CNC machining machinery parts use the geometry and use of slitting saws

CNC machining machinery parts use the geometry and use of slitting saws

When CNC machining requires cutting deeper than deeper materials, the slitting saw is ideal for getting the job done. The slit saw is unique due to its composition and rigidity, which allows it to accommodate a variety of machine materials that are straightforward and difficult to machine.

What is a slit saw?

The slitting saw is a flat (with or without a plate), a circular saw with a hole in the middle and a toothed outer diameter. When used with a shank, the slitter is used for machining purposes and requires the removal of large amounts of material in small diameters, such as grooving or cutting applications.

CNC machining, machining of mechanical parts

CNC machining processes include (but are not limited to) slitting knives, slotting knives, jewelry saws and slitting knives. A special type of slitting saw is sometimes used. For example, with a high number of teeth, it is possible to cut small, precise features. In the case of slitting saws for the machining of some special mechanical parts, the number of saw teeth is usually much higher than other types of saw teeth, so that the cutting is as accurate as possible.

 

Why use a slitting saw for CNC machining?

Designed to cut black and non-ferrous materials, these saws use their unique shape and geometry to cut thin groove features on parts more efficiently than any other tool.

 

Common applications:

If an application requires a piece of material (such as a rod) to be cut in half, the slitting saw will separate the parts well and increase efficiency. If installed correctly, the saw can perform an undercut application, which eliminates the need to completely reinstall the workpiece. Ability to create thin grooves with significant cutting depth.

When not to use a slitting saw

Although it may resemble a stainless steel circular saw blade from a hardware store, the slitting saw should always be used with construction tools such as watches or circular saws. When used on a manual machine, brittle saw blades such as slitting saws can break and cause damage when not used on the correct settings.

How to do technical analysis of CNC precision machined parts

The extensive application of CNC precision machining technology in China’s manufacturing industry has made more and more precision machining practitioners pay more attention to this. However, due to the complexity of CNC machining technology, operators need to learn in advance. In particular, the machining process analysis of CNC parts has a wide range of aspects. This paper analyzes the possibility and convenience of CNC precision machining.

First, the size data on the part drawing should be given in accordance with the principle of convenient programming.

1. The dimensioning method on the part drawing should be adapted to the characteristics of CNC machining.

On the NC machining part drawing, the same reference engraving size or directly giving the coordinate size, this marking method is very helpful for the convenience of programming, and also contributes to the coordination between the dimensions. In particular, it is very convenient to maintain the consistency of design basis, process reference, test reference and programming origin setting.

CNC precision machining

Since the part designer generally takes into account the use characteristics such as assembly in the process of dimensioning, the partial dispersion labeling method has to be adopted, which brings a lot of inconvenience to the process arrangement and the numerical control processing. Since the numerical control machining precision and the repetitive positioning accuracy are high, the use characteristics are not destroyed due to a large accumulation error, so the local dispersion notation method can be changed to the same reference engraving size or the coordinate method directly giving the coordinate size…

2. The conditions for the geometric elements that make up the contour of the part should be sufficient

When doing manual programming, you need to calculate the base point or node coordinates. In the case of automatic programming, the geometric elements that make up the contour of the part are defined. Therefore, in the analysis of the part drawing, it is necessary to analyze whether the conditions given by the geometric elements are sufficient.

For example, an arc and an arc are tangent to the pattern, but according to the dimensions given in the figure, when the tangency condition is calculated, it becomes an intersecting or dissociating state. Because the conditions that make up the geometry of the part are not sufficient, programming can’t be done. This situation needs to be negotiated with the part designer.

Second, the structural processability of each processing part of the part should meet the characteristics of CNC machining

1. The internal cavity and shape of the part are preferable of uniform geometry and size. This can reduce the tool size and the number of tool changes, making programming easier and improving production efficiency. Precision machining

2, the size of the inner groove rounding determines the size of the tool diameter, so the inner groove fillet radius should not be too small. The quality of the part is related to the height of the contour to be machined and the radius of the adapter arc.

3. When the part is ground in the bottom plane, the corner radius of the groove bottom should not be too large.

4. It is best to use a uniform standard positioning. In CNC machining, if there is no uniform reference positioning, the contour position and size of the two faces after machining will be uncoordinated due to the re-installation of the workpiece.

CNC machining precision machine parts to support a wide range of industries and applications

With our more than 10 years of CNC machining experience, including five-axis CNC machining, our Shenzhen precision machinery processing plant has met a wide range of applications.

Precision machinery parts processing needs in various industries.

The factory continues to expand our micromachining capabilities, which not only require CNC machining skills, but must also ensure high precision machining of small parts.

