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CNC Cutting Technology Review
Numerical control high speed cutting technology (High Speed Machining, HSM, or High Speed Cutting, HSC), is one of the advanced manufacturing technology to improve the machining efficiency and quality, the study of related technology has become an important research direction of advanced manufacturing technology at home and abroad. China is a big manufacturing country, in the world of industry transfer to accept the front instead of back-end of the transfer, to master the core technology of advanced manufacturing, or in a new round of international industrial structure adjustment, our country manufacturing industry will further behind. Imminent research on the theory and application of advanced technology.
1, high-speed CNC machining meaning
High speed cutting theory put forward by the German physicist Carl.J.Salomon in the last century and early thirty's. He concluded by a lot of experiments: in the normal range of cutting speed, cutting speed if the increase, will cause the cutting temperature rise, exacerbating the wear of cutting tool; however, when the cutting speed is increased to a certain value, as long as more than the inflection point, with the increase of the cutting speed, cutting temperature can not rise, but will decline, so as long as the cutting speed is high enough, it can be solved very well in high cutting temperature caused by tool wear is not conducive to the cutting problem, obtained good processing efficiency.
With the development of manufacturing industry, this theory is gradually paid more attention to, and attracted a lot of attention, on the basis of this theory has gradually formed the field of high-speed cutting technology of NC, relatively early research on NC High-speed Machining Technology in developed countries, through the theoretical basis of the research, basic research and applied research and development application, at present applications have entered the substantive stage in some areas.
The high-speed cutting processing category, generally have the following several kinds of classification methods, one is to see that cutting speed, cutting speed over conventional cutting speed is 5-10 times of high speed cutting. Also has the scholar to spindle speed as the definition of high-speed processing standards, that the spindle speed is higher than that of 8000r\/min for high speed machining. And from the machine tool spindle design point of view, with the product of DN diameter of spindle and spindle speed, if the value of DN to (5~2000) * 105mm.r\/min, is considered to be of high speed machining. In practice, different processing methods, different materials, high speed cutting speed corresponding to different. Is generally believed that the turning speed of (700~7000) m\/min, milling speed reaches m\/min (300~6000), that is in the high-speed cutting.
In addition, from the practical considerations, high-speed machining concept not only contains the high speed cutting process, integration and optimization also contains the process of cutting, is a can obtain good economic benefits and high speed, is the unity of technology and benefit.
High-speed cutting technology is in the machine tool structure and materials, machine tool design, manufacturing technology, high-speed spindle system, high performance and fast feeding system, a high performance CNC system, tool holder system, high performance tool material and tool design and manufacturing technology, high efficiency and high precision measurement and testing technology, the mechanism of high speed cutting, high speed cutting process and other related hardware and software technology are fully integrated into the development foundation. Therefore, high speed cutting technology is a complex system engineering, is a with the related technology development and the development of the concept of.
2, the superiority of high-speed CNC machining
Due to the large amplitude of the increase of the cutting speed, high speed machining technology not only improves the cutting productivity, and compared with the conventional cutting also has some obvious advantages: first, small cutting force: in high speed milling, cutting adopts the form of small quantities, high cutting speed, the cutting force is reduced by 30% compared to the conventional cutting, especially the radial cutting force greatly spindle bearing, tool, workpiece is reduced. Both to reduce tool wear, and effective control of the vibration machining system, improve the machining accuracy. Second, the material removal rate is high: the use of high speed cutting, cutting speed and feed rate are improved greatly, the same time the material removal rate is improved greatly. Thus greatly improve the processing efficiency. Third, thermal deformation small: in the high-speed cutting, cutting heat, most of the time to the work piece by the outflow of high-speed chip away, so the heating time of the machined surface is short, not because of the temperature rise leads to thermal deformation, is helpful to improve the surface accuracy, physical and mechanical properties of the machined surface processing method is better than the common. Fourth, high precision machining: high speed cutting usually feed is relatively small, so that the machined surface roughness is greatly reduced, at the same time as the cutting force is smaller than the conventional vibration cutting, machining system is reduced, the machining process more smoothly, so that good quality, can realize high accuracy, low degree of rough machining. Fifth, the green environmental protection: when high speed cutting, workpiece machining time is shortened, the use of energy and equipment rate, high processing efficiency, low processing energy consumption, at the same time, due to the high speed cutting can be achieved even without dry cutting, reduce the cutting fluid, reduce pollution and consumption.
