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Advantages of non-metallic five-axis machining centers and specific processes for machining parts

Published Time:

Oct 15,2021

Non-metallic five-axis machining centers have become a "main force" in modern manufacturing. Their high processing precision, efficiency, and stable accuracy have led to their increasingly widespread adoption in factories, research institutes, and schools. Non-metallic five-axis machining centers can meet the processing needs of products with more complex shapes and processes. A non-metallic five-axis machining center is a type of machining that uses three main axes of motion (X, Y, Z) and two rotary axes (generally A, C or B, C) together. It is typically used to machine parts with complex curves, such as impellers, wings, and molds.

　　 Non-metallic five-axis machining center It has become a "main force" in modern manufacturing. With its high processing precision, high efficiency, and stable accuracy, it has become increasingly popular in factories, research institutes, and schools. Non-metallic five-axis machining centers can meet the processing needs of products with more complex shapes and more processes.

　　A non-metallic five-axis machining center is a machining method where three main motion axes (X, Y, Z) and two rotary axes (usually A, C or B, C) of the machining center move together. It is usually used to machine parts with complex curves, such as impellers, wings, and molds. Because most or all of the processes for a part can be completed with a single clamping, it avoids the positioning errors that occur in multiple clamping operations in three-axis and four-axis machining centers. Therefore, the parts produced have higher precision and require less auxiliary time.

Non-metallic five-axis machining center

General process of machining parts with a non-metallic five-axis machining center

　　When machining parts with a non-metallic five-axis machining center, the first step is to prepare the machining program for the part. This is the work instruction for the CNC machine tool. The machining program is input into the CNC device, which then controls the speed change, start and stop, feed direction, speed, and displacement of the machine tool's main movement, as well as other actions such as tool selection and replacement, workpiece clamping and releasing, and the on/off switch for cooling and lubrication. This ensures that the tool, workpiece, and other auxiliary devices move strictly according to the sequence, trajectory, and parameters specified in the machining program, thereby machining parts that meet the requirements.

　　Examples of difficult problems and solutions for non-metallic five-axis machining centers

　　The shuttle plate is an important component of our factory's circular knitting machine, which is mainly used to produce woven bags, and the shuttle plate plays the role of threading and guiding the thread. In the traditional process, the production process of the shuttle plate is as follows:

　　(1) Casting the overall shape;

　　(2) Grinding the shape with a grinding machine to make it relatively smooth, leaving a margin;

　　(3) Milling the two sides symmetrically about the center on a milling machine, and milling the risers on the arc surface (upper and lower surfaces);

　　(4) Removing burrs and deburring sharp edges with a fitter's tools;

　　(5) Clamping twice on a milling machine to process the four compound inclined planes of the protrusions;

　　(6) Precision milling of the shuttle head;

　　(7) Drilling various straight holes and deep inclined holes on the fitter's drill press;

　　(8) Cleaning the roots and removing burrs from the four protrusions;

　　(9) Inspection.

　　After introducing the non-metallic five-axis machining center, the shuttle body machining process was improved, and the new process is as follows:

　　Casting the overall shape, leaving a 1mm margin on the upper surface;

　　Milling the two sides symmetrically about the center on a milling machine, and milling the risers on the arc surface (upper and lower surfaces);

　　The non-metallic five-axis machining center processes the compound inclined plane, drills the deep inclined holes and taps the threads, and precision mills the remaining amount on the upper surface in a single clamping operation;

　　Cleaning the roots and removing burrs from the four protrusions;

　　Inspection.

　　Compared with the old process, the new process has the following advantages:

　　In the new process, the overall shape is cast, leaving a 1mm margin on the upper surface. This margin is removed by the non-metallic five-axis machining center, which reduces the workload of grinding by the fitter in the old process 2, and also improves the accuracy and smoothness of the upper surface.

　　With a single clamping, the upper surface and the four compound inclined plane margins can be precision milled, and the inclined holes, straight holes, and threads can be completed, reducing the auxiliary time for secondary clamping and avoiding the positioning errors caused by secondary clamping.

　　The new process is concentrated, and both processing efficiency and precision are greatly improved, and the dimensions are stable.

　　In the new process 3, the following difficulties will be encountered during the actual processing with the non-metallic five-axis machining center:

　　Difficult clamping and positioning. The shuttle plate has dimensions of 472 × 126 × 111 mm, and is relatively large. The shuttle body is arc-shaped, only 5 mm thick, and made of integral cast aluminum. If the clamping force and cutting force are slightly larger, it is easy to deform. Therefore, we designed a special fixture. The fixture is made into an arc shape with the same radius as the shuttle plate, forming a relationship between the containing surface and the contained surface. There are two pads on each side of the fixture, and the four pads fix the two sides of the shuttle plate (the two sides have been precision milled in process 2) through screws. At this time, the clamping and positioning of the shuttle plate are completed.

　　Interference and collision are likely to occur during processing. When removing the remaining amount on the upper surface and the protrusions' compound inclined plane, the non-metallic five-axis machining center of the machine tool needs to be programmed using software. At this time, the interference problem should be considered: interference between the spindle and the worktable, interference between the tool holder and the fixture, and collision between the tool and the workpiece. During programming, the models of the worktable and fixture are included in the programming environment. In this way, when the program is automatically generated, the software will automatically calculate the possibility of interference and collision, and mark the program segments that may have interference and collision, and then modify them. Finally, machine simulation is performed. After it is found that there is no interference or collision, the post-processing program is generated to ensure safety during actual processing.

　　The non-metallic five-axis machining center plays an irreplaceable key role in overcoming processing difficulties, improving processing methods, and developing new products, greatly improving processing efficiency and precision. The shuttle plate in this article is a typical example. In actual processing, many difficulties and problems will indeed be encountered, but with the maturity of technology and the accumulation of experience, these problems will be solved, and the advantages of non-metallic five-axis machining centers will become increasingly obvious.

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How to use a five-axis machining center efficiently? Today, let's learn a few practical steps!

When using a five-axis machining center, the equipment must first be adjusted to ensure that the workpiece and fixture dimensions precisely match, and that the zero points of each axis are accurately adjusted.

Why do composite materials require 5-axis CNC machining?

Composite materials are widely used in various fields such as aerospace, automotive, construction, energy, energy storage, infrastructure, marine, pipelines and tanks, sports and entertainment, and transportation due to their light weight, high fatigue resistance, and strong fracture resistance. Among them, aerospace and automotive industries are the largest application markets for composite materials. Five-axis CNC plays an important role in the processing of composite materials. Why do composite materials need to be processed using five-axis CNC?

For businesses, when choosing a five-axis machine, should a dual-station or single-station model be selected?

Dual-station five-axis machines offer several significant advantages. First, while one station is being machined, the other can be used for material loading and unloading, ensuring continuous, non-stop machining and significantly improving production efficiency. Second, the dual-station design makes operation more convenient and reduces waiting time. However, dual-station five-axis machines typically cost more than single-station machines and may require more operating and maintenance space.

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