The particular mold speed milling Complex Overview
I. Benefits
In the modern day mold production like punch and die, with increasing large aesthetics and functional requirements with the plastic parts, plastic parts internal structure was created to be more plus more complex, the exterior design with the mold are getting increasingly complex, free-form surface improving proportion corresponding mold structure can be designed to be a growing number of complicated. Mold processing technology put forward higher requirements, must not only ensure the particular manufacture of large precision and surface area quality, but and also to the pursuit with the beauty of the particular machined surface. With all the deepening of the particular high-speed processing engineering, especially in marketing the development regarding machine tools, CNC method, tool systems, CAD / CAM software as well as other related technology, high-speed processing technology continues to be increasingly used inside the mold cavity running and manufacturing.CNC high-speed machining as the main one in the particular mold manufacturing superior manufacturing technology, is a couple of efficient, high-quality, low power consumption at a sophisticated manufacturing technology. In comparison to conventional machining, the cutting velocity and feed speed continues to be greatly improved, and the slicing mechanism is not similar. Cutting speed slicing essential leap product power metal removing rate of 30% to be able to 40%, a 30% lowering of cutting forces and also tool cutting life span has increased by 70% to stay in the workpiece, slicing heat The amplitude lowered low-level cutting vibration practically disappeared. With the particular increase in slicing speed, rough substance removal rate every unit time, cutting enough time to reduce the particular processing efficiency, to be able to shorten the merchandise manufacturing cycle, increase the market competitiveness with the products. At once, high-speed processing of handful of fast-forward the slicing force reduces the particular chip's high-speed discharge to cut back the the workpiece slicing forces and temperature stress deformation, raise the possibility of weak rigidity and thin-walled elements machining. Due for the reduction of the particular cutting forces, the speed increases so your cutting system frequency far from the low-order natural frequency with the machine, while the outer lining roughness of the particular workpiece is many sensitive to low-level regularity, thereby reducing the outer lining roughness. Electrical processing as well as the step of mincing and polishing may be substituted in the particular mold high-hardened metallic (HRC45 ~ HRC65) in the course of processing, the usage of high-speed cutting, thereby avoiding the manufacturing with the electrodes and time-consuming power processing, significantly reduce the fitter grinding and also polishing amount. A growing need searching for thin-walled mold workpiece, high-speed milling can be successfully completed, and also in high-speed milling CNC machining centres, a mold clamping can easily complete the multi-step running.High speed machining with the mold process to generate a huge impact, changing the original mold used annealing → milling machining → temperature treatment → mincing or EDM → palm sanding, polishing "complex and also lengthy process, and could even be used to replace every one of the original high-speed machining method. High-speed machining techniques may be applied to the particular the hardened mould cavity directly running (especially semi-finishing and also finishing), EDM electrode machining, Rapid Prototyping Manufacturing in addition has been widely employed. Mass production training shows that the effective use of high speed slicing technology can help save about 80% with the mold in the following processing manual mincing time, saving nearly 30% with the processing costs, the mold surface area machining accuracy all the way to 1 m, the tool cutting efficiency may be increased by 1.
