Shanghai Daoqin Plastics Co., Ltd.

         mold manufacturing main/primary 围绕锻造模, tensile 模, injection molding and metal pressure 铸铸造模 and other mold manufacturing. therefore it is automotive, machine, home appliances, active use product and electronics industrial and other industrial parts manufacturing equipment provide strong/high large 支持.

         as is industrial 之母, mold in from product to formed production parts production process process/workflow in has key/critical 位. this industry product is product 几何形状 relatively is complex, many mold has relatively deep type and relatively 陡 侧壁, mold type and type large separation is 自由曲面, mono parts production is 主, development cycle also short, therefore need using/adopting flexible also tool high processing process. complex 几何形状工 parts processing and need process flexible 则直接指 toward 5轴 processing.

        5轴 processing advantages in can achieve has 5 轴 meanwhile 运动, in upper 世纪90 year already is 业界 知晓. its not only can achieve 自由曲面, 圆柱面 and 球形曲面 铣削 processing and achieve parts 5 面 processing outer, important also in can relatively large 行距, short 铣刀, can 接近任意 几何形状 and obvious stability process control processing. in addition, parts in 定位基面 processing rear, through one-time 装夹即 can achieve full processing, more 次换夹 belt/tape degree and time issues.

        5轴联动 processing

        5轴联动 processing is through in has 3 笛卡尔直线坐标轴 upper formed 两 附 add 摆动回转轴 achieve (图1), make 铣刀以5 自由 degree versus for/regarding parts surface 进行5轴联动 processing, for/regarding relatively deep or difficult 于接近 type 腔自由曲面(图2), 凭借5轴 processing can using/adopting versus for short 铣刀(图3), reinforcement rigid property and improve/increase processing stability property.

         through 5轴 processing combined tool 几何角 degree has processing difficult 于切削 材 material. 而铣刀自由 几何定位 also make and parts maintain most 佳状态, is 铣刀 切削刀刃 can most 佳 贴近工 parts 轮廓, can make tool to relatively large 铣削行距, from shrink short processing time.

         and 3轴联动铣削 versus ratio, 5轴联动铣削 process can belt/tape process, 几何形状 and upper series advantages. can processing 任意几何形状 complex mold, 而5轴 processing force also in 于几乎 can in parts one-time 装夹 情况 lower full processing, improve/increase mold processing degree, parts surface quality, can shrink short processing time (免 工 parts and 换夹).

         pure 粹 3轴 machine 床, in processing 几何形状 complex mold 时, in 一定 困 difficult. in processing mold relatively small semi 径时, is 铣刀 刀尖 semi 径不允许 large mold this semi 径. in processing relatively deep type 腔时, also 往往必 must using/adopting fine long 铣刀, this also 会导致 processing unstable property and comparison surface quality.

         also 如当3轴 processing to relatively small demolding degree 时, 往往也 is difficult 于进行铣削 processing. make processing relatively large surface, can using/adopting very more relatively small 切削行距 切削 this surface. using/adopting 5轴 processing, versus for this surface 以 需 角 degree in one-time in can remove surface upper material. 5轴铣削 versus for/regarding 3轴铣削既 has advantages, has 弊端(见图4 and table/sheet 1). in processing non 自由曲面时, using/adopting 3+2 轴 processing tool has relatively more advantages.

        3+2轴定位 processing

        3+2轴 组 combined processing, through and 回转轴 will 切削刀 tool solid in 一 倾斜 位置 achieve parts 各部位 processing, achieve 3+2轴定位 processing. 3+2轴 although can processing 自由曲面, is can complex parts 5面 processing, in large more 数情况 lower, need for parts 进行2次甚至3次 换夹, this 样就不 need is more 次装夹 浪费 time. not only improve/increase production efficiency and processing degree, another, also improves machine processing active property. 显然, using/adopting this 样 5 轴 machine 床(3+2轴)也 is comparison 经济, is procurement new 5轴联动 processing in 心 费 use, large more need ratio 购置一台配备 has di 轴回转工 as 台 立式3轴 processing in 心 费 use need high very more. in addition, this type of 3+2轴 组 combined also tool has another advantages (table/sheet 2).

