Longquan Hongda Copper And Aluminum Casting Co., Ltd. , http://www.qd-diecasting.com
Accuracy retention and intelligent software are indispensable
Mr. Zhang Ming: China's tool demand is on the rise, especially for domestic tool companies that have not occupied a large share in the high-end market. The current growth momentum is also very fast. As a result, the demand for high-end tool grinders for the manufacture of these tools has also increased. As a tool grinder manufacturer, it is our primary responsibility to understand how tool manufacturers use our machines to make the tools they need. Schleifring mainly meets the needs of users through two major aspects: one is the satisfaction of precision; the other is the efficient processing of complex tool shapes.
Users are increasingly demanding products, including requirements for machine tool noise, smoothness and reliability. In the final analysis, they are the requirements for tool machining accuracy. However, the "accuracy" emphasized here does not refer to the accuracy of a knife. For machine tool builders, "precision" stands for the accuracy of precision, which is to ensure that the precision of the tools manufactured in a period of time is the same. Even if there are fluctuations, it is in a small range.
The accuracy is mainly guaranteed by three aspects, the first is the mechanical structure of the machine tool. In the initial stage of design, we must consider how to ensure the mechanical precision of the machine. For example, Walter's Helitronic series products are made of marble. The vibration resistance is very strong and the thermal deformation is small. The Helitronic Basic and Helitronic Power are made of cast iron bed to ensure that the machine does not move during processing. In addition, this series of products also adopts a special gantry structure design, which has greatly improved the stability and rigidity of the series compared with the ordinary column type tool grinding machine.
Second, the choice of spindle and drive components is also important for machine tool accuracy. The spindles we use are relatively thick, ensuring good rigidity and the use of relatively large lead screws to reduce wear. Finally, the thermal performance of the machine tool is good and does not produce distortion and distortion of the machine components. High-speed machining will cause the oil temperature to rise rapidly, and how to avoid thermal deformation at the point of contact with the oil is essential. With a reasonable mechanical design, Schleifring achieves a balance between the temperature-affected parts and the workbench with the upper part of the machine, allowing the workpiece to flexibly avoid contact with high temperature parts.
In addition to ensuring accuracy, the machining of complex tool shapes is also a challenge. At present, tool manufacturers' product refurbishment speed is getting faster and faster, and the shape of the product is becoming more and more complicated. This requires a set of highly flexible software to keep up with their research and development. "Tool Studio" is such a software.
"Tool Studio" covers a huge database, users can select all the existing tool shapes in the market without creating them. Just input the size, the system can be automatically generated, and the operation is very simple. We describe the software as “what you see is what you get†because it has 3D real-time simulation capabilities that not only meet conventional tool production, but also simulate part machining of any geometry. The shape of the tool displayed during programming is the shape that will be processed. It can also be checked whether the programmed program has the possibility of collision during the machining process. It is integrated with the machine itself, instead of being simulated separately on the computer. of. Intelligent tool programming guides, even for those unfamiliar with programming, can be used with ease. “Tool Studio†provides customers with a better, simpler and safer solution.
Guarantee machining accuracy in many ways
Mr. Tang Xinkang: The application of high-speed milling tools in the metal processing industry is more and more extensive, and the corresponding precision requirements for tools are getting higher and higher. Angke has always attached great importance to the improvement of tool grinding machine precision and machining efficiency through continuous technological innovation. In recent years, there are mainly several new technologies in improving the precision of machining tools.
1. For contour tools with high shape and precision requirements, Angke has introduced an in-machine high-precision online measuring system. The system uses a 300x pixel CCD camera with a detection accuracy of 2μ. By overlapping the actual grinding dimension of the tool with the theoretical contour of the tool design, any error can be found. At the same time, automatic compensation can be performed according to the theoretical contour tolerance range.
In this way, on the one hand, the error caused by the two sets of externally mounted cards is reduced, and the off-machine detection time is saved. On the other hand, if the general grinding machine performs the off-machine detection and compensation, it often only compensates for the radial or axial dimension by the grinding wheel, but the actual size of each contour segment needs to be compensated. The compensation cannot be satisfied by the traditional method. . Angke is not a simple compensation, but automatically compensates for the different deviations of different program points, which can eliminate the bad factors caused by the comprehensive error such as the arc angle error of the grinding wheel circle and the machine positioning error.
