UG undertakes high speed machines High Speed Machining

  • Time:
  • Click:87
  • source:DALLMAN CNC Machining
High speed treatment is spare parts treatment is brand-new way, it is compositive a variety of technologies, it is the simple union of high speed main shaft and fast and accurate feed on the machine tool not just. To use high speed processing technique, the processing factory must mix necessary new function organic ground combines indispensable new skill rise. In the meantime, also want those who alter a plant to run means and corporeal facilities. Shorten the consign cycle of the product and reduce cost and character, HSM can produce effect and very valuable. Any mills that plan executive HSM should consider carefully, take manufacturing site inside and outside seriously to be able to accelerate all technologies that manufacture cycle. Executive HSM does not have exclusive and right way, how ought to every kinds of circumstance apply HSM to also be done not have strict and changeless or the criterion of get effect instantly. We can see, HSM is not theory or the idea that have lab ability test and verify only after all, however practical technology. The article analyses with great concentration to be engaged in the applied example of two factories of HSM, hope to be able to be inspired somewhat to the reader. Plan the measure that if HSM is to achieve a certain goal only,lives with high speed cutting, use HSM to you can fend put? The answer of Mike Haverkamp and Brian TerBeek is " can " . They are in such making, these two associate change a programmer from machinist, turn HSM into entrepreneur next. Company of their Cad Cam Services is located in close hold outskirts of the Grand Rapids that bring a city, basically devote oneself to the contract treatment of great work of model of large figuration steel, Die Casting model and other. The fast prototype that this company provides melt deposit to make modular way not only is made, converse project and Die Casting model and the complete set production of the model that note model, still continue to provide CNC programming technology and 3D design service. Haverkamp and TerBeek established his company 1991, with contracting programming begins NC do business, this kind of job is very prosperous, but arrived in 90 time, as a result of the function the occurrence of the powerful, CAM system that is based on a PC, their job gets apparently desolate. There still can be programming during they discover the factory of our region is producing a summit however " fine neck " problem, in treatment the respect produces bottleneck possibly also. Haverkamp and TerBeek were certain this opportunity, the factory of the rough machining that can complete large mould part quickly and finish machining can make certainly people go after sth like a flock of ducks, they think, HSM can machine business to offer charming speed and price to the mould. At the same time they prepare somewhat to HSM technology: Necessary process designing skill, still have stable client base, include a lot of prospective clients, arrived then 1995, they formed a kind of brand-new collaboration strategy, make company of Cad Cam Services devotes oneself to business of high speed cutting. Haverkamp of HSM special establishment and TerBeek plan to buy a rough machining and semifinishing machining at first big machine tool and one adjusts finish machining machine tool, but in the Linuosi that be the same as Yi the joint efforts of importer of Rockford machine tool leaves the city, bought a Rambaudi Ramspeed to be used for finish machining, still have the Droop of a remodel&Rein vertical milling machine is used at rough machining. This invests not only to the partner buy appropriate machine tool, and investment build new plant. The foundation design of the machine tool considers company of 　 Cad Can Services to pursue large mould and punch pattern technically make, milling machine of Rambaudi Ramspeed high speed uses mill of essence of milling cutter of 1 inch of round heads model of large Die Casting, close orbit interval is generated coarse inferior have 0 only.

