“Processing small-volume chips and removing them out of the work area as quickly as possible†This is a flaw recommended by Makino's Alan Hollatz engineers for HSM users to make their high-speed machining successful. “In order to be able to machine small-volume chips, it is necessary to select a small amount of back-feeding in high-speed cutting, which also produces very low cutting temperatures that are usually passed quickly to parts and tools,†Hollatz said. “Not only that, The small back knife processing at high speed can also reduce the cutting force generated during cutting. In general processing, it is generally processed under the conditions of low spindle speed and large back knife, but it often causes thin wall type. The parts are greatly distorted. The cutting force generated during high-speed and small-back cutting is small, and the fixture design and processing quality of the machined parts are also reduced." Previous Next An Industrial Syringe Pump is a high-profile OEM product with compact Industrial Syringe Pump,Custom Industrial Syringe Pump,Automatic Industrial Syringe Pump,New Industrial Syringe Pump Baoding Chuangrui Precision Pump Co., Ltd. , https://www.crperistalticpump.com
In the processing of aluminum alloys, Hollatz recommends that the cutting speed be maximized, especially in the finishing of aluminum alloy parts. “If the highest spindle speed of the machine design is 30 000r/min, then the spindle speed of 30 000r/min is selected†Hollatz Says, "We try to use small tools for machining. The faster the speed, the smaller the diameter of the tool is selected, because large diameter tools are prone to large centrifugal forces." For example, to improve production efficiency, the spindle motor power developed by Makino is 80 kW. The largest type of machine with a maximum spindle speed of 33 000r/min is generally not used for tools larger than 50mm. It is recommended to select a tool with a diameter of 25mm or less for machining.
Like other machine tool builders, Hollatz believes that the use of a hollow shank (HSK) is better than CAT at high spindle speeds. He noted that the use of CAT can improve machining accuracy in the Z-axis direction. According to Hollatz, he has not heard that the CAT tool holder can work at too high a spindle speed. Since the HSK has a structural feature of positioning both the tapered surface and the end surface, it also has the feature of improving the machining accuracy in the Z-axis direction. He said: "You can choose CAT shank machining under the machining conditions of spindle speed of 20 000r/min; under the machining conditions of spindle speed of 30 000 r/min, choose HSK shank machining."
Another key aspect of HSM is the design of an advanced CNC system that can improve machining accuracy at high speeds. The most important feature of the forward-looking CNC system is the ability to control the cutting speed and acceleration/deceleration of the tool during machining with high precision. Therefore, the cutting speed and the acceleration/deceleration rate can be further improved.
The standard-type CNC system developed by Makino has been developed with the SGI.3 software version featuring the use of G-code to predict 60-80 sub-processes. According to Hollatz, the new version of S GI.4 software, which was later designed, can be predicted in the HSM to 180 to 250 sub-processing programs. Generally speaking, the more the advanced prediction sub-processing program, the stronger the forward-looking function of the CNC system, which can greatly improve the cutting speed in machining. In the high-speed machining of the same tool path with the same complexity, the cutting speed controlled by the new SGI.4 software can be 15% to 30% higher than the cutting speed under the control of SGI.3 software.
Haas has developed a new CNC system specifically for HSM. According to Reilly, it can process extremely complex parts and increase the feed rate in HSM cutting with complex tool paths. The main diagnosis - because the new CNC system uses the so-called "pre-cut acceleration" motion algorithm (that is, the tool selects the fast moving speed when it is no-load, and the normal feed speed when it is heavy), and the CNC control system. With a powerful forward-looking function that can predict up to 80 sub-processing programs in advance, Haas's HSM can perform high-reliability processing at a feed rate of 13 m/min to meet the high quality requirements of the design drawings. “The most important thing about this is that in the process of machining, the CNC system with powerful forward-looking functions ensures that the cutting speed remains the same when the tool changes in many secondary directions,†says Reilly. "Generally, the direction of the tool changes slightly, the cutting speed also changes, and the slight change in cutting speed is inversely proportional to the change in the number of cutting directions."
In recent years, in order to reduce the overall weight of aircraft, the aerospace manufacturing industry has become more and more urgent for the processing of composite materials. Take the Boeing 787 as an example, the aircraft fuselage and the wing are made of composite materials. For a long time, the HSM technology of aluminum alloys has been mastered by various manufacturers. But for composites, “there is usually a requirement to process the final shape of the product and the corresponding final dimensions (except for critical dimensions) in order to fit the holes and cavities of the mating piece,†said Jeff Crick of MAG Cincinnati. “A typical The example is that the composite hole is used to make the positioning hole in the wing of the aircraft wing. The manufacturing precision in the early stage can only reach the dimensional accuracy of 0.5mm. Generally, high-precision machining is required in the post-process, such as aluminum alloy, titanium alloy or The high machining accuracy of the final requirements for steel parts."
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