CNC Customize Parts Professional Solution & Processing Provider

high speed milling.

by:QY Precision      2019-10-06
From a programming perspective, at a combined business store and development lab in New Hampshire, we \'ve been pushing for a new high-speed machining center to see what it can do.
Most of the test cutting and related work we provide to our customers includes cutting the contour graphite electrode at a lateral rate of more than 300 ipm, using stepovers between channels of small as0. 001[inches].
But now we are working with steel companies, especially looking for possibilities for completion.
Bypass the EDM and hand-processed to cut the injection mold on the mold.
In one application, we are cutting the hardened S7 cutter steel (54 HRc)
Use a1/4 [at 30,000 rpm]inches]
Vertical mill with nocoolant with spindle speed of more than 150 ipm.
The heat is discharged with the chip, and the tool and the workpiece are cooled to contact.
In another application, we are cutting asteel (NAK 55)spiral 0. 187[inches]deep with 0. 0015[inches]
The wall between the spiral turns.
Almost all of our work is at the extreme high end of the exact scale;
Our machine, Roku-Roku GR-
435N, unique 1 [Mu][inches]
We\'re exploring five areas-decimal-
Positioning and programming.
Step by step, we are exploring the key issues encountered by shops and factories in high-speed milling
Especially for programming problems, high-speed machining reveals its unique focus and huge potential.
This is practical application work, not basic research.
What we are doing is analyzing and testing the actual limits of some work that has already been done in advanced mold manufacturing stores and some other industry corners.
High speed milling has been pushed to the top of the list of hot topics machine tool manufacturers are writing and promoting --
Recently, they have focused their attention on tool making.
Starting with the aircraft industry, 40,000 rpm, 40 KW spindle, high-speed processing machines and tools have grown at an amazing speed.
It has found an ideal home for itself in precision mold manufacturing, in precision mold manufacturing, complex profiles Plus demand for high precision and fine finish, for manual finishing that is expected to eliminate production bottlenecks and most manual
Accessories that make mold manufacturing so difficult and time-Consumption process.
In a way, high-speed milling is just milling faster.
The principle of metal cutting has not changed, and the foundation of tools or programming has not changed.
The tool life is still mainly a function of the tool temperature and the higher spindle speed that produces a higher temperature-
Everything else is equal.
High-Speed Milling plays certain aspects of machine dynamics that are usually not encountered at conventional speeds.
Vibration, impact and elasticity are at the back of their heads, affecting everything from machine design, tool selection to CNC cuttingPath policy.
Ballscrews with a speed of 400 or 500 rpm start to work like rubber bands. Thefine-
Incremental profiles make high-speed milling very attractive for mold manufacturing, especially in tool design and programming.
Finally, the large amount of data that CNC has to process forces us to pay close attention to the entire data flow from the installer to the final result of data processing: the machine\'s response to the positioning instruction.
The technology acts like a game of step-by-step, with every spin, speed-through, computer network, and internal controller improving.
Based on our recent experience, the most advanced technology is that the hardware is now willing and capable, and the software is competent for the job, thanks in large part to the CAM developers, they used powerful new programming tools.
What potential high-speed mechanics need now is an accurate perspective on what works and how to avoid going into a dead end with the wrong technology.
The best starting point is to understand the problems and solutions that arise when programming parts.
A key fact of high speed milling is that it requires fine cutting, high speed feed and consistent cutting depth.
There are several reasons for it.
First, the stress on the tool must be controlled and kept as consistent as possible, with minimal impact.
Secondly, it has higher precision, and most high speed machining is high precision machining.
Third, cutting dynamics at high surface speeds are beneficial to lighter chips, thus increasing tool life.
A simple shock is a tool-
Killer of high speed milling.
The first problem that must be solved in programming is to input the tool into ut.
Entry must be gentle.
This is the place to program and build carefully. in tool-
The entry program for some of the more powerful CAM programs will be rewarded first.
Several schemes are currently being used.
They are not necessarily invented for high speed milling, but in high speed cutting they are more necessary than elsewhere.
Cutting entries is the basic idea.
If the tool approaches the workpiece from the side, this can be as simple as the cut entrance.
This is automatically generated by CAMroutines. When an end-
Mill approaches work from above (
On the vertical mill), the tangent-
The solution based on it becomes more complex.
The tool must be put into work, but it must also be fed in the direction of efficient cutting.
If there is space, the tool can drop down along the sloping path.
If depth or space is not allowed, the cutter can tilt down in several steps, cutting the same angle
Each pass has a deeper floor pocket.
A very effective way is to cut out a small round pocket in a spiral or spiral path.
All of these routes are available in some CAM systems.
The same \"easy-to-go\" principle applies during machining, especially when a tool is used for rough machining and a tool with a smaller diameter is used for finishing.
In this case, there are large rounded corners, all on the right
Angle and any path or angle, the larger rougher cannot reach the final radius due to its size.
If you use the same program as rough machining for finishing, simply apply an offset to compensate for the smaller diameter of the finishing tool --
What is usually done when the speed is low
You can bury the finishing knife in the rest of the material.
In these cases, the tool is often overloaded and is likely to be interrupted.
At least one impact on the whole system, the accuracy will be lost.
There are some clever ways to solve this problem in the CAM system.
Pencil milling, rest milling, corner-
The selection and other names apply to the schemes used by different CAM manufacturers, and the logic of the various methods applies to one or a set of similar situations;
No single solution is the best.
The success of any such plan depends on whether the plan is aware of how much material is left and where it is.
These are very clever programs.
Nevertheless, some of these programs waste a lot of time because they make the tool go along each Z-
Pass horizontally, or each grating path on the workpiece.
