aspect, should strengthen the engine bed the multimedia functions and the online help function, regarding the common breakdown, the operator may act according to the computer prompt realization trouble shooting directly,Cnc machining  simultaneously this is also advantageous in strengthens the engine bed the feasibility and operator's operation skill.

  processing process precision  Through uses a series of advanced processing technology and the technique, at present the electric spark forming processing precision had the comprehensive enhancement, some has been possible to achieve the mirror surface processing level. But looked from the overall that, the vanguard technology insufficiently is also mature in the actual production application and widespread, therefore has the necessity comprehensive impetus to have the vanguard technology further consummation and to develop to the industrial production direction. In the guarantee processing speed, under the processing cost premise, makes the electric spark forming processing the precision level further to enhance, causes the electric spark forming to process into some major parts, the essential components finally processing way. At the same time, to processes the precision the weight not to be able to limit merely to the work piece size precision and the surface roughness, but also should include the profile the GDOP, deterioration level thickness as well as the microscopic crack, the oxidation, the corrosion and so on.

 (3) processing process micro refinement  An electric spark forming processing important application domain is the narrow trough, the deep cavity, the tiny components processing, therefore the processing process micro refinement will be the next important development direction. The electric spark processes the mechanism and the conventional electric spark forming processing tiny is same, but has own craft characteristic: Each pulse electric discharge energy is very small, driving fluid circulation difficulty, stable electric discharge gap scope small and so on. Based on these craft characteristic, the tiny electric spark forming processing processing equipment, the driving fluid circulatory system, the electrode preparation and so on inevitably and the conventional electric spark forming processing has the very big difference. Therefore, needs key to study the non-mechanical action。and the disturbance to the processing process influence and so on, further enhances the processing efficiency, the processing precision and the processing process stability.

  

(4) application scope expansion 

At present, not only the electric spark forming processing may process each kind of electric conduction metal material and the complex die space, but also can realize to the semiconducting material, the non-conducting material processing, and has obtained the good processing effect. At the same time, the electrode material type also unceasingly increases. This aspect main trend of development is: Further studies the semiconducting material, the non-conducting material electric spark machining mechanism, promotes its processing efficiency, the processing precision, the processing process stable enhancement, the expansion to be possible to process the material the scope; Besides the processing complex die space,Cnc machining  further realizes to the three dimensional die space, the complex profile processing; Development performance superior new electrode material.

Electric spark forming processing equipment structure improvement

Electric spark forming processing equipment structure improvement

  The model modern machining engine bed development experience, the electric spark forming processing equipment develops to the numerical control direction is a irreversible tendency. On the one hand should by the high accuracy, the high velocity, change into the pursue goal automatically, seizes the market by the technical superiority;precision parts  On the other hand should consider fully the equipment the performance price compared to, through to the engine bed function reasonable localization, makes the structure improvement and the modular design, uses the open numerical control system, enhances rationality which the engine bed designs, provides by the lowest price and the enough function to the user may satisfy each kind of electric spark forming processing engine bed which the different processing needs.

 Modern machining technological development impact, before suits uses the electric spark machining a part of processing domain to substitute gradually for the machining way. But, the modern science and technology development proposed to the components manufacture precision a higher request, each kind of high performance material application is day by day widespread, simultaneously, some components structure tends to the complication, precision parts the microminiaturization, thinly, this all causes the machining technology to be restricted in certain processing domain application, but these are exactly the electric spark forming processing technical superiority, also is it has the existing space and the development potential reality basis.

  For the comprehensive impetus electric spark forming processing equipment technology advancement, while uses the advanced control system, the engine bed structure design also needs further to consummate, its main development direction displays in following two aspects:

 (1) straight line servosystem application  The electric spark forming processing equipment uses the straight line electrical machinery servosystem to be possible to cause the workability to obtain the distinct improvement, the concrete manifestation is:  May realize the axis direct translation, omits a guide screw nut transmission link, thus guarantee axis high speed movement;  Uses the straight line electrical machinery and the slide integration structure, may eliminate between the slide and the electrical machinery because of has the machinery lag in response phenomenon which the middle link causes, enhances the system the sensitivity, reduces the dynamic response time, the guarantee processing process stability;  The straight line electrical machinery servosystem mode of motion had decided its position examination link must use the straight line position feedback part, the realization not middle link direct position examination, thus constitutes an entire closed-loop system, the guarantee processing process high accuracy and the precision retentivity. At present, the straight line servosystem application in deep narrow, the small die space processing and a mould pressing components mold multi-cavity processing aspect has the obvious technical superiority. But, these technical superiority must realize truly, except must unify the electric spark forming processing electric discharge process characteristic, outside the solution straight line servosystem itself technical difficult problem, but also must solve a series of and the straight line servosystem necessary related technology, like translation system dynamic equilibrium, work table structure improvement and so on.

