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Application of three axis machining in traditional vertical machining center

Time of publication:2017-04-08 11:36:43

With the rapid development of automobile industry Chinese tire, as an important link, its position has been hitherto unknown attention; on the other hand, in the process of tire manufacturing, both the design of the computer, or introduction of new composite materials and nanotechnology, the tire industry has undergone tremendous changes. At this stage, less than 1% of the tire mold processing enterprises use 4-5 axis machining centers, plus the operation level and the limited knowledge of hardware and software, far from the benefits. In the tire mold, the pattern of the size and shape of a direct impact on the performance of the tire, not only can improve the vehicle in contact with the characteristics of different road surface, and is an important safety index of high-speed vehicles; Chinese is a comprehensive development of expressway, the tire is put forward higher technical requirements. Therefore, if the domestic tire mold can not break through

The bottleneck, it is difficult to adapt to the needs of the market, will be eliminated by the market. In order to meet the continuous development and changes in the processing requirements of the die industry, DMG company has designed and introduced many types of five axis machine tools. The main advantage of five axis machining is that it can process complex shapes with one clip. Compared with multiple clamping, the five axis machining can greatly reduce the processing time and fixture number, and improve production efficiency. Moreover, the clamping error is easy to occur during the process of assembling and disassembling workpieces.

In addition, an important advantage of five axis machining is that it can be machined with a shorter tool, because the pendulum / turret can shorten the distance between the tool and the workpiece and the tool can move on the workpiece surface. As a result, higher cutting speed, higher tool life and less tool wear can be achieved without loading more force on the tool. Compared with three axis machining, five axis machining allows the use of shorter tools and reduces tool vibration when machining deep holes or deep cavities. This improves machining accuracy and even reduces the time cost of manual polishing. Almost no special tool is used, which simplifies the application of cutting tools and reduces the cost of cutting tools.

The use of five axis machining allows the machining of particularly complex surfaces on solid blanks without the use of specially cast blanks. For prototype or small batch processing, this approach will be faster and more economical. It takes no more than 2 months or more to do the casting and processing, and it takes only 1 to 2 weeks to complete.

A lot of drilling time can be saved by using five axis machining. Compared to the machining of complex holes and cavities, the drill seems to be small. In fact, drilling a large amount of inclined holes can waste a great deal of time. If the three axle machine tool is used to drill the skew hole, different tooling must be made for each hole. With five axis machining, the swing head / turntable accurately enables the tool to perform drilling operations more rapidly along the axis of each inclined hole.

Two. Most practical five axis machine tools consist of three linear coordinate axes XYZ and two rotating shafts BC or AC or AB. I will briefly introduce the general situation of the five axis machining. 1, five axis machining, in general, is divided into five sides processing, five axis positioning processing and five axis synchronous contour processing. As shown in figure 5:

A. five processing: in accordance with the cube rule, workpiece position in the reference surface, making it the five axis machining B. fifth positioning processing in a process (3+2 axis positioning processing) this is the use of five face machining, combination of multi angle characteristics and the working plane. Two groups of rotating platform, axis only the positioning of the workpiece position. The spindle is always vertical to handle the required applications - drilling or milling C. five axis simultaneous contouring machining: tool follow, which is applied to the processing components that require simultaneous movement of the five axes. 2., five axis machining market share,

In fact, the application of five axis machining in mass production is increasing day by day. Some parts of the parts do need five axis linkage machining, and some parts do not need five axis linkage. The increase in this application is due to the increasing complexity of parts and higher requirements for the accuracy of parts. The tire processing is different from the conventional process, and needs to be divided into different segments. These segments contain different shapes of steps. Only by using CAD/CAM technology can the quality of the die be improved and the machining cycle is shortened. There is no doubt that PowerMILL is fully equipped to meet the requirements mentioned above. This paper mainly discusses the use of PowerMILL software, combined with the tire mold processing characteristics, the preparation of a reasonable and effective tire mold pattern of CNC machining program, in DMG HSC75linear to achieve high-speed cutting. A tire tread PowerMILL Machining NC programming 1. dimensional analysis model of A, first of all, first import the 3D model, careful analysis and measurement of the document, determine the convenient clamping method, which can determine the tire mold size and work to create a coordinate system, as shown in figure 7. Powermill provides powerful coordinate system creation capabilities that create coordinate systems according to processing areas to meet processing requirements. According to the shape and size of 3D model, choose to use the humanized HEIDENHAINiTNC530 control system with high torque and high feed (all axes are driven by linear motors) DMGHSC75linear5Axis on the tire mold processing.