Really smart people focus on one area until it\'s done to clean up that particular corner or other feature.
A good finish, separating all spindle speeds from lateral speeds, gives you a lot of freedom when deciding on the path to take over the job.
Because in many of the work of applying high-speed milling, the final completion is the goal (
Especially the mold)
They need special attention.
Many such work pieces are clearly outlined and often cut with balls, which makes programming work complicated
Noseendmills: a tool that seems to contradict the realization of a uniform surface speed and tip height.
The spiral path is a CAM program that is suitable for the plane.
Exquisite apartment
The milling program also includes local
The area grating path and projection path that vary according to the angle of the surface. Two-
The axis curve is positioned as step cutting depth or step cutting through the cutting depth, moving the machine tool workbench in two ways
Axis profile when cutting.
Complex profiles are more difficult, mainly because of the effect of stepping the tool incrementally in one of the three axes. Z-
Horizontal machining is the most common way to process accurate, fine, where the tool profile in X and Y is then stepped on the Z axis between the contour cutting
Finish the profile with a high speed grinder.
It usually keeps the surface speed more consistent. but not always.
According to the shape of the part, profile analysis of it in X and Z or Y and Z may result in inconsistent load and speed. Z-
Shaft machining, however, better enhances consistency in another way: you can keep the tool or traditional cutting all the time, and consistency in this regard is critical to the finish.
In most cases, in Z-
Level is the ideal way.
The development of these cams is usually suitable for contour machining, but it is particularly important in high-speed milling.
The pause cannot be moved, the transition from climbing to traditional cutting, and the uneven finish caused by a quick change in the tool load when you try to minimize or eliminate manual machining.
This is usually the main reason for high speed milling.
We are working on high-speed milling from the programming side and from the data side-
Strictly speaking, handling is not a programmer\'s problem --
However, if we want to know the direction of technology, this is something we cannot avoid.
Here\'s a leaflet on what\'s important: when it comes to data --
Processing ability, the more the better, the less the better.
It is smug, but not far from the mark.
When we start high-speed milling some of our 1-
The Mbyte program of Grewto 10 MB size.
We took advantage of high-speed technology: we used finer positioning increments and we took smaller steps to get a smoother, more accurate finish.
After all, this is a key advantage of high-speed milling, which is making programs that size balloons.
However, high data volumes and communication rates are manageable.
Here are the problems and solutions: there are some ways to reduce the size of the program.
The tangent arc of the curve rather than multiple line segments (
Even more compact curves recently)
Pack a lot of information into less space.
Somtrotrols allows variable string sizes and basically sets the accuracy on the sliding scale according to geometric requirements.
Processing a truck of data has a lot of room for innovation and efficiency in processing the database. In the end, larger computer storage capacity, faster processing and faster communication can best meet the needs of high data.
What\'s more, it\'s really better-
Like in a desktop computer.
The overall trend is getting faster and faster.
In the discussion of high-speed machining, data hunger is a term thrown out, but it is not widely understood.
We take apart a machine with a resolution of ten times that of other high-speed machining centers using a fully selected Fanuc 16iM controller, which ensures our Roku-
Roku is not eager for data.
The commercial hardware and software currently available can do the job.
Even with look-
In addition to all other technologies, CNC provides data to the servo system as quickly as possible.
So, where are the potential bottlenecks and how to avoid them?
Looking back from the servo motor, the first question was answered: up-to-
Date on which data can be provided by CNCs.
However, they also have to get the data, and without a fast device to provide them with the data, they can\'t handle the high-speed machining requirements.
More cnc ram memory is not the answer.
We all want to keep up with the size of the program by providing enough RAM to handle them.
The answer for today and the foreseeable future is the data server: the hard drive and its built-in-
In electronics, there are buses.
Upload data to the level data path of CNCs on a high-level computer-bus rates.
If the hard drive has enough speed and capacity, a small amount of cnc ram memory can act as a buffer for a fairly large program.
These are now standard projects for high-speed machining centers.
The data server saves the entire program at the same time, using the traditional DNC link of the programming department, which can send the program leisurely.
But with 10-
The 50 MB program creates a nightmare that will eventually get in the way of work.
The transmission rate at the normal baud rate is arranged in the order of hours instead of minutes, just like when the program is shorter.
The best answer now is the Ethernet connection.
They need a network card in CNC.
Their data rates allow for rapid exchange of programs, making the entire process of downloading, storing and processing smooth and efficient.
In a program as big as CNCwith, only minor edits may be done --
Tool inventory quantity or overall speed adjustment-
But still the editing program needs to be sent back to the programming computer.
Ethernet makes it practical.
Network connections may evolve and Ethernet may be replaced, but this does not change the basic direction of high-speed milling data processing.
The trend is more and more data, larger programs, and the need for fast communication between programming computers and CNC.
CNCs themselves can do the job, and it looks like they won\'t be overtaxed because of existing technology or chip speed.
At least the mode has been set before the next big idea comes up.
Look at our Roku.
Roku machine tool hardening tool steel, we can see that high speed milling has just begun to have a huge impact on mold manufacturing and other processing that requires speed, the accuracy and finish it provides.
We are on holiday with graphite because the machine is easy-
We just let go of the throttle and watch the dust fly because the machine cuts so fast and the load on the workpiece is so low that we can move as fast as we can.
The processing of graphite electrodes with these machines is so complicated that the direction in which the electrodes are made is beyond doubt.
What we have to deal with is something more stubborn.
Machines and knives are able to understand programming programs well and can be used on CAM systems in today\'s market.
According to what we have seen, the direction of cutting the mold directly from hardened steel is the same as the processing electrode.
More information about Vard-
Smith Associates Midland Park, New Jersey
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