 (2) engine bed mode of motion improvement

   Breaks through the existing electric spark forming processing engine bed mode of motion the limitation, is displays its technical superiority, impels its industrial development another important way. The model modern machining technology development experience, may direct the human circular motion in the engine bed main processing forming movement foundation, specially uses the multiple spindle rotary system and many kinds of translation coordinating group synthesizes many kinds of compound motion way, adapts the different type work piece processing request, the expanded electric spark forming processing processing scope, enhances it in the precise processing aspect comparison superiority and the technical benefit. At present, many electric spark forming processing engine bed has made some improvements in the mode of motion, if Swiss Arch Company produces AGIF the MONDO STAR20(50) engine bed has the EQUIMODE function, can realize the spatial any direction hemisphere stable motion, this kind of stable motion function has the very high practical value in the actual processing. But the present electric spark forming processing engine bed additionally builds the mode of motion is also unitary, the application scope is limited. The electric spark forming processing must in aspects and so on processing precision, processing efficiency, processing scope obtain the significant breakthrough, an important development direction is to the engine bed forming mode of motion innovation and the diversification. Recently, Japan University of Tokyo -odd component doctor, increased Ze prosperous long Professor and so on to propose loss concepts and so on electrode, namely through to processed the way the reasonable plan, might cause the electrode to lose is at and so on the loss conditions, thus caused the compensation which the electrode lost to become extremely simple.

 This concept statement has provided the essential theory basis for the electric spark forming processing mode of motion improvement. Certainly, produces from this the engine bed structural change and the correlation technology theory research also must further the deep person and the consummation, even has the possibility to develop one kind of brand-new processing theory.

 In addition, precision parts the engine bed overall construction design must consider fully the environmental protection as well as a human machine coordination, with the aid of the advanced design method and the method (for example CAD, the finite element analysis and so on) carry on the comprehensive optimized design to the engine bed structure, enhances the engine bed structure fully the sophistication and the rationality.

Electric spark forming processing technology trend of development

Electric spark forming processing technology trend of development

  The advanced technique of manufacture fast development and the manufacturing industry market competition aggravating proposed to the electric spark forming processing technology a higher request,cnc milling machine  simultaneously also for the electric spark forming processing technology processing theory research and the craft development, the equipment renewed has provided the new power. The next electric spark forming processing processing object will be supposed mainly to face the tradition machining not not easily to realize difficultly to process processings and so on material, complex profile, in which fine processing, the precise processing, the narrow dadoing, the deep cavity processing and so on becomes the development priorities. At the same time, but also should pay attention with other special processing technology or the tradition machining technology compound application, displays each processing method difficultly to process in the material processing fully the superiority, obtains the union increment effect. Is opposite says in the machining technology, the electric spark forming processing technology was still a young technology, therefore in the next development, will be supposed to profit from the experience and the achievement which in the machining technological development process will obtain, will process own technical characteristic according to the electric spark forming, will select the suitable processing theory, the control principle and the technique, and will have in the achievement foundation in oneself to consummate, the innovation unceasingly. The electric spark forming processing engine bed the tendency which develops to the numerical control direction already irreversible, but should pay attention cannot pursue blindly “large and complete”. should take the market as the guidance, cnc milling machine the establishment has the open numerical control system. Overall, the electric spark forming processing technology next trend of development should be the high efficiency, the high accuracy, the low loss, the micro refinement, the automation, the security, the environmental protection and so on

 electric spark forming processing theory trend of development

  In recent years, the electric spark forming processing basic theory research not yet made the substantive progress, although some scholars to the processing process electric discharge trace, the material eclipse eliminated the principle and so on to propose some new views, but obtained the significant breakthrough by no means in the electric spark machining mechanism research aspect. The more active research area mainly concentrates in the processing craft theory and the control theory aspect.

  In the processing craft fundamental research aspect, how does the research   8  hot spot mainly is enhance the electric spark forming processing the surface quality and the processing speed, reduces the loss, the development electric spark machining scope, as well as exploration complex, tiny structure processing method and so on. Will apply through the research results in the production practice, will comprehensively enhance the electric spark forming processing workability. In the control fundamental research aspect, the intelligent control always is the research key. The domestic and foreign production new electric spark forming processing engine bed mostly has used the intelligent control technology, this technical application makes the engine bed operation to be easier, requests to the operator lowly. At the same time, the intelligence control system has from the learning capability, but the online automatic monitor, the adjustment processing process, realizes the processing process optimized control.

