In the face of brilliant exhibits, to see the machine tools that are familiar to them, how to find the unique technology contained in them, so as to carry forward these technical ideas, must also be evasive. Therefore, this article starts with specific details, and elaborates on the experience, sample materials, and the featured techniques of on-site promotion videos of the exhibition, so as to expand the ideas and fill the gaps.
First, we can do it?
From the details of thinking, for example: the machine tool to improve the accuracy of 1mm, the efficiency of 1min increase time may be easier, maybe 3 details to get. It is not so easy to increase the unit's accuracy by 1μm, 0.1s unit time, or higher requirements. It may take tens or even hundreds of details to be jointly promoted, and breakthroughs in key technologies are required. Some of the machining centers in this year's show seemed insignificant and technically common, but some distinctive features highlighted the importance of attention to detail.
Yujia Industrial's TC-20α drilling and tapping machining center, table size 600×400mm, spindle speed 4000r/min, φ80mm diamond blade face milling cutter, aluminum alloy sample, machining by milling, the surface of the specimen reaches the mirror Grade roughness. Analysis of this machine: The design concept in light of the need for light cutting, lightweight workbench configuration; spindle using direct drive, so that the spindle throat becomes shorter; in particular, Z (back) and Y-direction movement protective cover, single use Sections and monolithic form, to adapt to high-speed and high-precision features; Therefore, the whole control precision, anti-interference ability, fast moving speed.
The VBZ640 vertical machining center of Dima Digital Machines, with a worktable specification of 750×360mm, is also milling on a 16×16×25 mm cold-drawn steel and takes 40 minutes to machine a needle bar (φ0.7× 25mm) workpiece, highlighting the excellent performance of this machine. The machine's biggest feature is the use of mineral casting base, the whole machine has a very good vibration absorption, high precision and thermal stability; in addition to highlight a concept, from castings, parts to the machine assembly to commissioning, there are strict high-quality inspection system To support.
Comparing the main parameters of the above two machine tools, and thinking about the same performance conditions, we can also do these characteristics? In fact, we don’t need to deliberately find “technical secretsâ€. We just need to analyze the details and pull them up. We can do it!
Second, some of the characteristics of the processing center structure and concept
1. Observe those manufacturers who are good at machining centers, you can see the structure and layout of 3-axis or 5-axis machining centers, and adopt more common modularization methods. The structure pays special attention to the comprehensive improvement of rigidity, compact structure, and Conducive to the removal of chips.
GF's HSM series 3-axis and 5-axis machining centers are typical examples. The concept of the machine tool is to ensure the shock resistance and stability of the entire machine. For this purpose, the design adopts a shocking integrated design concept with good rigidity and stability. This one-piece structure layout facilitates approaching the work area from three sides, so that the machine tool has excellent visibility and facilitates loading and unloading of workpieces by the crane; and the O-type structure serves as an interface to subtly realize automatic workpiece loading and unloading. This also prompts us: design should focus on high-precision methods and initiatives; to take into account the low-end and high-end machine modularity, but also cleverly achieve dual, multi-table automation exchange or automated assembly line.
2. Nowadays, the linear axis motion of the machining center often focuses on the movement of the processing head, and the table has little or no movement in order to achieve high-speed motion processing. In addition, such a layout also makes it easier to protect the guide rail and the screw. The machine footprint is also smaller.
More typical we see W1-801 booth, Hammer's C42U five-axis vertical machining center in Germany. The machine adopts a one-piece gantry marble bed, and the three-axis movement is all the tool movement of the machining head. The load bearing and the driving are all above the working area. The protection is favorable, and the workpiece has an independent dynamic property. In addition, the pick-up magazine integrated with the bed makes the space requirement of the machine smaller. Another unique technology is the machine tool spindle with monitoring collision protection (axial), which is not yet seen in other machining centers.
DMG MORI's DMC1450V vertical machining center, working table specifications 1700 × 750mm, carrying 2000kg. The machine also uses a high-stability marble bed, all three-axis movement is the tool movement of the processing head, the table is suspended on the bed body, the chip removal is very smooth. This kind of structure layout, because the worktable does not move, do not need to worry about the workpiece and other parts of the machine tool interfere. At the same time, high-precision machining can be achieved smoothly for workpieces with incorrect center-of-gravity positions.
The DMG MORI's DMF260-11 column-type 5-axis vertical machining center can be said to set a new benchmark in the design of moving column machining centers. The 3200×1100mm fixed table, which is carried by marble bed, thermal symmetrical column, equipped with thermal balance system, ensures high rigidity and long-term stability of the machine. The stroke of X/Y/Z axis reaches 2600/1100/900mm. The processing head type B-axis, embedded fixed desktop C-axis, so that the machine is suitable for 3-axis milling to 5-axis linkage processing, can fully meet a variety of tasks and different parts of the industry processing. It should also be pointed out that with the higher weight of marble, the dynamic performance of the X-axis is also better, and the X-axis can move up to 80 m/min with a linear motor, which is very competitive in similar machine tools.
3. The compound machine tool based on the machining center is the main form of many composite machine tools in this exhibition. Commonly, the turning and milling and milling machining center is used to achieve high-efficiency process intensive. With the innovation of thinking, technological progress and technology integration, the connotation of compound machine tools is expanding. This exhibition has two more typical composite machine tools, reflecting this idea.