The expertise accumulated in this area for more than 10 years has enabled us to meet the needs of increasingly diverse precision small parts applications, especially

In the medical device industry.

Shenzhen Precision Machinery Processing Factory has almost all the skills of processing metal together. We are in 5-axis CNC machining and other multi-axis machining processes.

Expertise extends to our ability to process complete material arrays, allowing customers to design materials in parts that are intended for customers

Use to provide the best performance.

Our in-depth knowledge of material properties and multi-axis CNC machining characteristics allows us to select processes that produce the correct tolerances, regardless of

What precision mechanical parts do you use to machine materials, including many different grades of stainless steel, titanium, aluminum, brass, and copper.

How to achieve the target cost through flexible CNC machining customization services

Leverage the user’s supplier resources

Larger vendors tend to have more resources available. For OEMs, this means more cost savings. CNC processing manufacturers with sufficient funds have purchased the machinery needed for the most efficient custom processing.

Even if a piece of equipment has only five years of history, a suitable CNC processing supplier will evaluate newer models and use equipment that will save customers the most money.

The user’s manufacturer should also work with their suppliers to learn more about the cost-effective methods of machining parts. The material supplier helps the user’s manufacturer understand the new material and select the right coolant and machine for the specific environmental conditions. Metal manufacturers should meet with suppliers on a regular basis, preferably at least once a week.

In addition to metalworking services, skilled manufacturers also provide their expertise. Through product audits, experts can provide users with advice on process and design techniques to help users reduce CNC machining costs. For example, the following strategies can help users save money:

1. Reduce the wall thickness

Minimizing wall thickness can significantly reduce costs. However, it is important not to overdo it. Too thin a wall can actually increase the cost of the user because it does not stay in good shape during the manufacturing process.

2. Limit depth

Design shallow holes as much as possible and eliminate unwanted holes. The rib depth should not exceed 2 inches, and the user should try to eliminate unnecessary undercuts in the design of CNC machined parts.

3. Minimize small functions

It takes more time to machine small functions because they are difficult to mill. Unless some small features are absolutely necessary for the user’s product operation, eliminate them to reduce costs.

4. Avoid text

The sunken text on CNC machined parts costs extra money because of the long processing time. If users use expensive materials, it is especially important to reduce the text – a mistake on expensive materials can greatly increase the cost of the user.

In the user’s entire relationship, the user’s supplier should be flexible and adapt to the needs of the user. It is not uncommon for an OEM to call a supplier in the afternoon and say that it sends a batch of fixtures that need to be processed the next morning. In most cases, the user’s supplier should be able to meet this requirement. With flexible, customized processing services, users’ businesses will gain the attention they need to thrive.

The most comprehensive metal surface treatment summary

The surface treatment is the formation of a layer of one or more special properties on the surface of a material by physical or chemical means. Through the table

Surface treatment can improve the appearance of the product, texture, function and other aspects of performance.

First, anodizing

Mainly aluminum anodizing is the use of electrochemical principles to form a layer of Al2O3 (alumina) film on the surface of aluminum and aluminum alloy. This layer

The oxide film has special properties such as protection, decoration, insulation and wear resistance.

Process flow:
Monochrome, gradient:
Polishing / sand blasting / drawing → degreasing → anodizing → neutralization → dyeing → sealing → drying
Two colors:
1 polishing / sand blasting / drawing → degreasing → shading → anodizing 1 → anodizing 2 → sealing → drying
2 polishing / sand blasting / drawing → degreasing → anodizing 1 → laser engraving → anodizing 2 → sealing → drying

Technical features:
1, increase the strength
2, achieve any color other than white
3, to achieve nickel-free sealing, to meet the requirements of Europe, the United States and other countries for nickel-free

Technical difficulties and key points for improvement:
The yield level of anodizing is related to the cost of the final product. The focus of improving the oxidation yield is the appropriate amount of oxidant, suitable.

Temperature and current density, which require structural parts manufacturers to continuously explore in the production process, seeking breakthroughs.

Products Recommended:
E+G curved handle, anodized material, environmentally friendly and durable.

Second, electrophoresis

Used in stainless steel, aluminum alloy, etc., it can make the product appear in various colors, and maintain the metallic luster, while enhancing the surface properties, it has better

Anti-corrosion properties.

Process flow:
Pretreatment → electrophoresis → drying

advantage:
1, rich in color;
2, no metal texture, can be combined with sandblasting, polishing, drawing, etc.;
3, processing in a liquid environment, can achieve the surface treatment of complex structures;
4, the process is mature, mass production.

Disadvantages:
The ability to cover defects is general, and the electroforming of die-casting parts requires higher pre-treatment.