Next, high-speed milling equipment
Speed cutting technology is probably the main development course of cutting technology with a higher level with all the development of the essential technology of CNC engineering, microelectronic technology, fresh materials and fresh structure. Due for the mold special running and high-speed running technology, the engineering and process methods for high-speed machining regarding molds (equipment tools, CNC method, tool, etc. )#) put forward higher requirements compared to the traditional Mold Accessories.A top stability of the device tool support associateHigh-speed cutting equipment tool bed support member needs to have a good energetic and static rigidity the the very hot stiffness and damping qualities. Most of the particular machines are high-quality, high rigidity and also high tensile gray iron being a support member substance, add some equipment tool companies still base a top damping characteristics regarding polymer concrete to boost its vibration level of resistance and thermal stability This will ensure the equipment accuracy and stableness, but also stops the cutting application chatter. The sealed bed design, total casting bed, symmetrical structure with the bed with atmosphere of ribs can be an important measure to boost machine stability. Their R & N departments of several machine tools inside the design process, but in addition using modal examination and finite aspect structural calculations to be able to optimize the structure with the machine more secure and reliable help member.2. Equipment spindleThe performance regarding high-speed machine tool spindle can be an important condition regarding achieving high-speed machining. High-speed slicing machine tool spindle velocity range to 10000 ~ 100000m/min, and 15kW spindle power higher than. Axial gap involving the shank and spindle handle spindle compressed oxygen or cooling system just isn't greater than 0. 005mm. Also requires the particular spindle performance (with a very high angular velocity and deceleration) together with rapid acceleration, rapid accurate take a look at the specified place, high-speed spindle usually hydrostatic bearings, aerostatic having, hot-pressed silicon nitride (Si3N4) ceramic bearings permanent magnet bearing type construction. Lubrication to utilize more oil lubrication and also jet lubrication engineering. Spindle cooling generally utilize the spindle internal water-cooled or perhaps air-cooled.3. Equipment drive systemTo fulfill the needs regarding high speed machining with the mold, the high velocity machining machine application drive system needs to have the following qualities:(1) a top feed rate. Studies demonstrate that, for small diameter tool to boost the speed and how much feed per enamel helps reduce application wear. The feed rate array of 20 ~ 30m/min, including the use of a big lead ball twist drive, feed rate around 60m/min; linear motor allows speeds all the way to 120m/min feed.(2) a top acceleration. Three-dimensional complex surface contour with the high-speed machining specifications drive system provides good acceleration qualities, to provide high-speed nourish drive (quickly forward speed regarding 40m/min, 3D contouring velocity of 10m/min) to offer 0. 4m/s2 to be able to 10m/s2 acceleration and also deceleration.Most machine suppliers closed loop place servo control cause large-size, high-quality basketball screw or direct screw bulls. With all the development of generator technology, advanced linear motor has turn out, and successfully placed on theCNC machine equipment. No mass inertia superior linear motor pushed CNC machine equipment, advanced, hysteresis and vibration issues faster servo reply speed and increase the the servo handle accuracy and accurate machining.4. CNC methodAdvanced CNC system can be a key factor to ensure the quality and performance of high-speed machining regarding mold complex surface area, the basic requirements with the numerical control method of high-speed machining with the mold:(1) high-speed electronic digital control loop (Electronic digital CONTROL loop), which includes: a 32-bit or perhaps 64-bit parallel model and 1. 5Gb more hard disk drives; very short sampling time of your linear motor(a couple of) the pace and acceleration feedforward handle (Feed forwards control); crawl control with the digital drive method (Jerk handle).(3) superior interpolation method (according to NURBS spline interpolation), to secure a good surface top quality, precise dimensions and also high geometric accuracy and reliability.(4) pretreatment (Look-ahead) operate. Requires a huge capacity buffer sign up, pre-reading and checking multiple block (for instance DMG machine can block around 500 the Simens block system around 1000 to 2000), to be processed surface condition (curvature) occurs change to adopt timely measures to improve the feed rate in order to avoid excessive cutting.(5) problem compensation function, including fever due to thermal error compensation as a result of linear motor spindle quadrant problem compensation, the computing system error settlement. In addition certain requirements of high-speed machining with the mold on the info transmission speed can be high.(6) info interface, such since RS232 serial slot transmission speed regarding 19. 2kb, while many state-of-the-art machining centres have adopted Ethernet LAN (Ethernet) regarding data transfer speeds all the way to 200kb.5. Chilling lubricationHigh-speed machining making use of coated carbide punch pins slicing tools without slicing fluid, in the truth of high-speed, high-temperature, successful cutting. This is really because: the high speed rotation with the milling spindle, cutting fluid to succeed in the cutting location must first overcome a fantastic centrifugal force; even when it overcomes the particular centrifugal force in to the cutting area, are often due to the warm of the slicing area and right away evaporated, the chilling effect is tiny even not; cutting fluid brings about the intense temperature changes with the cutter blade, easily cause cracks, so dried up cutting oil and gas cooling and also lubricating. This manner can find high pressure gas quickly impressed by the cutting with the cutting zone, so your large amount regarding cutting tropical move, while the atomizing the lubricant may be provided in the particular the tool blade portion as well as the workpiece surface to make a thin level of micro-protective motion picture, can be efficiently extend tool living and improve the grade of the parts with the surface.