        举一 实例: for/regarding pure 粹 5轴 machine 床, 第4 and 第5 轴 more is in as upper, as formed dry 扰 情况 relatively more. this need relatively high parts tool or using/adopting relatively long tool, 但随之而 is machine as stability property lower slip, 会引起振动, most reduce machine processing degree and efficiency. need is parts is in add as upper, dry obvious decrease/reduce. 由此就 can using/adopting easy generate short tool.

        3+2轴 solutions its it advantages in 移动 部 parts quality upper. 5轴 machine must accelerated and made machine as and parts, for/regarding add 1 or 2 轴 is has parts 回转轴进行移动, can obvious decrease/reduce quality, 由此, reduce electrical can consumption.

        近几 year, 5轴 processing in development trend strong/high 劲, 涡轮叶 sheet/slice, 叶轮, formed or other 自由曲面 parts, need 5轴联动 processing in 心. is has very more different processing 任务, 5轴联动 processing for/regarding many application is has necessary, 且不经济, is has in 5轴 processing in upper processing 90% is pure 粹 5面 processing. using/adopting 设置第4 and (if necessary)设置第5 轴 3轴立式 processing in is high production rate solutions. is 说, using/adopting has and 回转轴 立式 processing in 心常常 is 经济, and flexible processing solution/scheme. it can meet/satisfy procurement use, can property, as 业面积 and can consumption and other requirements.

         in production in, in 3轴铣床 upper di 轴回转工 as formed is 一台5轴 processing in 心(图5), utilizing this 样 3+2轴 solutions, and pure 粹 5轴 machine versus ratio, this type of machine relatively easy achieve parts more processing. using/adopting relatively large specifications as 台, also can more parts processing, tool has relatively high production rate.

        5轴铣削 is types requirements very high processing, most formed in very large degree upper 取决于 machine 床, tool, and control system versus most combined.

        5轴 machine 床

         according to and 回转轴 different 配置, can formed various different type type 5 轴 processing machine 床. can is 立式, also can is and 立柱移动式(can has relatively large as 空间), can is 龙门式(can combined large parts processing). Common is and 回转工 parts 台5轴 machine 床, in 摆动轴 支 base/seat upper 常常设置一 回转工 as 台(也 can more 回转工 as 台, achieve more processing, 图6), this type of machine combined processing in small dimensions parts, 摆动工 as has using/adopting di 面支承(图6), has mono 面支承 (图7).

         currently, 随 直线 electrical machine and electrical machine application, 直接驱动 5轴 machine day increase more, this not only make machine tool has very high accelerated degree, and improve/increase machine 床 工 as degree. using/adopting 5轴 high speed processing processing parts can in relatively short time obtain very high processing degree and surface quality.

         processing complex mold, new CNC程序初次 debugging especially need attention/notes tool and parts 碰撞. is 此, GF阿奇夏米尔 company development Mikron HPM 600U and HPM800U high 效铣床就装 has machine 床主轴保护模 block (Machine Spindle Protection HPM), utilizing this type of system can 避免主轴 loss bad, make machine 床 几何精 degree loss decrease/reduce machine time.

        5轴 high speed processing in 心 普遍 features is using/adopting 龙门式 frame structure, reinforcement machine rigid property, machine 床床身则 using/adopting polymer mixed 凝土, due to this type of material tool has relatively good retardant property can and relatively low hot rate, machine heat stabilized property for/regarding ensure processing high degree is very important conditions, is 此, has high degree processing in through for has and parts (如轴驱动 plant/unit) cooling process 监控进行 machine internal temperature degree 调控, ensure processing in high, separation stability processing degree.