Third, micro arc oxidation

The process of applying a high voltage to form a ceramized surface film layer in an electrolyte solution (generally a weakly alkaline solution), which is a physical discharge

The result of synergy with electrochemical oxidation.

Process flow:
Pretreatment → Hot water wash → MAO → Drying
advantage:
1, ceramic texture, dull appearance, no high-gloss products, delicate touch, anti-fingerprint;
2. Wide range of substrates: Al, Ti, Zn, Zr, Mg, Nb, and alloys thereof;
3, the pre-treatment is simple, the product has excellent corrosion resistance, weather resistance and good heat dissipation performance.

Disadvantages:
At present, the color is limited, only black, gray, etc. are more mature, and bright colors are currently difficult to achieve; the cost is mainly affected by high power consumption,

One of the most costly aspects of surface treatment.

Fourth, PVD vacuum plating

Full name physical vapor deposition, a process in industrial manufacturing, is a technology that mainly uses physical processes to deposit thin films.

Process flow:
Pre-PVD cleaning→Intake vacuuming→washing target and ion cleaning→coating→coating finish, cooling out→posting (polishing, AFP)

Technical features:
PVD (Physical Vapor Deposition) can be plated on metal surfaces with high hard plating and high wear resistance.

Porcelain decorative coating

Five, plating

It is a process of attaching a metal film to the surface of a metal by electrolysis to prevent corrosion, improve wear resistance, conductivity, and anti-

A technique for the effects of light and aesthetics.

Process flow:
Pretreatment → Cyanide-free copper → Cyanide-free white copper tin → Chrome plating

advantage:
1. High gloss and high quality metal appearance;
2. The substrate is SUS, Al, Zn, Mg, etc.; the cost is lower than PVD.

Disadvantages:
Environmental protection is poor and the risk of environmental pollution is high.

Six, powder coating

The powder coating is sprayed onto the surface of the workpiece by a powder spraying device (electrostatic spray machine), and the powder is uniformly adsorbed under the action of static electricity.

The surface of the workpiece forms a powdery coating; the powder coating is cured by high temperature baking and flattening, and the effect is different (different kinds of powder coating)

The final coating of the class effect).

Process flow:
Upper part→electrostatic dust removal→spraying→low temperature leveling→baking

advantage:
1, rich in color, high gloss, matte optional;
2, low cost, suitable for building furniture products and heat sink shells;
3. High utilization rate, 100% utilization, environmental protection;
4, strong ability to shade defects; 5, can imitate wood grain effect.

Disadvantages:
Currently used for electronic products is relatively small.

Eight, sandblasting

Compressed air is used as the power to form a high-speed jet beam to spray the spray at a high speed to the surface of the workpiece to be treated, so that the surface of the workpiece surface

A process in which the appearance or shape of the face changes to achieve a certain degree of cleanliness and different roughness.

Technical features:
1. Achieve different reflections or matt.
2. It can clean the tiny burrs on the surface of the workpiece and make the surface of the workpiece smoother, eliminating the damage of the burr and improving the grade of the workpiece.
3, clear the residual dirt left in the pre-treatment, improve the smoothness of the workpiece, can make the workpiece exposed uniform and uniform metal color, so that the workpiece appearance

More beautiful and beautiful.

Products Recommended:
E+G classic bridge handle, sandblasted surface, high-end atmosphere.

Nine, polished

Modification of the surface of the workpiece with a flexible polishing tool and abrasive particles or other polishing media. For different polishing processes:

Rough polishing (basic polishing process), medium polishing (finishing process) and fine polishing (glazing process), the best polishing can be achieved by using a suitable polishing wheel.

The effect, while improving the polishing efficiency.

Process flow:
Technical features:
Improve the dimensional accuracy or geometric accuracy of the workpiece to achieve a smooth surface or mirror gloss, while also eliminating gloss.

Products Recommended:
E+G long handle, polished surface, simple and generous

X. Etching

Generally, the etching referred to as photochemical etching refers to removing the protective film of the region to be etched after exposure plate making and development, during etching.

Contact with the chemical solution to achieve the effect of dissolving corrosion, forming the effect of unevenness or hollowing.

Process flow:
Exposure method:
The project is based on the drawing to prepare the material size – material preparation – material cleaning – drying → film or coating → drying → exposure → development → drying – ec

Engraved → stripped → OK
Screen printing method:
Cutting→cleaning plate (stainless steel other metal materials)→screen printing→etching→release film→OK

advantage:
1. Fine processing of metal surfaces;
2. Give special effects to the metal surface;

Disadvantages:
Corrosive liquids (acids, alkalis, etc.) used in etching are mostly harmful to the environment.

