At present, the homogenization competition in the manufacturing industry is becoming more and more fierce. Only with unique core technology, achieving higher production efficiency under the premise of ensuring quality, or making high value-added products that others can't, can we stand out. It is against this background that five-axis machining is favored by more and more manufacturers.
01
Why choose five axes?
The five-axis machining center is based on the addition of two rotation axes of A/B/C on the basis of the three axes. It is characterized by the linkage relationship and structure of the added two rotation axes and the linear axis.
Then why do more and more manufacturers tend to choose five-axis? There are mainly the following reasons:
1) The update cycle of new products is shortened, the cost is forced to be reduced, and the traditional process cannot meet the delivery requirements.
2) Product quality and quantity depend on labor, and labor costs are getting higher and higher.
3) EDM needs to process electrodes, the process cost is high, the efficiency is low, and the quality is poor, and the five-axis can be replaced.
4) The maturity of three-axis machining technology has led to fierce competition for homogenization.
02
Five-axis core value
(1) Machining accuracy
For some complex multi-faceted processing products, it is difficult to achieve high precision in three-axis processing, and it takes a long time for manual intervention, while five-axis processing can realize fast positioning processing, mainly from the following aspects to increase the processing accuracy of products:
1) Introduce a five-axis fixture.
2) Reduce the clamping process.
3) There is no manual multiple clamping, and the clamping error is reduced.
4) You only need to find the coordinate system once to reduce manual errors.
5) Reduce the length-to-diameter ratio of the tool and reduce the risk of knife snapping.
Five-axis machining of mold slider, reducing 13 processes to 2 processes
(2) Surface quality
The five-axis can improve the surface processing quality of the workpiece from the following angles:
1) Use a tool with a relatively short length and diameter to improve processing stability.
2) The process of reducing discharge, the whole surface is more uniform.
3) Use the side edge processing of the ball cutter to improve the surface quality of the workpiece.
4) The reversing point of the 3-axis can be avoided to improve the surface quality.
Use a tool with a relatively short length and diameter to improve processing stability
Use the side edge processing of the ball cutter to improve the surface quality of the workpiece
There will be errors between the screw and the guide rail at the forward and reverse conversion points of the 3-axis motor
(3) Processing efficiency
The five-axis can improve the machining efficiency of the workpiece from the following angles:
1) Use a tool with a relatively short length and diameter to increase the machining feed.
2) Use five-axis linkage machining to reduce electric discharge.
3) Use the side edge machining of the ball cutter, and use the multi-blade cutter to increase the feed rate of the machining.
(4) Five-axis QCD concept
High-precision and high-rigidity five-axis + multi-blade ball cutter:
Quality: 1-point use ⇒ Improve machining accuracy and eliminate the influence of tool accuracy.
Costdown: full blade use ⇒ reduce cost Divide the use area of the full blade of the ball knife, use all effective blades, prolong the life of the tool and reduce the cost of the tool.
Delivery: Multi-edge tool ⇒ Shorter processing time The number of tool edges increases, the feed rate is doubled, and the processing time is shortened.
03
Case Sharing – Inclined roof of automobile bumper
Whether it is high-efficiency five-axis machining of large parts or high-precision five-axis machining of small parts, Makino can provide solutions for corresponding models.
Workpiece material: 1.2738
Size: 900x800x100mm
Weight: 640kg
Difficulties in processing:
1) More processing steps
2) The types and requirements of inclined holes are higher
3) Long processing time
4) High accuracy requirements for groove processing
(1) Makino vertical machining center V80S/V90S solution
1) 5-axis linkage (deep groove side wall processing)
picture
Tool used: D8R4
Processing conditions: S12000 F5000
Processing capacity: 0.07mm
Processing time: 172min
Key point: The direction of the 5-axis linkage is along the sliding direction of the insert
2) 5-axis linkage (boss angle clearing)
Tool used: D6R3
Processing conditions: S12000 F3000
Processing capacity: 0.07mm
Processing time: 16min
Key points: High-precision 5-axis linkage, which is more efficient than 3-axis, and has no tool marks compared to graduated processing
(2) Makino vertical machining center D series solution:
For the processing of large parts such as mold cores and sliders for the inclined roof of automobile bumpers, the vertical machining center V80S/V90S can achieve a machining accuracy of <±0.02mm without manual tooling, which can well meet the processing requirements. For parts with high precision requirements such as small inserts of molds, D series machine tools can be used to achieve high precision machining. The perfect product mix and combination greatly improves the processing efficiency and production competitiveness.
