As the main basic technology of manufacturing technology, CNC machining has made great progress in recent years with the development of manufacturing technology. It has entered the development of high-speed cutting, development of new cutting processes and processing methods, and provision of complete sets of technology. A new stage of development. It is an important industrial sector in the manufacturing industry, such as the automotive industry, aerospace industry, energy industry, military industry and emerging mold industry, electronics industry and other major processing technologies, and is also an important factor in the rapid development of these industrial sectors. Therefore, the United States, Germany, Japan and other countries with developed manufacturing maintain a rapid development momentum. As a necessary supporting equipment for CNC machine tools, metal cutting tools have entered the development stage of “CNC tools†driven by CNC machining technology, and have shown high efficiency, high precision, high reliability and specialization. "High one special" new features. The new cutting processes, such as dry cutting and hard cutting, which are represented by high-speed cutting, have shown many advantages and strong vitality, and become the main way for manufacturing technology to improve processing efficiency and quality and reduce costs.
Hard cutting is an application field of high-speed cutting technology, which is to use hardened parts with single-edged or multi-blade tools. It has higher efficiency, better flexibility, simple process and less investment than traditional grinding. It has been used in some applications. The field produces better results. In the automotive industry, CBR tools are used to machine 20crmo5 hardened gears (60hrc) inner holes instead of grinding, and the surface roughness can reach 0.22μm, which has become a new process promoted by the domestic and international automotive industry.
The development of new cutting processes such as high-speed cutting to promote the development of manufacturing technology is a new task facing modern cutting technology. Contemporary high-speed cutting is not a local improvement of cutting speed. It is a major advancement in technology, including CNC machine tools, tool materials, coatings, tool structures, etc., in order to achieve cutting speed and advancement. By doubling the speed, the overall machining efficiency of the manufacturing industry can be significantly improved. Putting the current high-speed cutting level into practical use, improving the overall cutting efficiency of machining in China by one to two times, and narrowing the gap with industrial developed countries, is the goal and face of professionals engaged in cutting and tooling technology in the new century in China. A major challenge.
In the industrialized countries such as the United States, Germany, and Japan, the mold industry is undergoing a large-scale technological revolution in recent years. This is to gradually replace the electric processing equipment with high-speed cutting machine tools, and to efficiently and precisely process the mold cavity. These machine tools mainly include various high-speed CNC milling machines and machining centers.
At present, in the mold processing and manufacturing process, it is mainly based on ordinary machining and EDM. Ordinary machine tool processing mold cavities are generally roughed, semi-finished and finished before heat treatment, and then ground, polished and polished, time-consuming and laborious. Electric discharge machining is performed after annealing, followed by heat treatment, electric discharge machining, and finally grinding and polishing.
With the acceleration of the upgrading of consumer products, higher and higher requirements are placed on the production efficiency and manufacturing quality of molds. The disadvantages of low production efficiency and unstable quality of EDM molds are gradually exposed. To shorten the manufacturing cycle and reduce costs, mold companies must widely adopt advanced cutting technology, and the emergence of high-speed cutting technology representing advanced manufacturing technology meets the requirements and characteristics of modern mold processing.
The advantages of high-speed cutting technology for machining molds are mainly reflected in:
(1) The machining efficiency is greatly improved. Not only the machine speed is high, the feed speed is fast, but the rough finishing can be completed at one time, which greatly improves the production efficiency. Combined with the numerical control technology, the manufacturing cycle of the mold can be shortened by about 40%.
(2) High-speed cutting molds do not need to be electrodes, and do not need subsequent grinding and polishing. It is also easy to automate the processing process and improve the development speed of the mold.
(3) High-speed cutting technology can be used to process hardened steel, and high surface quality can be obtained. The surface roughness is lower than Ra0.6μm, and the processing effect of milling and grinding is obtained, which not only saves a lot of time but also improves Surface quality.
In order to achieve high-speed machining of the mold cavity and its related parts, the machine tool needs to have the following characteristics:
(1) Large load-bearing and high rigidity This is because the mold is developing in the direction of large-scale, and the processing equipment must have a sufficiently large table size and working stroke to adapt to it. Nowadays, molds of several tons to several tens of tons are very common, requiring machine tool work surfaces to withstand large weights. The strength and hardness of the mold material are very high, and the mold cavity is often processed by a small-diameter end mill with a large elongation, so that the process is prone to chattering. In order to ensure the machining accuracy and surface quality of the parts, high-speed machine tools used in mold manufacturing must have high dynamic and static stiffness to improve the positioning accuracy, tracking accuracy and vibration resistance of the machine.
(2) High-speed and high-power high-speed machining is the development direction, and high-speed milling has shown great advantages in mold processing. In order to adapt to the machining of the mold cavity surface, the radius of the tool should be smaller than the minimum circumferential radius of the cavity surface to avoid "interference" between the tool and the workpiece during the machining process. Due to the small diameter of the tool, the spindle speed is very high. The spindle speed of foreign high-speed machining machine tools has reached 40,000~100,000r/min, and the rapid feed rate can reach 30,000 to 60,000min. The cavities and other parts of the mold parts are often finished in a single clamping of the workpiece, so the spindle power is large, and the spindle power of the medium-sized mold milling machine and the machining center is often 10 to 40 kW, and some are even higher.
(3) Multi-axis linkage and good deep cavity comprehensive cutting capability The mold cavity is composed of complex space 6 curved surface and groove, and many molds have deep cavity. In order to achieve high precision, high speed and high stability processing of 3D surfaces, the machine tool needs multi-axis linkage and has a good deep hole cavity comprehensive cutting capability. A five-axis linkage machining center can be used, in addition to the linear motion of three coordinates, there are two feed motions of the rotation coordinates. The milling head or table can be used for multi-axis linkage for continuous rotary feed, which is suitable for machining mold parts with complex cavity surfaces.
Composite machining is one of the development directions of mold processing. Although the machining center has been able to combine many machining processes on one machine tool, it still cannot fully adapt to the mold processing, and combines machining with electrical, chemical, ultrasonic and other different principle processing methods, and has more than two process characteristics. The composite processing will have broad prospects in the future mold manufacturing.
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