The most comprehensive metal surface treatment summary in history (process flow + advantages and disadvantages)

Surface treatment is the formation of a layer of one or more special properties on the surface of a material by physical or chemical means. Through the table

Surface treatment can improve the appearance of the product, texture, function and other aspects of performance.

First, anodizing

Mainly aluminum anodizing is the use of electrochemical principles to form a layer of Al2O3 (alumina) film on the surface of aluminum and aluminum alloy. This layer

The oxide film has special properties such as protection, decoration, insulation and wear resistance.

Process flow:
Monochrome, gradient:
Polishing / sand blasting / drawing → degreasing → anodizing → neutralization → dyeing → sealing → drying
Two colors:
1 polishing / sand blasting / drawing → degreasing → shading → anodizing 1 → anodizing 2 → sealing → drying
2 polishing / sand blasting / drawing → degreasing → anodizing 1 → laser engraving → anodizing 2 → sealing → drying

Technical features:
1, increase the strength
2, achieve any color other than white
3, to achieve nickel-free sealing, to meet the requirements of Europe, the United States and other countries for nickel-free

Technical difficulties and key points for improvement:
The yield level of anodizing is related to the cost of the final product. The focus of improving the oxidation yield is the appropriate amount of oxidant, suitable.

Temperature and current density, which require structural parts manufacturers to continuously explore in the production process, seeking breakthroughs.

Products Recommended:
E+G curved handle, anodized material, environmentally friendly and durable.

Second, electrophoresis

Used in stainless steel, aluminum alloy, etc., it can make the product appear in various colors, and maintain the metallic luster, while enhancing the surface properties, it has better

Anti-corrosion properties.

Process flow:
Pretreatment → electrophoresis → drying

advantage:
1, rich in color;
2, no metal texture, can be combined with sandblasting, polishing, drawing, etc.;
3, processing in a liquid environment, can achieve the surface treatment of complex structures;
4, the process is mature, mass production.

Disadvantages:
The ability to cover defects is general, and the electroforming of die-casting parts requires higher pre-treatment.

Third, micro arc oxidation

The process of applying a high voltage to form a ceramized surface film layer in an electrolyte solution (generally a weakly alkaline solution), which is a physical discharge

The result of synergy with electrochemical oxidation.

Process flow:
Pretreatment → Hot water wash → MAO → Drying
advantage:
1, ceramic texture, dull appearance, no high-gloss products, delicate touch, anti-fingerprint;
2. Wide range of substrates: Al, Ti, Zn, Zr, Mg, Nb, and alloys thereof;
3, the pre-treatment is simple, the product has excellent corrosion resistance, weather resistance and good heat dissipation performance.

Disadvantages:
At present, the color is limited, only black, gray, etc. are more mature, and bright colors are currently difficult to achieve; the cost is mainly affected by high power consumption,

One of the most costly aspects of surface treatment.

Fourth, PVD vacuum plating

Full name physical vapor deposition, a process in industrial manufacturing, is a technology that mainly uses physical processes to deposit thin films.

Process flow:
Pre-PVD cleaning→Intake vacuuming→washing target and ion cleaning→coating→coating finish, cooling out→posting (polishing, AFP)

Technical features:
PVD (Physical Vapor Deposition) can be plated on metal surfaces with high hard plating and high wear resistance.

Porcelain decorative coating

Five, plating

It is a process of attaching a metal film to the surface of a metal by electrolysis to prevent corrosion, improve wear resistance, conductivity, and anti-

A technique for the effects of light and aesthetics.

Process flow:
Pretreatment → Cyanide-free copper → Cyanide-free white copper tin → Chrome plating

advantage:
1. High gloss and high quality metal appearance;
2. The substrate is SUS, Al, Zn, Mg, etc.; the cost is lower than PVD.

Disadvantages:
Environmental protection is poor and the risk of environmental pollution is high.

Six, powder coating

The powder coating is sprayed onto the surface of the workpiece by a powder spraying device (electrostatic spray machine), and the powder is uniformly adsorbed under the action of static electricity.

The surface of the workpiece forms a powdery coating; the powder coating is cured by high temperature baking and flattening, and the effect is different (different kinds of powder coating)

The final coating of the class effect).

Process flow:
Upper part→electrostatic dust removal→spraying→low temperature leveling→baking

advantage:
1, rich in color, high gloss, matte optional;
2, low cost, suitable for building furniture products and heat sink shells;
3. High utilization rate, 100% utilization, environmental protection;
4, strong ability to shade defects; 5, can imitate wood grain effect.

Disadvantages:
Currently used for electronic products is relatively small.

Eight, sandblasting

Compressed air is used as the power to form a high-speed jet beam to spray the spray at a high speed to the surface of the workpiece to be treated, so that the surface of the workpiece surface

A process in which the appearance or shape of the face changes to achieve a certain degree of cleanliness and different roughness.