Research and application of numerical control high speed cutting technology, 3
In view of the above characteristics of high speed machining, the technology has great application potential in the field of traditional processing weak. First of all, the workpiece for thin-wall parts and slender, uses the high-speed cutting, the cutting force is significantly reduced, the heat is chipping away, can be very good for using the traditional method of the deformation problem caused due to the influence of cutting force and cutting heat, greatly improving the processing quality. Secondly, because of the cutting resistance is small, to reduce tool wear, materials of high manganese steel, hardened steel, austenitic stainless steel, composite materials, wear-resistant cast iron is difficult to be processed by traditional methods, can be studied using numerical control high speed cutting technology to process. In addition, in the automotive, aerospace, mold, manufacturing field, some integral components require relatively large material removal rate, the feed speed CNC high speed cutting with the cutting speed increase and the corresponding increase in unit time, so that the material removal rate is greatly improved, thus in the mold manufacturing, automobile manufacturing, aerospace manufacturing application of numerical control high speed cutting technology, will produce the enormous economic benefits. Fourth, because of the high-speed cutting, machining process is stable, the vibration is small, compared with the conventional cutting, high speed cutting can significantly improve the precision of 1~2, can be cancelled completely finishing, and subsequent, adopt numerical control high speed cutting technology, can achieve and rough, finishing on the overall structure of complex parts in a machine, reduces the likelihood of locating error transfer process, which is also conducive to improve the machining accuracy. Therefore, high speed cutting technology has a wide application prospect in precision manufacturing. Aluminium mould such as a business process, the mold cavity length is 1500mm, the required size error of ± 0.05mm, surface roughness Ra0.8 μ m, manufacturing process the original: rough planing - semi finish planing - finishing - Manual scraping - manual polishing, manufacturing cycle is 60 hours. Using high speed milling, after semi-finish machining and finish machining, the processing cycle is only 6 hours, not only improve efficiency, but also greatly improve the quality of mold.
4, research on Key Technologies of high-speed CNC machining
NC High-speed machining is a complex systems engineering, involves cutting mechanism, cutting machine, cutter, cutting process monitoring and processing technology and other related hardware and software technology, implementation and development of numerical control high speed cutting technology, rely on this system of various elements, the key technology to realize high-speed CNC cutting technology cannot do without, specifically in the following aspects:
1) the mechanism of high speed cutting: the various materials in high speed machining conditions, the chip formation mechanism, variation of cutting force, cutting heat, tool wear patterns and effects on the surface quality, the basic theory above experiments and research, will be conducive to promoting the high-speed cutting process for determining and cutting the amount of choice, and provide a theoretical basis for the processing of specific parts and material formulation, which belongs to the technical principle. At present, to determine the process specification of high speed cutting and cutting ferrous metals and difficult to machine materials, is one of the difficulties in the production of high-speed cutting, and is also the focus of research in the field of high speed machining.
2) technology of high speed cutting machine tool module: high-speed cutting machine needs high-speed spindle system, feeding system and high-speed CNC control system. Able to work in very high speed under the high-speed processing requirements of spindle unit, the above general spindle speed 10000 r\/min, some even as high as 60000-100000r\/min, and to ensure good dynamic and thermal properties. The key part is the main shaft bearing, it decides the life of high-speed spindle and load capacity, one of the core components and high-speed cutting machine tool spindle structure, improvement and performance improvement is one of the most important technology of high-speed machine tools. Another important element of the technology is high speed feed system. With the development of machine tool spindle speed increasing, in order to ensure each cutter teeth or feeding amount per rotation invariant, machine tool feed speed and acceleration is also a corresponding increase, the same time to improve travel speed. Therefore, machine tool feed system must move quickly and fast and accurate positioning, which is obviously on the machine tool guide, servo system, working table, put forward new and higher requirements, is the key technology of high-speed machine tool technology control unit.
3) the high speed cutting tool technology module: high-speed machining process system composed of machine tools, tool and workpiece, tool is the most active factor. The cutting tool is one of the key technology to ensure high speed cutting smoothly. With the substantial increase of cutting velocity, have put forward different from traditional speed cutting requirements of cutting tool materials, geometric parameters of cutting tool, cutter body structure, high speed cutting tool material and tool manufacturing technology has undergone tremendous changes, high-speed machining, to ensure productivity and high machining precision, but also to to ensure safety and reliability. Therefore, high speed cutting tool system must meet with a clamp repeat positioning accuracy of geometric accuracy good and high loading, clamping rigidity, good high speed when the equilibrium state and safe and reliable. As far as possible to reduce the knife body quality, in order to reduce the high speed rotating centrifugal force by security, meet the requirement for high speed cutting tool, clamping method improvement. Technology research and development tool system is one of the key tasks of high-speed CNC machining.