In the modern day mold production like punch and die, with increasing large aesthetics and functional requirements with the plastic parts, plastic parts internal structure was created to be more plus more complex, the exterior design with the mold are getting increasingly complex, free-form surface improving proportion corresponding mold structure can be designed to be a growing number of complicated. Mold processing technology put forward higher requirements, must not only ensure the particular manufacture of large precision and surface area quality, but and also to the pursuit with the beauty of the particular machined surface. With all the deepening of the particular high-speed processing engineering, especially in marketing the development regarding machine tools, CNC method, tool systems, CAD / CAM software as well as other related technology, high-speed processing technology continues to be increasingly used inside the mold cavity running and manufacturing.CNC high-speed machining as the main one in the particular mold manufacturing superior manufacturing technology, is a couple of efficient, high-quality, low power consumption at a sophisticated manufacturing technology. In comparison to conventional machining, the cutting velocity and feed speed continues to be greatly improved, and the slicing mechanism is not similar. Cutting speed slicing essential leap product power metal removing rate of 30% to be able to 40%, a 30% lowering of cutting forces and also tool cutting life span has increased by 70% to stay in the workpiece, slicing heat The amplitude lowered low-level cutting vibration practically disappeared. With the particular increase in slicing speed, rough substance removal rate every unit time, cutting enough time to reduce the particular processing efficiency, to be able to shorten the merchandise manufacturing cycle, increase the market competitiveness with the products. At once, high-speed processing of handful of fast-forward the slicing force reduces the particular chip's high-speed discharge to cut back the the workpiece slicing forces and temperature stress deformation, raise the possibility of weak rigidity and thin-walled elements machining. Due for the reduction of the particular cutting forces, the speed increases so your cutting system frequency far from the low-order natural frequency with the machine, while the outer lining roughness of the particular workpiece is many sensitive to low-level regularity, thereby reducing the outer lining roughness. Electrical processing as well as the step of mincing and polishing may be substituted in the particular mold high-hardened metallic (HRC45 ~ HRC65) in the course of processing, the usage of high-speed cutting, thereby avoiding the manufacturing with the electrodes and time-consuming power processing, significantly reduce the fitter grinding and also polishing amount. A growing need searching for thin-walled mold workpiece, high-speed milling can be successfully completed, and also in high-speed milling CNC machining centres, a mold clamping can easily complete the multi-step running.High speed machining with the mold process to generate a huge impact, changing the original mold used annealing → milling machining → temperature treatment → mincing or EDM → palm sanding, polishing "complex and also lengthy process, and could even be used to replace every one of the original high-speed machining method. High-speed machining techniques may be applied to the particular the hardened mould cavity directly running (especially semi-finishing and also finishing), EDM electrode machining, Rapid Prototyping Manufacturing in addition has been widely employed. Mass production training shows that the effective use of high speed slicing technology can help save about 80% with the mold in the following processing manual mincing time, saving nearly 30% with the processing costs, the mold surface area machining accuracy all the way to 1 m, the tool cutting efficiency may be increased by 1.