Technical features:
1. Achieve different reflections or matt.
2. It can clean the tiny burrs on the surface of the workpiece and make the surface of the workpiece smoother, eliminating the damage of the burr and improving the grade of the workpiece.
3, clear the residual dirt left in the pre-treatment, improve the smoothness of the workpiece, can make the workpiece exposed uniform and uniform metal color, so that the workpiece appearance

More beautiful and beautiful.

Products Recommended:
E+G classic bridge handle, sandblasted surface, high-end atmosphere.

Nine, polished

Modification of the surface of the workpiece with a flexible polishing tool and abrasive particles or other polishing media. For different polishing processes:

Rough polishing (basic polishing process), medium polishing (finishing process) and fine polishing (glazing process), the best polishing can be achieved by using a suitable polishing wheel.

The effect, while improving the polishing efficiency.

Process flow:
Technical features:
Improve the dimensional accuracy or geometric accuracy of the workpiece to achieve a smooth surface or mirror gloss, while also eliminating gloss.

Products Recommended:
E+G long handle, polished surface, simple and generous

X. Etching

Generally, the etching referred to as photochemical etching refers to removing the protective film of the region to be etched after exposure plate making and development, during etching.

Contact with the chemical solution to achieve the effect of dissolving corrosion, forming the effect of unevenness or hollowing.

Process flow:
Exposure method:
The project is based on the drawing to prepare the material size – material preparation – material cleaning – drying → film or coating → drying → exposure → development → drying – ec

Engraved → stripped → OK
Screen printing method:
Cutting→cleaning plate (stainless steel other metal materials)→screen printing→etching→release film→OK

advantage:
1. Fine processing of metal surfaces;
2. Give special effects to the metal surface;

Disadvantages:
Corrosive liquids (acids, alkalis, etc.) used in etching are mostly harmful to the environment.

Accuracy requirements for each process of CNC machining center

Accuracy is used to indicate the fineness of the workpiece product. It is a special term for evaluating the geometric parameters of the machined surface and an important indicator for measuring the performance of the CNC machining center. In general, the machining accuracy is measured by the tolerance level, and the lower the level, the higher the accuracy. Car, milling, planing, grinding, drilling, and boring are common processing forms of CNC machining centers. How much processing precision should these machining processes achieve?

1. Turning accuracy
Turning refers to the rotation of the workpiece, and the turning of the turning tool in a plane for linear or curved movement is used to machine the inner and outer cylindrical faces, end faces, conical faces, forming faces and threads of the workpiece.

The surface roughness of the turning process is 1.6-0.8 μm.

Rough turning requires high cutting depth and large feed rate to improve turning efficiency without reducing the cutting speed. The surface roughness requirement is 20-10um.

Semi-finished and refined cars use high speed and small feed and cutting depth as much as possible, and the surface roughness is 10-0.16um.

The high-precision lathe is equipped with a finely ground diamond turning tool for high-speed finishing of non-ferrous metal workpieces with a surface roughness of 0.04-0.01um. This turning is also called “mirror turning”.

2. Milling accuracy

Milling refers to the use of a rotating multi-blade tool to cut a workpiece, which is a highly efficient machining method. Suitable for processing planes, grooves and special shapes such as splines, gears and thread dies.

The machining accuracy of milling is generally 6.3-1.6 μm.

The surface roughness during rough milling is 5-20 μm.

The surface roughness during semi-finishing is 2.5-10 μm.

The surface roughness during finish milling is 0.63-5 μm.

3. Planing accuracy

Planing is a cutting method that uses a planer to horizontally reciprocate the workpiece horizontally. It is mainly used for the shape processing of parts.

The surface roughness of the planing process is Ra6.3-1.6 μm.

The surface roughness of the rough planing is 25-12.5 μm.

The semi-finished surface has a surface roughness of 6.2-3.2 μm.

The surface roughness of the fine planing is 3.2-1.6 μm.

4. Grinding accuracy

Grinding refers to the processing method of using abrasives and abrasive tools to remove excess materials on the workpiece. It belongs to the finishing industry and is widely used in the machinery manufacturing industry.

Grinding is usually used for semi-finishing and finishing, and the surface roughness is generally 1.25-0.16 μm. The precision grinding surface roughness is 0.16-0.04μm.

Ultra-precision grinding surface roughness is 0.04-0.01μm.

The surface roughness of mirror grinding can be less than 0.01μm.