4) numerical control high speed cutting process: high speed cutting as a new cutting method, to be applied to actual production, the lack of application examples for reference, not the amount of cutting and processing parameter database, parameter optimization technology of high speed machining is one of the key technologies of the current constraints should be used. In addition, the high-speed cutting parts NC program must ensure stable load in the whole cutting process, but most CNC software is now used in the automatic programming function still cannot meet the requirements, needs to be added and optimized by manual programming, which reduces the high speed cutting value in a certain extent, must study a new programming method, so that the cutting data power characteristic curve for high speed spindle, give full play to the advantages of numerical control high speed cutting.
Development and comprehensive development and application of high speed machining technology depends on the key technology of the above principles, machine tool, cutting tool, the process of the.
Research status and development trend of high speed cutting technology, 5
Due to the high speed cutting has great potential in improving production efficiency, has already become important technologies in the field of competing for the United States and Japan, Germany and other countries. The United States Japan as early as the 60 century, started to study on the mechanism of high speed cutting. The last century 70's, the United States has developed high-speed milling machine maximum speed of up to 20000r\/min. Now, Europe and the United States and other developed countries the production of different specifications of the various high-speed machine tool has the commercial production and into the market, the actual application in aircraft, automotive and mold manufacturing industry. For example, manufacturing enterprises in the American Boeing aircraft, has adopted the high-speed CNC machining technology to machining integral super high-speed milling of aluminum alloy, titanium alloy thin-walled structure and the waveguide, flexible gyroscope frame of the ordinary method of parts. In recent years, the United States, Europe, Japan and other countries of the new generation of NC machine tools, high-speed machining center, high speed tool system and industrialization process further speed up the pace, the specialized production electric spindle technology and high performance products increase; tool system technology of high performance rapid development; application of linear motor in high speed feed system.
Our country in the research and development of high speed cutting technology, many universities and research efforts and exploration, including cutting mechanism, cutting tool material, spindle bearing, etc., have also made considerable achievements. However, compared with developed countries, there is still a big gap, basically still in the research stage of laboratory. In order to meet the needs of economic and social development, to meet the needs of aerospace, automobile, mold and other industry, NC Application Research of high-speed cutting technology has a long way to go.
At present, the research of high-speed cutting technology has been to the application stage from the stage of experiment. Research in the application of includes two aspects: one is the basic theoretical research on the key technology of high speed machining, including high speed spindle unit and a high speed feed unit, realizing the localization of high-speed machine tool. On the other hand, based on existing laboratory practice technology, application of process performance and process scope. Among them, research on the high speed cutting process is one of the most active research areas at present, the main goal is to directly process through advanced equipment testing or import, processing technology to resolve the issue of key parts, the development and perfection of the high-speed cutting method of special materials; research and development to adapt to the CAD\/CAM software system in high speed machining and post processing system, the processing state safety monitoring system based on a new detection technology.
When we entered the twenty-first Century, from the observation of the world, we are in the advanced manufacturing technology unprecedented rapid development period. Due to the advent of CNC machine tool (NC), the development of a series of CNC machining, such as machining center (MC), flexible manufacturing unit of flexible manufacturing system (FMS), computer integrated manufacturing system, and even the emergence of virtual axis machine tool is completely different with the traditional machine (also known as the six legs machine), closely and machine tool at the same time complement each other up the development of high speed machining technology, new tools, new technology, make the mechanical processing greatly reduces the labor intensity, auxiliary time is greatly shortened, the product quality and the production efficiency is improved greatly, become the development of manufacturing industry and the global economy has played a tremendous role in promoting. In the case of the United States, the manufacturing industry is known as the most economic sectors in the United States, for the United States in the 90's gross domestic product (GDP) growth reached 29%.