Next, high-speed milling equipment
Speed cutting technology is probably the main development course of cutting technology with a higher level with all the development of the essential technology of CNC engineering, microelectronic technology, fresh materials and fresh structure. Due for the mold special running and high-speed running technology, the engineering and process methods for high-speed machining regarding molds (equipment tools, CNC method, tool, etc. )#) put forward higher requirements compared to the traditional Mold Accessories.A top stability of the device tool support associateHigh-speed cutting equipment tool bed support member needs to have a good energetic and static rigidity the the very hot stiffness and damping qualities. Most of the particular machines are high-quality, high rigidity and also high tensile gray iron being a support member substance, add some equipment tool companies still base a top damping characteristics regarding polymer concrete to boost its vibration level of resistance and thermal stability This will ensure the equipment accuracy and stableness, but also stops the cutting application chatter. The sealed bed design, total casting bed, symmetrical structure with the bed with atmosphere of ribs can be an important measure to boost machine stability. Their R & N departments of several machine tools inside the design process, but in addition using modal examination and finite aspect structural calculations to be able to optimize the structure with the machine more secure and reliable help member.2. Equipment spindleThe performance regarding high-speed machine tool spindle can be an important condition regarding achieving high-speed machining. High-speed slicing machine tool spindle velocity range to 10000 ~ 100000m/min, and 15kW spindle power higher than. Axial gap involving the shank and spindle handle spindle compressed oxygen or cooling system just isn't greater than 0. 005mm. Also requires the particular spindle performance (with a very high angular velocity and deceleration) together with rapid acceleration, rapid accurate take a look at the specified place, high-speed spindle usually hydrostatic bearings, aerostatic having, hot-pressed silicon nitride (Si3N4) ceramic bearings permanent magnet bearing type construction. Lubrication to utilize more oil lubrication and also jet lubrication engineering. Spindle cooling generally utilize the spindle internal water-cooled or perhaps air-cooled.3. Equipment drive systemTo fulfill the needs regarding high speed machining with the mold, the high velocity machining machine application drive system needs to have the following qualities:(1) a top feed rate. Studies demonstrate that, for small diameter tool to boost the speed and how much feed per enamel helps reduce application wear. The feed rate array of 20 ~ 30m/min, including the use of a big lead ball twist drive, feed rate around 60m/min; linear motor allows speeds all the way to 120m/min feed.(2) a top acceleration. Three-dimensional complex surface contour with the high-speed machining specifications drive system provides good acceleration qualities, to provide high-speed nourish drive (quickly forward speed regarding 40m/min, 3D contouring velocity of 10m/min) to offer 0. 4m/s2 to be able to 10m/s2 acceleration and also deceleration.Most machine suppliers closed loop place servo control cause large-size, high-quality basketball screw or direct screw bulls. With all the development of generator technology, advanced linear motor has turn out, and successfully placed on theCNC machine equipment. No mass inertia superior linear motor pushed CNC machine equipment, advanced, hysteresis and vibration issues faster servo reply speed and increase the the servo handle accuracy and accurate machining.4. CNC methodAdvanced CNC system can be a key factor to ensure the quality and performance of high-speed machining regarding mold complex surface area, the basic requirements with the numerical control method of high-speed machining with the mold:(1) high-speed electronic digital control loop (Electronic digital CONTROL loop), which includes: a 32-bit or perhaps 64-bit parallel model and 1. 5Gb more hard disk drives; very short sampling time of your linear motor(a couple of) the pace and acceleration feedforward handle (Feed forwards control); crawl control with the digital drive method (Jerk handle).(3) superior interpolation method (according to NURBS spline interpolation), to secure a good surface top quality, precise dimensions and also high geometric accuracy and reliability.(4) pretreatment (Look-ahead) operate. Requires a huge capacity buffer sign up, pre-reading and checking multiple block (for instance DMG machine can block around 500 the Simens block system around 1000 to 2000), to be processed surface condition (curvature) occurs change to adopt timely measures to improve the feed rate in order to avoid excessive cutting.(5) problem compensation function, including fever due to thermal error compensation as a result of linear motor spindle quadrant problem compensation, the computing system error settlement. In addition certain requirements of high-speed machining with the mold on the info transmission speed can be high.(6) info interface, such since RS232 serial slot transmission speed regarding 19. 2kb, while many state-of-the-art machining centres have adopted Ethernet LAN (Ethernet) regarding data transfer speeds all the way to 200kb.5. Chilling lubricationHigh-speed machining making use of coated carbide punch pins slicing tools without slicing fluid, in the truth of high-speed, high-temperature, successful cutting. This is really because: the high speed rotation with the milling spindle, cutting fluid to succeed in the cutting location must first overcome a fantastic centrifugal force; even when it overcomes the particular centrifugal force in to the cutting area, are often due to the warm of the slicing area and right away evaporated, the chilling effect is tiny even not; cutting fluid brings about the intense temperature changes with the cutter blade, easily cause cracks, so dried up cutting oil and gas cooling and also lubricating. This manner can find high pressure gas quickly impressed by the cutting with the cutting zone, so your large amount regarding cutting tropical move, while the atomizing the lubricant may be provided in the particular the tool blade portion as well as the workpiece surface to make a thin level of micro-protective motion picture, can be efficiently extend tool living and improve the grade of the parts with the surface.
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