5. Boring

Boring is an internal diameter cutting process that uses tools to enlarge holes or other circular contours. Applications range from semi-roughing to finishing. The tools used are usually single-edged boring tools (called masts).
It is an inner diameter cutting process that uses tools to enlarge holes or other circular contours. Its application range is from semi-roughing to finishing. The tools used are usually single-edged boring tools (called masts).

The precision of the boring of steel materials is generally 2.5-0.16 μm.

The precision of precision boring can reach 0.63-0.08μm.

Easily solve complex aluminum alloy parts processing problems


The aluminum alloy parts have good mechanical properties, small specific gravity, good corrosion resistance and excellent processability. They are commonly used in universal structural parts and frame parts, which can meet the requirements of mechanical strength and precision, and can be effective. It reduces the weight of the equipment and is therefore widely used in complex parts.

However, the complex aluminum alloy structural parts have complex shapes, many precise matching elements, and high dimensional accuracy requirements.
First, the processing problems faced by complex aluminum alloy parts
In the process of processing complex aluminum alloy structural parts, the deformation of the parts caused by the large material removal margin must be solved first. Because the blank is a bar, a pipe or a thick plate, in order to make the size close to the part itself, it needs to be removed after machining. Most of the margin. Due to the large amount of material removal, the original fiber structure state is completely destroyed, the processing stress is large, and the residual stress after processing is rebalanced, causing deformation of the parts and increasing the processing difficulty.
Another problem that complex aluminum alloy structural parts have to overcome during processing is the stress deformation problem. There are two kinds of residual stresses, one is the initial residual stress and the other is the processing residual stress. The initial residual stress is the relative equilibrium internal stress existing in the aluminum alloy blank. When the excess material is removed, the original stress balance is destroyed and the stress is rebalanced, which may cause the part to deform. The residual stress is the plastic deformation of the area where the tool interacts with the workpiece under the interaction of cutting force, cutting heat or both. The deformation generates residual stress under the influence of other factors.
Insufficient process conditions are another problem that must be solved in the processing of complex aluminum alloy parts. For the processing of complex aluminum alloy parts, four-axis and above machine tools are required, and the machine tool must have high geometric accuracy and good stability.
In the processing of complex aluminum alloy parts, it is necessary to solve the problem of insufficient strength of the base. Due to insufficient rigidity, some parts of complex aluminum alloy parts are elastically deformed under the action of cutting force during the machining process, forming a knife, and rebounding after unloading, resulting in an oversize difference. Because the knife makes the cutting process unstable, it is often accompanied by a vibrating knife, which results in a large vibration pattern on the machined surface, which seriously affects the surface quality of the part.
Second, the cracking method of complex aluminum alloy parts processing problems
In order to ensure the processing quality, the processing deformation problem must be overcome during the processing of complex aluminum alloy parts. Therefore, in the design of the process route, the general principle of “first deformation and post-processing” should be grasped, and the process division, process dimension design, tool and parameter selection, fixture and clamping mode selection, and auxiliary clamping should be based on this.
Most of the machining allowance should be removed during the roughing phase. The grooves, holes, tables, etc. that cause the whole or important local deformation of the part should be pre-machined. In particular, the sidewall opening groove, the through-plane on the circumference, the asymmetric slot structure, etc., these parts will break the original stress balance after processing, causing large deformation of the part, so the general outline should be processed in the roughing stage. For functional holes and slots such as weight reduction with low precision requirements, it can be directly processed to the final size.
The choice of machining tools. In the roughing stage, the goal of high efficiency and low cost is low, and the tool requirements are low. However, due to the large cutting allowance, a large amount of cutting heat is generated, and the residual stress is increased. Therefore, the tool should be kept sharp and sufficiently cooled during processing. In the finishing stage, the tool should be selected to have sufficient rigidity and good wear resistance to ensure dimensional and dimensional tolerance accuracy. The tool should be sharp and the cutting edge should be clean to reduce the cutting force, reduce the cutting heat, and make the cutting process. Smooth and reduce system chatter. Use carbide milling cutters and coated knives as much as possible. When conditions permit, polycrystalline diamond tools are available.
The tooling should be designed reasonably and reliably positioned. The clamping and pressure can meet the clamping requirements and minimize the impact on the deformation of the parts.
A reasonable process route must be established. Due to the complicated structure and high precision, the complex aluminum alloy structural parts must be divided into rough machining, semi-finishing and finishing, and the heat treatment process is interposed in the middle to reduce the influence of residual stress. The allowance between processes should be reasonably distributed according to the structural characteristics of each part, and the finishing allowance should be minimized under the premise that the remaining amount after deformation can be ensured. Dimensional elements with large tolerances should be guaranteed during semi-finishing to reduce the allowance for finishing and reduce the probability of deformation.
For the rough machining of complex aluminum alloy parts, the vise or three-jaw clamp can be used for the purpose of removing the balance. The clamping force should ensure the clamping is reliable. In the case of finishing, in order to ensure the dimensional and dimensional tolerance accuracy, the positioning datum must have a good flatness, so that the positioning surface and the working platform have a good fit. Therefore, before finishing, the process is usually specially arranged to finish the finishing surface to eliminate the deformation of the positioning surface caused by semi-finishing and stress-reduction. The open plane generally selects fitter grinding, and the closed plane selects high-precision machine tool. Milling. When finishing the positioning surface, the vise is usually used for clamping, and the clamping force is required to be small, and the parts are clamped under natural conditions and must not be flattened.
In the finishing stage of complex aluminum alloy parts, multi-face machining is generally required, and thus the clamping method of the tooling positioning is adopted. In order to prevent deformation caused by over-tightening, it is required that the pressing force of the pressing plate be perpendicular to the force receiving surface, and the lateral component force should be avoided as much as possible. When the pressing position is selected, the workpiece should be solid at the force receiving position and in close contact with the positioning tool. There should be no large windows, suspended space, etc., to reduce the influence of the pressing force factor.
When the complex parts of aluminum alloy are processed, the rigidity of some areas is insufficient, which may cause the knife to be accompanied by vibration lines, which seriously affects the size and surface quality of the parts. In order to reduce or even eliminate the knife phenomenon, in addition to optimizing the cutting parameters, it is also possible to increase the auxiliary support method, which can greatly reduce the phenomenon of the knife and the vibration knife, and ensure the dimensional accuracy and surface quality of the parts.
The dimensional change caused by local deformation can be adjusted by the numerical control program. By analyzing the detected data, the advance and retraction compensation programs are added to the program. Through the lifting knife compensation, part of the thickness dimension change caused by the deformation is compensated for, so as to meet the requirements of batch stability.
Due to its complex structure and high precision requirements, complex parts of aluminum alloys should follow the principle of “first deformation, post-processing” for the processing difficulties of complex parts. Under this principle, a reasonable processing route is formulated, equipped with suitable process equipment, and measures such as selecting appropriate process parameters, positioning and clamping methods, correctly processing the finishing positioning surface, increasing auxiliary support, and introducing numerical control program compensation, etc. Thereby effectively solving the processing problem of high-precision complex aluminum alloy.
HS SMART is a long-term enterprise engaged in CNC machining of aluminum alloy parts. It has strong technical force and advanced processing equipment. At the same time, it has an elite technical team with rich theoretical knowledge and practical experience. It is proficient in structural design and product development of aluminum alloy parts. He has accumulated rich experience in the processing of aluminum alloy parts, especially high-precision complex aluminum alloy parts. For many years, he has provided high-quality aluminum alloy parts design and processing services for many corporate customers.