 Although the electric spark forming processing fundamental research in aspects and so on basic theory, processing craft theory, control theory all has certain development and the enhancement, but the processing craft theory, the control theory need to obtain the further full scale development, must have the breakthrough in the entire electric discharge process mechanism research. Therefore, the electric spark forming processing fundamental research trend of development will be further is discussing the processing craft theory and the control theory, cnc milling machine enhances the electric spark forming processing workability and the processing scope, obtains the better control effect at the same time, key research electric discharge process mechanism.

 The electric spark forming processing mechanism research has not made the unprecedented progress the primary cause except outside the electric discharge process itself complexity, randomness, but also because the research technique and the method lack the innovation. Therefore, it is necessary to profit from other research area the success experience, directs the human advanced research technique and the experimental technology, the victory tradition research technique limitation, the deep person analysis and the revelation entire electric discharge process intrinsic essence, cnc milling machine the establishment may reflect objectively the electric discharge process rule the theoretical model, instructs the electric spark forming processing craft theory and the control theory research, but the computer simulation technical possibilities realizes this process effective tool.

Electric spark forming processing technology present situation and trend of development

Electric spark forming processing technology present situation and trend of development

 Introduction 

 As an advanced technique of manufacture important branch, the special processing technology, the electric spark machining technology, since the 20th century 40's foundations, has had been through repeatedly in particular for more than half centuries the development, Cnc machining has become the advanced technique of manufacture domain indispensable important constituent. Enters after in particular the human for 1990s, along with high technology and new technology and so on information technology, networking, aviation and astronautics technology, materials science technology development, the electric spark forming processing technology also faces a deeper level, the high level direction is developing. Although some traditional processing technology through own unceasing renewal development as well as with other correlation technology fusion, difficult to process the material processing domain in some (especially in mold processing domain) to display the processing efficiency higher superiority, but these technical application has been impossible to substitute for the electric spark forming processing technology difficultly to process processing domain completely and so on in the material,Cnc machining complex profile, mold statuses. On the contrary, the electric spark forming processing technology through profits from other processing technology the development experience, to the micro refinement, highly effective directions and so on, precision, automation, intellectualization is developing unceasingly.

  Electric spark forming processing technology development present situation

   At present, in electric spark machining basic theory research area, because the electric discharge process itself complexity, randomness as well as the research method lack the innovation, until now not yet made the unprecedented progress. But in processing craft and control fundamental research domain, because the research results may apply directly in the production practice, therefore has become in the present electric spark forming processing engineering research a more active domain, its research hot spot mainly concentrates in the highly effective processing technology, the high precise processing technology (glassy surface processing technology), Cnc machining the low loss processing technology, the tiny processing technology, the non-conducting material processing technology, the electric spark surface treatment technology, the intelligent control technology (for example artificial neural networks technology, fuzzy control technology, expert system and so on) as well as aspects and so on operational safety, environmental protection. In the process unit development aspect, the present new electric spark forming processing engine bed in aspects and so on processing function, processing precision, automaticity, reliability improved comprehensively, many engine beds have had online functions and so on examination, intelligent control, modulation, no longer is in the traditional significance special processing engine bed, but looks like in the machining the numerical control engine bed even to process the center.

Light Cutting

Light Cutting

 Besides carbide and tungsten, light is an appropriate “tool material” for  micro-holemaking. Although most laser drilling is performed in the infrared spectrum, the SuperPulse technology from The Ex One Co., Irwin, Pa., cnc milling machine uses a green laser beam, said Randy Gilmore, the company’s director of laser technologies. Unlike the femtosecond variety, Super- Pulse is a nanosecond laser, and its green light operates at the 532-nanometer wavelength. 

 The technology provides laser pulses of 4 to 5 nanoseconds in duration, and  those pulses are sent in pairs with a delay of 50 to 100 nanoseconds between individual pulses. The benefits of this approach are twofold. “It greatly enhances material removal compared to other nanosecond lasers,” Gilmore said, “and greatly reduces the amount of thermal damage done to the workpiece material” because of the pulses’ short duration. 

    The minimum diameter produced with the SuperPulse laser is 45 microns, but one of the most common applications is for producing 90μm to 110μm holes in diesel injector nozzles made of 1mm-thick H series steel.cnc milling machine  Gilmore noted that those holes will need to be in the 50μm to 70μm range as emission standards tighten because smaller holes in injector nozzles atomize diesel fuel better for more efficient burning.  

 In addition, the technology can produce negatively tapered holes, with a smaller entrance than exit diameter, to promote better fuel flow.

  Another common application is drilling holes in aircraft turbine blades for cooling.  Although the turbine material might only be 1.5mm to 2mm thick, Gilmore explained that the holes are drilled at a 25° entry angle so the air, as it comes out of the holes, hugs the airfoil surface and drags the heat away. That means the hole traverses up to 5mm of material.  “Temperature is everything in a turbine” he said, “because in an aircraft engine, the hotter you can run the turbine, the better the fuel economy and the more thrust you get.”