DMG MORI has introduced the idea of ​​3D laser processing, including additive manufacturing, Mold surface treatment and so on. By integrating laser machining in a 5-axis simultaneous machining center, a new generation of composite machine tools has been created, enabling 5-axis milling and laser surface texturing, or laser surfacing, to be performed in only one clamping. The LASERTEC 65 3D compound machine that was exhibited this time is an additive manufacturing of milling quality, and it is very economical to process a large workpiece with a very high cutting rate.
The M80-G compound machine tool of Austrian WLF Company is a quite typical composite machining center. The machine's process intensive capability is unprecedentedly powerful. It is the perfect combination of machining center and turning center. It is suitable for processing of rotary parts. Therefore, the machine layout is in the form of slanted bed lathe, but more powerful support comes from the creative design of the milling and milling unit. , as well as the design and layout of innovative and complex tool magazine systems.
Third, pay attention to the improvement of the performance of the machining center with functional technologies and components.
Today's machine tool manufacturing industry, especially the functional performance of machining centers, is more embodied in the form of technological integration. Professional design and manufacturing of functional components and socialized production procurement have become a normal state. The rapid development of interconnection and logistics has enabled product designers to have more technical options and peripheral support for improved host performance.
Ultrasonic spindle of Taiwan Xutai is a bright spot. This functional part is applied in the VMC850u ultrasonic vertical machining center of Shenyang Machine Tool. In the W1-101 booth, DMG MORI has introduced ultrasonic vibration machining technology for advanced material processing. In booth E1-711, the functional small device cleaning fan of Shanghai Chunan Technology is very creative. In the booth of E4-112, Beibei Precision Machinery's "Automatic Door Synchronized Chain Tool Magazine" deserves our attention. Many magazine manufacturers in this exhibition have many details to improve, thus improving tool change speed and reliability. In the E4-315 booth, Taiwan's inspirational telescopic pull cover design ideas and initiatives are worth mentioning. Each of the details of the move will contribute to the high-speed movement and high-precision machining of the machining center. The designer must always grasp the function technology. The influence of the selection and selection on the performance of the host computer cannot be underestimated.
Therefore, the development of functional technologies and components is related to the improvement of the performance of the host computer, and may even have a great impact sometimes. Host and functional components are closely related to each other. The focus on grasping new technologies and components and innovating integrated applications is an inevitable requirement for the design and manufacture of machine tools.
IV. Development of Intelligent Technology in Machining Centers
Intelligent technology is an important highlight in this exhibition, which has a profound impact and chewing.
1. Five-axis machine precision analysis and intelligent machine calibration
Because the five-axis machining center has two more rotary axes than the three-axis machine, the relative relationship between them has a more complicated influence on the machining accuracy. In particular, the five-axis linkage for curved surface processing is more restricted by the relative positional accuracy of the rotary axis and the linear axis. For example, the deviation between the rotation axis and the linear axis, and the verticality deviation between the rotation axis and the linear axis... These errors will affect the 5-axis machining accuracy.
Under normal circumstances, even if the factory precision of the machine is adjusted properly, it will change with the change of the ambient temperature and the placement of the machine after the user arrives. Due to the different coefficients of expansion of the various parts of the machine tool and the wear of the parts after the machine is running, etc. Changes that affect accuracy. After these changes in accuracy, adjustments, even for professionals, will take more than one day, or longer, to adjust, and even ordinary professionals may not be able to complete them, requiring higher-level technicians to do so.
As a result, manufacturers in the industry that specialize in five-axis machining centers have introduced intelligent machine calibration technologies to automatically detect and compensate the aforementioned accuracy. The idea is to maintain the accuracy of 5-axis machining centers.
Dawu Machinery's "five-axis reconciliation function" is a major highlight. The principle is: using a datum ball, and then using the ruby ​​probe to measure, through the intelligent system of the machine tool, detect and compensate the displacement and inclination of the linear axis and the rotary axis, and automatically repair these above-mentioned precisions and restore the previous precision. Otsuka's machine tool compensation program can reach 11 items, which can provide customers with a longer guarantee of machine tool accuracy.
2, other characteristics of intelligent technology
The HMP800U high-performance 5-axis simultaneous machining center exhibited by Swiss GF company features a 20,000-rpm spindle and a high-tech electric spindle with an intelligent module. The motorized spindle with the MSP function module is intelligently controlled by the response of the machine tool. As long as the M function is activated to activate the safe mode, it can handle collisions in all directions. Therefore, in addition to the tool, the machine and the spindle can be free from damage. And after the collision, the machine only needs to run the intelligent five-axis correction function for 5 minutes to return to the ideal accuracy and resume normal production.
From the exhibition, for the high precision and high efficiency of machine tools, manufacturers have competed on the intelligent technology level. From the four intelligent technologies proposed by Daxie Machinery, you can feel more intelligent connotation. Its MULTUSU3000 intelligent multi-tasking machine tool is a milling and laminating machine tool based on a lathe. The machine has a thermal affinity concept. , anti-collision systems, processing and navigation of the three major intelligent technologies, more typical of this exhibition, the high-end processing center of the concept and technology of intelligence.
V. Conclusion
As an indicator of technological development, the exhibition has always paid great attention to the experts in the machine tool industry. As a main machine type of the equipment manufacturing industry, the machining center has a series of changes related to it, as well as its eternal theme of high precision, high efficiency, automation, and intelligence, which are gathering more and more applications of key technologies and the development of innovative thinking. In order to achieve a qualitative leap with new structures and new ideas.
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