Precision mechanical parts manufacturers use drive systems to increase reliability and flexibility

In order to ensure that the machine tool has good process adaptability and continuous and stable working ability, CNC machine for CNC precision machine parts processing manufacturer The characteristics of the bed structure design should have sufficient rigidity, precision, vibration resistance, thermal stability and precision retention. CNC precision mechanical parts The mechanical transmission chain of the processing system of the processing manufacturer uses ball screws, static pressure screws and gapless gear pairs to minimize the backlash. Shenzhen precision mechanical parts processing experts pointed out that in the processing of precision mechanical parts, the machine tool uses plastic anti-friction guide rails, rolling guides or Statically press the guide rail to improve the smoothness of the movement and prevent creeping when moving at low speed.

Due to the use of a wide-speed feed servo motor and a wide-speed spindle motor, it is not necessary to process precision mechanical parts. Or less gear and gear shifting, which simplifies the machine’s transmission. The machine layout is convenient for chip removal and workpiece loading and unloading, part of the CNC The machine is equipped with an automatic chip conveyor and automatic workpiece changer. In Shenzhen precision machinery parts processing enterprises, most CNC machine tools use programmable logic controllers with microprocessors instead of power cabinets. A large number of relays improve the reliability and flexibility of the machine’s high- power control.

Surface finishing of mechanical parts, talk about the scope and characteristics of grinding

Grinding is a kind of cutting process in which the high-speed rotation of the grinding wheel is used as the main motion, and the low-speed rotation and linear movement of the workpiece (or the movement of the grinding head) is used as the feed motion to cut off the excess metal layer on the workpiece. Grinding is one of the most common processing methods in machine building.