2. On-line grinding wheel dynamic balancing device, when machining high-precision tools, the dynamic balance performance of the grinding wheel itself will affect the tool size accuracy and surface quality. Even if the dynamic balance of an independent grinding wheel is controlled within a reasonable range, it is not enough because the cumulative eccentricity of a group of grinding wheels will cause slight vibration during high-speed grinding of small-diameter tools and surface polishing. Not only can the precision size not be controlled, but the error in the cutting edge can also damage the life of the tool and the quality of the product being processed. Angke adopts the internal grinding wheel dynamic balance system, which can detect the comprehensive dynamic balance performance of the grinding wheel group during working hours, including the magnitude and direction of the eccentricity. Then the software will prompt the position of the grinding wheel set lock nut plus the weighting screw. This very simple and effective method can greatly reduce the eccentricity of the grinding wheel set.
3. The launch of the MX7. The traditional tool grinder is enough to complete a variety of machining of 5 axes, but the MX7 also adds the Q axis, which is "the precise indexing and memory axis of the grinding spindle." In order to reduce the error of two loadings, many customers often carry out wheel dressing and dynamic balancing in the machine. After that, the grinding wheel set will be put into the grinding wheel library. Then, the next time the robot puts the grinding wheel set back into the grinding spindle, it is possible to grind. The direction and angle of the spindle and the grinding wheel set will be different. According to the HSK interface standard in the ISO standard, the original positioning and grinding wheel are generated when the repeating positioning accuracy and the original runout error are 2μ, and the grinding wheel set is returned to the grinding spindle interface at different angles. The dynamic balance performance is completely different.
4 tool grinder clamping system. No matter how high the factory precision of a tool holder clamping system is, the jacket will wear out after a period of use, which will increase the original runout, which will affect the tool life and the precision of the machined parts. In response to this situation, Encore's "floating support device" adopts American Arobotec technology and can be adjusted according to the diameter of the machining tool, and the adjustment range is 8 to 10 mm. The floating bushing is hydraulically sensed and passes through 3 support plates without manual adjustment. It can effectively reduce the original beat of the tool to 4~5μ, eliminating the complicated calibration and setting time of the traditional fixed support.
The demand for PCD and PCBN tools for tool grinding machines Mr. Shu Zhiyong: Most diamond tool grinding machines in China have the following two features: one is to sharpen PCBN and PCD tools, and the natural diamond tools; the other is mainly used for cutting edges. Grinding and super-hard turning tools and boring tools, as well as disc and shaft cutters.
At present, with the rapid development of technology and market, PCBN and PCD tools have been widely used. The market puts high demands on the grinding efficiency of PCD and PCBN tool grinding equipment, mainly as follows.
1. The proportion of the indexable insert grinding is increased, requiring special equipment, simple structure and strong rigidity. With the deepening of division of labor, more than 80% of customers use this equipment to mass produce the same type of tool, namely PCNB, PCD or alloy indexable inserts, welding turning tools, etc. For a single requirement, the machine structure can be simplified and the rigidity of the equipment is greatly enhanced. This not only reduces equipment costs, but also lays a solid foundation for efficient production.
2. The main part of the auxiliary time - the tooling time requirement is greatly shortened. The arc of the insert is formed by the rotation of the table. Adjusting the center of the arc of the tool to coincide with the rotary axis of the table (ie, the action of the tool) is a prerequisite for grinding, and the "knive action" runs through the tool. The whole process, and repeated, is the root cause of the traditional machine tool can not get rid of manual operation.
3. It is required to operate conveniently and reliably, and try not to rely on the operator's manual skills. In order to grind natural diamond tools, the traditional machine tools introduce the "flexible feed" and "constant pressure grinding" processes, which have the effect of "knife" protection for the highly brittle natural diamond knives. Conventional equipment uses a cylinder feed to achieve this effect, which greatly sacrifices the grinding efficiency of PCD and PCNB tools. In addition, due to the lack of precision in mechanical manufacturing, this machine tool is very unstable and requires a lot of manual skills to exert its strengths.
Demingner uses modern high-tech means to solve the key technical problems in tool sharpening. Based on the traditional BT-150A diamond tool grinding machine, BT-150B (electric type), BT-150C (Economy) and BT-150D (Intelligent) series of blade grinding machines have basically found a solution to the above problems.
Guardian of tool grinding tool accuracy
In the field of modern metal processing, although the cost of the tool only accounts for a small part of the machining production cost, it directly affects the overall processing efficiency of the machine shop. Tool performance is also rapidly evolving as tool user demand continues to increase, both in terms of accuracy and complexity of tool shape. So how can the tool grinder, the maker of the tool, keep up with the development of the tool? Each machine tool manufacturer has unique insights.