The main features of Highlights: all shaft to use the spindle motor and lifting type linear motor equipped with standard 18000rpm Pai cut two large fan door provides excellent chip can good operation performance configuration of rotary table and swing head can realize 5 axis machining B. coordinate system created in the center of the surface of the blank position.

The choice of the C. tool, through careful analysis, creates a tool that meets the requirements of the process. The minimum radius of the 3D model can be detected by the unique features of the PowerMILL to facilitate the determination of the minimum tool use.

According to the 3D model, the disc milling cutter, flat bottomed end milling cutter, tool nose end milling cutter and ball end milling cutter are selected. Disc milling cutters are mainly used for rough cutting, roughing and rough machining of two inclined ends. The use of phi 40R5, Phi 20R3. Tool tip end milling cutter is mainly used for rough machining of pattern block, cavity opening and finish machining of cavity bottom. 10R0.5, Phi 6R0.5 and phi 8R0.5 are chosen. Flat end milling cutter is mainly used in the machining of straight line arc finish and bottom clearance, with the choice of phi 16 and phi 3. Ball end mill is mainly used in the finishing of various types of surfaces, local cleaning processing, etc., using 6R3, Phi 3R1.5, Phi 1.5R0.75, Phi 1R0.5. The 3. step in the process of editing editing process, have been identified according to the tool clamping method and selection with good to arrange the working order, processing range, tool path defined parameters and mechanical parameters (such as speed, feed rate and cutting depth, cutting width, machining allowance).
The blank is a square CK45, the excess material cutter cavity part of the diameter of 40R5 rapid removal of blank; as for the excess material two side, must be created on both sides of face perpendicular to the coordinate system, the tool path to generate 3+2 positioning. The lower right corner is the rough material shape.

Obviously, this method is also 3+2 positioning machining. The straight edge of the straight arc surface is machined by the side edge of the 16 flat bottomed end milling cutter.

Select the "20R3" disk milling cutter for further rough, the right side is continued after the rough shape.

The processing of the bottom surface requires five axis synchronous contour machining, that is, five axis machining. The M128 point end milling cutter with 8R0.5 is used to start the tool point tracking function, which is simple and fast. Figure 15 is the result of the processing of the strategy on the right.

Even allowance is an important prerequisite for finishing. After rough machining, most of the remaining material has been removed, but the material on the cavity surface is stepped, not uniform. In order to make the allowance even and prepare for the finishing process, semi finishing is needed.

The single pitch coarse / semi finish / finishing / clear angle of tool path generation, according to the tread pattern pitch arrangement through rotating the whole block copy form coarse / semi finish / finishing / corner cleaning tool path. After the tool path is generated, the correctness of the software is checked by simulation of the advanced function of the machine tool, and the safety is ensured without collision!

File two, postprocessing cutter path and machining optimization after debugging through the HEIDENHAIN can be generated after thoroughly tempered, recognition of the NC program and NC as shown in Figure 24 form processing.

The generated HEIDENHAIN format NC program input to the HSC75linear five axis machine tool under the TNC directory, in strict accordance with the NC processing form choice to meet the requirements of the installation tool handle corresponding to that obtained after the processing such as tire mold shown in figure 25.

Summary on the use of PowerMILL with the HSC75linear5 DMG axis machine tool processing of tire mold, hardware and software play the most incisive, greatly improves the accuracy and efficiency of tire mold processing, provide a strong guarantee for the tire industry manufacturers, to win in the fierce market competition.