Grinding has a wide range of applications, including inner and outer cylindrical surfaces, inner and outer conical surfaces, flat surfaces, forming surfaces and combined surfaces. Grinding can process highly hard, superhard materials that are difficult to machine with other cutting methods, such as hardened steel, high strength alloys, carbides and ceramics. Grinding can also be used for rough processing (grinding billets, cutting risers, etc.), roughing, finishing and superfinishing.
The grinding wheel used for grinding is a special tool. Each abrasive grain is equivalent to one tooth. The whole grinding wheel is equivalent to a large knife with a large number of teeth.

When grinding, the abrasive grains with sharp edges and corners cut fine chips from the surface of the workpiece; abrasive particles that are blunt or less convex can only draw fine grooves on the surface of the workpiece; The abrasive particles produce sliding friction with the surface of the workpiece, and the latter two abrasive grains generate fine dust during grinding. Therefore, the grinding process differs from the general cutting process in that it has scribing and polishing action in addition to the cutting action.

 

(1) The cutting edge of the grinding wheel is irregular. The shape, size, and distribution of the cutting edges are in an irregular random state, usually with a large negative rake angle and a small relief angle.

(2) The grinding allowance is small and the machining accuracy is high. In addition to the high-speed, powerful grinding that can be used to machine blanks, roughing and semi-finishing must be performed before grinding the workpiece. Grinding and finishing IT7IT5, the surface roughness can reach Ra0.80.2μm. With the high-precision grinding method, the surface roughness can reach Ra0.10.006μm.

 

(3) High grinding speed and high temperature. The general grinding speed is about 35m/s, and it can reach 60m/s during high-speed grinding. At present, the grinding speed has been developed to 120m/S. However, during the grinding process, the grinding wheel has a strong pressing and friction effect on the workpiece, and a large amount of cutting heat is generated, and the instantaneous temperature in the grinding region can reach about 1000 °C. In the production practice, in order to reduce the cutting temperature during grinding, it is necessary to add a large amount of cutting fluid, reduce the amount of backing knife, appropriately reduce the grinding wheel speed and increase the workpiece rotation speed.

 

(4) Strong adaptability. As far as the workpiece material is concerned, both soft and hard materials can be ground; in terms of the surface of the workpiece, many surface quality requirements can be processed; in addition, various complicated tools can be sharpened.

(5) The grinding wheel is self-sharp. During the grinding process, the abrasive grains of the grinding wheel gradually become dull, and the cutting resistance acting on the abrasive grains will increase, causing the blunt abrasive grains to break and fall off, exposing the sharp cutting edge to continue cutting, which is the sharpening of the grinding wheel. Sex. It enables the grinding wheel to maintain good cutting performance.

What are the common faults CNC systems in daily work?

The numerical control system is the abbreviation of the digital control system. The English name is (Numerical Control System), which performs part or all of the numerical control functions according to the control program stored in the computer memory, and is equipped with a dedicated computer system of the interface circuit and the servo drive device. By using digital commands composed of numbers, words and symbols to realize the motion control of one or more mechanical devices, it usually controls the mechanical quantity and the switching amount such as position, angle and speed.

CNC systems and related automation products are mainly for CNC machine tools. CNC machine tools are mechatronic products formed by the penetration of new technologies represented by numerical control systems into the traditional machinery manufacturing industry: CNC machine tools greatly improve the accuracy, speed and efficiency of parts processing.

Common faults and causes:

Position loop: This is the key link for the CNC system to issue control commands and compare with the feedback value of the position detection system to further complete the control task. It has a high frequency of operation and is connected to peripherals, so it is prone to failure.

Common faults are:

1-position control loop alarm: It may be that the measurement loop is open; the measurement system is damaged, and the position control unit is damaged internally.

2 Movement without instruction, may be excessive drift, positive feedback, position control unit failure; measurement component damage.

3 measuring component failure, generally showed no feedback value; the machine tool can not return to the reference point; the high-speed leakage pulse can cause the alarm may be caused by the grating or the read head is dirty; the grating is broken.

Servo drive system: The servo drive system is associated with the power grid, mechanical system, etc., and it is always in a state of frequent start and run during operation, so this is also a part with more faults.

Power section: The power supply is the energy support part that keeps the system working properly. The direct result of failure or failure is the system shutdown or the destruction of the entire system. Generally speaking, in Europe and the United States, there are few such problems. In terms of design, there are not many factors in consideration. However, due to the large fluctuations in power supply and poor quality in China, there are hidden interferences such as high-frequency pulses, plus artificial Factors (such as sudden power failure, etc.). These causes can cause power failure monitoring or damage. In addition, part of the numerical control system operation data, setting data and processing programs are generally stored in the RAM memory, and after the system is powered off, it is maintained by a backup battery or a lithium battery of the power source. Therefore, the downtime is relatively long, and the power supply or the memory may be lost, and the system may not operate.