0005 inches surface. bear the weight of force and the sex that lie between shake, because shake,can reduce finish machining precision. Two original machine tools face-to-face and buy, workpiece is transmitted in order to facilitate between two machine tools, and a jockey can attend two machine tools. This workshop covers an area of 10000 square foot, in-house height enough installs a hook to be apart from the ground 50 tons of 20 feet overhead traveling crane. Underground laid conduit of computer network cable, cable receives each machine tool in workshop or workstation. Workshop front has two office area, every are 5000 square respectively foot, nevertheless Cad Cam Services takes up only at present a below. The vertical machining center that forming a few 15 horsepower along the wall that produces a division, one rises fall a type tool milling machine, EDM and a pair of grinder, sheet makes by these machine tools Cad Cam Services forms the modern mould processing factory with an excellent facilities. However the pillar of Cad Cam process capability is door of dragon of vertical of Rambaudi Ramspeed B27L machining center, its X, Y and Z axis journey achieve 106 × 86 × 40 inches, power of main shaft electric machinery 18 horsepower, top speed 25000 Rpm, sharp speed of advance spends 600 Ipm, apply to high speed finish machining technically. It is headstock installs the Droop on fixed lathe bed on corridor&Rein3 axis establishs mill. Compare with photograph of Ramspeed machine tool, the workbench of machine tool of this 50 horsepower is a bit long and narrow, 2000 Rpm of main shaft speed. This machine tool often is used 4 or milling cutter of 5 inches of end panel that set blade undertakes rough machining is operated, to this kind of cutting tool and rough machining of generous of penetration of a cutting tool, the speed enough of 2000 Rpm produces appropriate exterior cutting rate. LEM93-M5 of another large machine tool comes from Italian manufacturer FPT, compare with photograph of machine tool of other rough machining, the fixed workbench of FPT agrees with more serious work. The power of this FPT machine tool is lesser, main shaft 30 horsepower, but rotate speed is higher, with Droop&Rein photograph is compared, often undertake operating with the cutting deepness of the feed speed of 2 times and half. The scope of activity that engorge knife measures although these machine tools are mixed in main shaft speed do not belong to with Ramspeed on feed speed same a class, they remain strategy of HSM of Cad Cam company impartible cut one share, place of just as Haverkamp says, "A key with high speed successful cutting depends on rough machining and semifinishing machining ability, rough machining and semifinishing machining must excise a lot of metals effectively, withhold very small mental allowance to high speed finish machining. " rough machining and semifinishing machining not only important and treatment amount is large, for example, the big, weight that Die Casting model may be two freezer at the beginning the 4140 steel semifinished product of 75000 pounds, and arrive when finish machining, the stuff that has had 20000 pounds was dropped by mill, stay only 0.

020 inches finish machining surplus, and overmuch data cannot keep in corner or round part part, geometrical precision is very so crucial. The Droop of this remodel&Rein machine tool is pie-eyed perhaps, but be convenient to use, it is used at rough machining and semifinishing machining is one of keys of success of high speed essence. Illustration states this is in mill of essence of life antrum of a model. The case of a typical rough machining that FPT place has is: Use plated film of 5 inches of TiAIN to set milling cutter of blade end panel first, main shaft speed 450 ～ 500 Rpm, feed leads 150 ～ 175 Ipm, cutting deepness 0.

050 inches, shua of a large number of the Shua that cut bits when treatment fly fall. Cent workpiece sends greater part to the outside heat treatment after rough machining. Workpiece is returned begin semifinishing machining, use milling cutter of head of 2 inches of balls normally in rotate speed 2000 Rpm and feed speed 125 ～ 150 Ipm issues semifinishing machining. To following pattern of milling of move back and forth model face cutting, orbit interval is in 0.

125 inches of less than. When making zigzag cutting, the rotate speed that can use likeness and feed speed and 0.

020 to 0.

050 inches cutting deepness, use a diameter 2.

Head of 5 inches knife of smaller part diameter. In addition, smaller cutting tool still can use join to pour wine cup. 3 big machine tools all deserve to have Fidia controller, make of operator groom become simple easy travel. Be not had jumped over more quickly mention high speed finish machining, haverkamp is abided by " do not jump over more quickly good certainly " criterion, this criterion probably startling. He says: "We use the main shaft rate of 12000 Rpm above rarely, " although the main shaft speed of Rambaudi machine tool can amount to 25000 Rpm, "Element of a few economy must consider, and they follow treatment task and change. " he explains, "For example, we can acquire the longest knife head life below inferior speed, and can be used can get at any time, the common cutter hub with dog-cheap price and arbor. " say commonly, if use 1 inch of balls to carry the milling cutter that set blade, speed of high speed finish machining is in limits of 9750 ～ 10000 Rpm, commonly used feed rate is 275 Ipm, cutting deepness and orbit interval each 0.

020 inches. This milling machine is the oldest feed speed 400ipm, can use higher main shaft rate originally, but the cutting power that keeps the most appropriate is more main. "Conservative model " HSM not just for managing cutting tool, because give priority to an axis,still wear away below high rotate speed bigger. This machine tool is maintaining normally 3 years many are used continuously below the condition, still had not changed main shaft and bearing. "Nobody are attended or full automatic machine " inferior to main shaft rotate speed cutting also is better bet, although company of Cad Cam Services has an operator to be on duty only from beginning to end, operator need not each movement that anxiously ground is staring at a machine tool. Can manage 3 machine tools by 2 operator collaboration commonly. Additionally the machine tool maintains target precision in ground of the without striking a blowing inside inferior speed limits: Model face precision ± 0.

