What is the difference between the 3 axis machining center, 3+2 axis, 5 axis machining center and other processing solutions that we often mention? Let me introduce to you first:
3 axis machining center
3 axis machining center processing is processed by linear feed axis X, Y, Z. Processing characteristics: The direction of the cutting tool remains unchanged during the movement along the entire cutting path. The cutting state of the tool tip cannot be perfect in real time.
3+2 axis 5 axis
The two rotating axes fix the cutting tool in an inclined position first, and then perform processing by the feed axes X, Y, and Z. This machine tool is also called a positioning five-axis machine tool. The rotating work plane in space can be defined by 3+2 axis machining (such as rotary head or rotary table). In this work plane, 2D or 3D machining operations can be programmed.
Processing characteristics: The rotary axis always rotates to the position where the processing plane is perpendicular to the tool axis for processing, and the processing plane remains fixed during processing.
5 axis machining center
Five-axis machining consists of linear interpolation movement of feed axes X, Y, Z and any 5 axes of X, Y, Z rotation axes A, B, and C.
Processing characteristics: The tool direction can be optimized during the movement along the entire path, and the tool can move linearly. In this way, the best cutting condition can be maintained on the entire path.
How do you realize the advantages of the five-axis machine? Here is an example of processing 28 parts at the same time. Through the design of the turntable and the fixture, and the three processing surfaces of the part are combined into one processing program in the five-axis processing program, the purpose of reducing the cycle time is achieved.
The turntable can expand the original processing space through precise positioning. The well-designed fixture can not only improve the processing efficiency, but also reduce the idleness of the machine, and the operator can also get out of it.
For example, to process the first three faces of the parts shown in the figure below, if the clamping method of the vise is used, a total of 264 seconds are required for each part (the clamping time is not counted).
By designing a more compact fixture and making full use of the processing space provided by the turntable, it has the opportunity to process 28 parts at a time.
In the production of the fixture, an aluminum alloy with a size of 114*114*550mm is selected as the base body, positioning pins are used as positioning, and a compression fixture that occupies a smaller processing space is selected for faster clamping.
Then mill the four faces of the base body, and process one positioning pin hole for each part, two grooves for avoiding empty locking fixtures, and two threaded holes for locking. This is all the manufacturing steps.
The complete composition of the fixture includes: 28 positioning pins, 56 positioning locking blocks (reusable), 56 screws, and wrenches. This fixture design can shorten the original processing time from 264 seconds to 202 seconds (not counting the clamping time). This means that the processing time has been reduced by 23.5%.
Not only that, because the processing program has merged the three processing surfaces of the part into one processing program, the cycle time of a single program has become 95 minutes. During this period, the machine has been processing, no need to wait for the frequent operation of the operator. Clamping, which will greatly reduce the labor intensity of the operator.