  To further enhance the technology’s competitiveness, Ex One developed a  patent-pending material that is injected into a hollow-body component to block the laser beam and prevent back-wall strikes after it creates the needed hole. After laser machining, the end user removes the material without leaving remnants.   “One of the bugaboos in getting lasers accepted in the diesel injector community is that light has a nasty habit of continuing to travel until it meets another object,” Gilmore said. “In a diesel injector nozzle, that damages the interior surface of the opposite wall.” 

  Although the $650,000 to $800,000 price for a Super- Pulse laser is higher than a  micro-holemaking EDM, Gilmore noted that laser drilling doesn’t require electrodes. “A laser system is using light to make holes,” he said, “so it doesn’t have a consumable.” 

  Depending on the application, mechanical drilling and plunge milling, EDMing and laser machining all have their place in the expanding micromachining universe. cnc milling machine“People want more packed into smaller spaces,” said Makino’s Kiszonas.

  

Turn to Tungsten

Turn to Tungsten

  EDMing is typically a slow process, and that holds true when it is used for  microdrilling. cnc milling machine “It’s very slow, and the finer the details, the slower it is,” said , president and owner of Optimation Inc. The Midvale, Utah, company builds Profile 24 Piezo EDMs for micromachining and also performs microEDMing on a contract-machining basis. 

 Optimation produces tungsten electrodes using a reverse-polarity process and machines and ring-laps them to as small as 10μm in diameter with 0.000020" roundness.  cnc milling machine  Applying a 10μm-dia. electrode produces a hole about 10.5μm to 11μm in diameter, and blind-holes are possible with the company’s EDM. The workpiece thickness for the smallest holes is up to 0.002", and the thickness can be up to 0.04" for 50μm holes.

  After working with lasers and then with a former EDM builder to find a better way to produce precise microholes, Jorgensen decided the best approach was DIY. “We literally started with a clean sheet of paper and did all the electronics, all the software and the whole machine from scratch,” he said. Including the software, the machine costs in the neighborhood of $180,000 to $200,000. 

  Much of the company’s contract work, which is provided at a shop rate of $100 per hour, involves microEDMing exotic metals, such as gold and platinum for X-ray apertures, stainless steel for optical applications and tantalum and tungsten for the electron-beam industry. cnc milling machine  Jorgensen said the process is also appropriate for EDMing partially electrically conductive materials, such as PCD.  “The customer normally doesn’t care too much about the cost,” he said. “We’ve done parts where there’s $20,000 [in time and material] involved, and you can put the whole job underneath a fingernail. We do everything under a microscope.”

Microvaporization

Microvaporization

 Electrical discharge machining using a sinker EDM is another micro-holemaking option. Unlike ,Cnc machining  which create small holes for threading wire through the workpiece when wire EDMing, EDMs for producing microholes are considerably more sophisticated, accurate and, of course, expensive. 

 For producing deep microholes, a tube is applied as the electrode. For EDMing smaller but shallower holes, a solid electrode wire, or rod, is needed. “We try to use tubes as much as possible,” said Jeff Kiszonas,Cnc machining  EDM product manager for Makino Inc., Auburn Hills, Mich. “But at some point, nobody can make a tube below a certain diameter.” He added that some suppliers offer tubes down to 0.003" in diameter for making holes as small as 0.0038". The tube’s flushing hole enables creating a hole with a high depth-to-diameter ratio and helps to evacuate debris from the bottom of the hole during machining。

 One such sinker EDM for producing holes as small as 0.00044" (11μm) is Makino’s Edge2 sinker EDM with fine-hole option. In Japan, the machine tool builder recently produced eight such holes in 2 minutes and 40 seconds through 0.0010"-thick tungsten carbide at the hole locations. The electrode was a silver-tungsten rod 0.00020" smaller than the hole being produced, to account for spark activity in the gap. 

  When producing holes of that size, the rod, while rotating, is dressed with a charged EDM wire. The fine-hole option includes a W-axis attachment, which holds a die that guides the electrode, as well as a middle guide that prevents the electrode from bending or wobbling as it spins. With the option, the machine is appropriate for drilling hole diameters less than 0.005".

 Another sinker EDM for micro-holemaking is the Mitsubishi VA10 with a fine-hole jig attachment to chuck and guide the fine wire applied to erode the material. “It’s a standard EDM, but with that attachment fixed to the machine, we can do microhole drilling,” said Dennis Powderly, Cnc machiningsinker EDM product manager for MC Machinery Systems Inc., Wood Dale, Ill. He added that the EDM is also able to create holes down to 0.0004" using a wire that rotates at up to 2,000 rpm.