001 inches, detail precision ± 0.

0005 inches. Do not cross a machine tool add, it is very tall that decelerate is spent, and motion is smooth. Programming gets used to the company of need Cad Cam Services that produces a workshop to have very powerful cutting tool and cutting tool method to design ability, this is no wonder, it regards an independent CAD/CAM workshop as cutting tool, and the company has 5 the name can design a pattern and the full-time CAD/CAM engineer of work out machine program. Because design the union of ability and process designing ability, production gives the pattern with very tall machinability, this is an advantage below environment of current fast rhythm. TerBeek emphasizes, it is very important to have competent process designing personnel supports HSM, he says: "The situation that programmer must understand manufacturing site and the opinion that listens attentively to machine treatment person. " the milling machine of lathe bed of activity of FPT of knife 　 　 of rough machining, semifinishing machining and finish machining is in thick mill a bath dish the flank of the mould. Fast excision metal is date key, although this machine tool can have precision work. Provide method program to all use the WorkNC of Sescoi company, presiding programmer Gary Thelen favores WorkNC system, because this system can handle cutting tool order quickly, say according to him programming is automatic greatly. And, programming and department of spot classics customs examination are very heavy, mr Thelen explains, the programmer that has experience can analyse the emulation of cutting tool method, can identify which share program quickly to go up in the machine tool likely a problem. Below a lot of circumstances, to machine a place of workpiece geometry appearance, programmer can be examined and use a few kinds of methods, the result makes files of a few alone cutting tool method, offer choose of machine treatment person selected. If according to the expression of cutting tool the circumstance has a kind of kind apparent excel another kind, can pick the cutting tool way that has compared surely, await this part to work to won't protracted time definitely new process designing. Programmer still knows when to use routine of method of HSM appropriative cutting tool, for instance, "Radial feed " and " radial retreats a knife " the way that program place makes begins with circular arc or end, and cutting tool contrail and direction taking a knife changes in sky, make the local face that uses treatment of technology of different process designing transfers glossily between each other. Mr TerBeek emphasizes, programmer and job shops should carry timely news report, this to effective rough machining, semifinishing machining and HSM it is indispensable, he " communication " look very importantly, because this and Thelen wrote a software that builds data page, use an assemble file of method of each cutting tool. Program name marks on the page, the cutting that explains program place is abided by is politic, give out the detail that installs cutting cutting tool, the knife grain height that stipulates treatment gets, and offer other all concerning information. This page still includes relevant view, make operator can imagine whole unit process of cargo bandling intuitionisticly. "Want executive cutting tool way to machining place, our machine tool operator said to calculate, so we hope they master complete information, in order to make correct judgement. " TerBeek explains so. Manufacturing site regards a company as the terminal of the network with the Windows-NT PC machine of industry housing, also be this machine file server of CNC machine tool. These PCs use TCP/IP of agreement of Internet standard communication to have news report of high speed data. The Rambaudi machine tool that Cad Cam Services of new point of view of 5 axes machine tool uses can undertake 5 axis (lever) at the same time behavioral cutting, main shaft head is OK below programme controll tilt according to the change of cutting face and circumgyrate, the right way that goes up in order to assure cutting tool in whole way. However, company of Cad Cam Services uses 5 lever means rarely, and the operation that basically completes 3 axes machine tool impossible with this machine tool, for instance the Zhou Xianxi of inside of forging die of edge assured source pours wine cup. This company discovers, use dividing head tilt and circumgyrate is united in wedlock with photograph of function of a of controller of machine tool Fidia special software, meet case other place is practical, quick. This software function calls " rotate cutting tool midpoint (RTCP) " , the whirl that it makes be based on method of cutting tool of calculative of institute of center of ball head milling cutter and corresponding axis is completely corresponding. This function is beardless program of to change cutting tool length new fixed position, also need not relapse for the whirl of every axis build original position. CNC Milling CNC Machining