        5轴 high speed processing in in price upper need ratio 3轴 processing in high very more, according to 德马吉森精 machine DMC75V series 5轴 processing in and 3轴 processing in 心进行 price comparison, 5轴 need ratio 3轴 price high 50%. 5轴 high speed processing in price high, this type of high machine especially combined use processing complex 几何形状 mold. 5轴 processing in in processing relatively deep, relatively type 腔时, can through parts or 主轴头 附 add and is 立铣刀 processing most process conditions, 并避免刀 tool and and type 腔壁发生碰撞, decrease small tool processing 时 抖动 and tool loss 危险, from has improve/increase mold surface quality, processing efficiency and tool lifespan.

         according to Germany from automotive machine parts and material container and other mold manufacturing 厂家, Meissner company 28台铣削床 in has 14台 used for 5轴联动 processing, has relatively use experience. due to 5轴铣削 众 more advantages, 像铣削 used for type molding 模时, company using/adopting 5轴铣削 need ratio front using/adopting 3轴铣削 cost large reduce semi.

        数控编程 and system

         currently, 数控编程 basic upper is through CAD/CAM system achieve, upper, if use combined 适 编程 system, can significantly decrease/reduce 编程工 as, 且编程 can 靠. 5轴铣削 编程并不会像3轴铣削 编程 that 样费事, 起码不会 that complex. usually, utilizing CAD/CAM system, 3轴, 3+2轴 and 5轴 铣刀路径连同 选 machine 床 运动 is can 视, is utilizing CAM system can through 模拟仿 true 检验生 formed tool 轨迹 精 degree and processing process in 诸如刀 tool, parts, and machine 床主轴 between can can 碰撞, also can processing positive property.

        CNC control system is high speed 5 轴 processing in important formed separation, it in very large degree upper machine processing speed degree, degree and surface quality. therefore, for/regarding processing mold 自由曲面 high speed machine 床, system property can tool has especially important 意义.

         processing high degree 自由曲面时, micro 段直线 and 圆弧构 formed tool 轨迹造 formed large parts 程序, this data need machine control system and 处理, therefore 程序段处理 time long short is 决定CNC control system as efficiency important indicators. currently, high 档CNC control system 程序段处理 time generally can 达0.5ms(如海德汉 iTNC530数控 system), has 别数控 system 程序段处理 time already shrink short to 0.2ms-0.4ms or more short.

        应 used for mold high speed processing 现代CNC数控 system, remove tool has is ensure high speed to speed degree necessary very short 程序处理 time outer, also tool has Nurbs and strip/profile function, can nano separation rate 进行工 as, in high speed processing lower obtain high processing degree and surface quality.

         currently, high 档 数控 system can and different CAD/CAM system 进行连接, data from CAD/CAM system 经以太网以 very high speed degree to control system upper. CAD/CAM集 formed to control system in very large degree upper make mold complex processing obtain good 效果, for shrink short adjustment time and time as separation important 贡献.

        刀 tool and 刀夹

         in mold processing in, main/primary using/adopting fine pellets overall hard alloy tool (球头铣刀 and has 刀尖圆弧 semi 径 立铣刀), large more has hard coating and especially 刀刃几何角 degree. most large 直径16-20mm, due to tool usually relatively difficult 接近工 parts 轮廓, therefore need using/adopting fine long structure 夹头. to fine long structure and in high speed 铣削时必 must high 回转精 degree and versus balanced quality, combined mold processing main/primary has types 刀夹: hot cold shrink 夹头(utilizing 刀夹材 material hot and cooling shrink small features, achieve tool and 进行换刀) and force 锁紧夹头(如三棱应 force 锁紧夹头 and liquid pressure 膨胀夹头, this category of is 依靠夹头 machine deformation achieve tool 夹紧). in mold parts 时, due to material remove amount large, toward force relatively small, selection this category of is combined 适.

        结语

        5轴 high speed processing in development and as property can improve/increase is mold manufacturing 业 以 high and high degree processing mold important front 提, is processing complex mold key/critical equipment. using/adopting 直接驱动 5轴 processing in 心, can significantly improve/increase processing in 心 行程 speed degree, property can and 定位精 degree. 5轴 processing is parts full processing conditions, from can decrease/reduce time, decrease/reduce parts 搬运, amount and process process/workflow time. for manufacturing mold 说, 5轴联动铣削 already formed is mold processing key/critical process. especially is 5轴 high speed hard can large large mold manufacturing production process process/workflow, improve/increase mold processing quality, shrink short mold manufacturing time and reduce production cost, from large large improve/increase mold manufacturing enterprise competition force.