Today, vigorously develop the NC technology and equipment, has become the strategic decision of the governments in the world, with CNC equipped modern industry and transformation of traditional industries have become the developing direction of manufacturing countries in the world. In the late 90's as the output of CNC machine tools of Germany, Japan, Italy, the rate has reached more than 51.75%. CNC machine tools has become the main equipment in modern manufacturing technology, NC machining technology has become the mainstream of the advanced manufacturing technology, a new era of the modern manufacturing industry. The party's sixteen big clearly pointed out: "to revitalize the equipment manufacturing industry". New China's equipment manufacturing industry after many generations, especially the 20 years of reform and opening up and modernization construction, has established a relatively complete, independent industrial system, has the certain material and technical basis, the overall production scale has been ranked the fourth in the world. Many economists predict, in
數(shù)控切削技術(shù)綜述
數(shù)控高速切削技術(shù)(High Speed Machining,HSM,或High Speed Cutting,HSC),是提高加工效率和加工質(zhì)量的先進(jìn)制造技術(shù)之一,相關(guān)技術(shù)的研究已成為國(guó)內(nèi)外先進(jìn)制造技術(shù)領(lǐng)域重要的研究方向。我國(guó)是制造大國(guó),在世界產(chǎn)業(yè)轉(zhuǎn)移中要盡量接受前端而不是后端的轉(zhuǎn)移,即要掌握先進(jìn)制造核心技術(shù),否則在新一輪國(guó)際產(chǎn)業(yè)結(jié)構(gòu)調(diào)整中,我國(guó)制造業(yè)將進(jìn)一步落后。研究先進(jìn)技術(shù)的理論和應(yīng)用迫在眉睫。
1、數(shù)控高速切削加工的含義
高速切削理論由德國(guó)物理學(xué)家Carl.J.Salomon在上世紀(jì)三十年代初提出的。他通過大量的實(shí)驗(yàn)研究得出結(jié)論:在正常的切削速度范圍內(nèi),切削速度如果提高,會(huì)導(dǎo)致切削溫度上升,從而加劇了切削刀具的磨損;然而,當(dāng)切削速度提高到某一定值后,只要超過這個(gè)拐點(diǎn),隨著切削速度提高,切削溫度就不會(huì)升高,反而會(huì)下降,因此只要切削速度足夠高,就可以很好的解決切削溫度過高而造成刀具磨損不利于切削的問題,獲得良好的加工效益。
隨著制造工業(yè)的發(fā)展,這一理論逐漸被重視,并吸引了眾多研究目光,在此理論基礎(chǔ)上逐漸形成了數(shù)控高速切削技術(shù)研究領(lǐng)域,數(shù)控高速切削加工技術(shù)在發(fā)達(dá)國(guó)家的研究相對(duì)較早,經(jīng)歷了理論基礎(chǔ)研究、應(yīng)用基礎(chǔ)研究以及應(yīng)用研究和發(fā)展應(yīng)用,目前已經(jīng)在一些領(lǐng)域進(jìn)入實(shí)質(zhì)應(yīng)用階段。
關(guān)于高速切削加工的范疇,一般有以下幾種劃分方法,一種是以切削速度來看,認(rèn)為切削速度超過常規(guī)切削速度5-10倍即為高速切削。也有學(xué)者以主軸的轉(zhuǎn)速作為界定高速加工的標(biāo)準(zhǔn),認(rèn)為主軸轉(zhuǎn)速高于8000r/min即為高速加工。還有從機(jī)床主軸設(shè)計(jì)的角度,以主軸直徑和主軸轉(zhuǎn)速的乘積DN定義,如果DN值達(dá)到(5~2000)×105mm.r/min,則認(rèn)為是高速加工。生產(chǎn)實(shí)踐中,加工方法不同、材料不同,高速切削速度也相應(yīng)不同。一般認(rèn)為車削速度達(dá)到(700~7000)m/min,銑削的速度達(dá)到(300~6000)m/min,即認(rèn)為是高速切削。
另外,從生產(chǎn)實(shí)際考慮,高速切削加工概念不僅包含著切削過程的高速,還包含工藝過程的集成和優(yōu)化,是一個(gè)可由此獲得良好經(jīng)濟(jì)效益的高速度的切削加工,是技術(shù)和效益的統(tǒng)一。
高速切削技術(shù)是在機(jī)床結(jié)構(gòu)及材料、機(jī)床設(shè)計(jì)、制造技術(shù)、高速主軸系統(tǒng)、快速進(jìn)給系統(tǒng)、高性能CNC系統(tǒng)、高性能刀夾系統(tǒng)、高性能刀具材料及刀具設(shè)計(jì)制造技術(shù)、高效高精度測(cè)量測(cè)試技術(shù)、高速切削機(jī)理、高速切削工藝等諸多相關(guān)硬件和軟件技術(shù)均得到充分發(fā)展基礎(chǔ)之上綜合而成的。因此,高速切削技術(shù)是一個(gè)復(fù)雜的系統(tǒng)工程,是一個(gè)隨相關(guān)技術(shù)發(fā)展而不斷發(fā)展的概念。
2、數(shù)控高速切削加工的優(yōu)越性
由于切削速度的大幅度提高,高速切削加工技術(shù)不僅提高了切削加工的生產(chǎn)率,和常規(guī)切削相比還具有一些明顯的優(yōu)越性:第一、切
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