In order to win in the fierce market competition, the integration of machine value-added functions is developing. Representing this trend is a composite machining machine that uses a machine tool for composite machining and different methods of processing, as a trump card that can achieve multi-variety, small-volume production, and different varieties of production. More than half of the original machining centers and CNC lathes will be replaced by composite machining machines, and it is expected to reach the production and sales scale that can compete with all machining centers.
The concept of a changing composite machining machine
Today's manufacturing industry, especially at the machining site, has the following characteristics. 1 variety, small batch production 2 Short lead time 3 Reduce cost 4 With light weight, performance compounding adds a complex shape of the product 5 lacks skilled operators and skilled personnel. In order to adapt to this situation, we will win in the fierce market competition, and the composite processing machine as the "Ace" will debut.
A machine that has several processes and different processing properties for machining complex shapes of workpieces is called a compound machining machine. In order to achieve the same purpose, there is also a method of multi-axising the control coordinates, expanding the processing function, and multi-functioning. In short, the process integration method is used to improve production efficiency and increase the added value of the machine tool. Therefore, here, the former machine tool that realizes different types of machining in one machine and the multi-coordinate control machine tool of the latter are collectively referred to as a composite machining machine.
The function of a composite machining machine changes with the times. In the past, there was a time when the machining center was called a composite machining machine. However, due to the limited variety of tool exchange processing, and the field of cutting processing, the general machining center is no longer called a composite machining machine. . Similarly, the era of today's multi-tasking machines no longer known as multi-tasking machines may not be far behind.
The development and production of composite machining machines are constantly being promoted. In particular, the number of sales of machine tools that combine the turning function and the rotary cutting function has increased rapidly, and it is expected to reach the production and sales scale comparable to the machining center in the future.
At the beginning, Japan's multi-tasking machine was based on a lathe, plus milling and strengthening. This is because almost all machining of the lathe is subject to secondary milling and hole machining. The development of composite machining machines was originally aimed at synthesizing these machining processes.
However, the recent multi-tasking machine tool has changed from the original turning machine to the main part of the milling machine, and the use of the machining center has increased.
At the end of the 1970s, the emergence of multi-process machine tools in the Japanese market was the end of the 1970s and the early 1980s when the peak period of CNC machine tool production.
The 5LC composite CNC lathe, which was released by Hitachi Seiki Co., Ltd. in 1979, has a spindle and Y-axis for milling, an ATC (automatic tool changer), and an indexing function for the lathe spindle. It is an advanced product that combines the style of a multi-tasking machine.
During the same period, Yamazaki Mazak Company published a CNC lathe with a milling function called the foundation of the current multi-tasking machine. In 1983, the company began selling the slant turn 40ATC milcenter CNC lathe with ATC (Automatic Tool Exchange) as the prototype of the current multi-tasking machine.
In Europe, in 1995 EMAG developed a vertical spindle type vertical lathe (also known as an inverted lathe). This is a multi-tasking machine that can mount the workpiece on the spindle, integrate the feeding device and the measuring function, and has a good chip discharging function. It is attracting attention as a “machine tool that responds to environmental requirements†conforming to the dry cutting structure. Recently, its processing range has been further expanded to process heavier workpieces.
In addition, turning machining centers for roughing to complex shape machining have also been developed.
Type of compound processing machine
1. Turning processing as the main body
The multi-tasking machine with turning machining as the main body is the turning center. The turning center starts from the machining process, and the lathe tool and the rotary tool that can be milled are arranged on the tool holder, and the cylindrical workpiece and the rod-shaped workpiece can be grooved and machined. Recently, a double spindle head mode has appeared, and the other end can be processed by an alternate method without removing the workpiece.
At least 70% of the current turning parts require two or more processes. As a high-performance, high-quality machining of these parts, there are three points in the same position processing technology at the same time as turning.
(a) Integration of internal and external processing: The functions of primary (surface) and second (inside) machining are input to the primary/secondary machining machine in the machine tool.
(b) Machining and compounding: Turning processing, milling, grinding, and other functions are all integrated in the machine tool.
(c) Intelligentization: The storage, handling, and processing are stored in the machine tool, and it is possible to perform workpiece recognition, control of workpiece control, adaptive control, information networking, etc. It is a unit processing machine tool using the latest monitoring technology.
Machining center multi-coordinated
(a) Five-coordinate control: Based on the three coordinate controls of X, Y, and Z, the product developed to change the direction of the tool and set the swing position at a specific angle around the feed axis is a five-axis machining machine.
The five-axis machining machine has the following two methods of use: (1) The rotary control axis uses the indexing, and the workpiece is tilted to the target tool, and the three-coordinate control is processed in this state. (2) All the control axes are used at the same time and continuously operated. This is called five-axis linkage, and it can process a curved-shaped workpiece with a protruding shape such as an impeller.
There are many characteristics of the five-coordinate linkage machining machine: A. It can avoid the condition B with zero cutting speed, and can shorten the tool length C: It can process workpieces with protruding shapes that cannot be processed without reloading. Now, the demand for such equipment in the aircraft industry and the metal mold industry is increasing.
(b) Six-coordinate control
Due to the multi-axis control, the milling machine can not only perform complex shape processing, but also perform composite machining. For example, an angular shape or a square-shaped hole can not be processed in the past because the process is not changed, and is generally replaced by an electric discharge machine. Now, the chisel-like tool is used instead of the rotary tool, and the six-coordinate control is used for the simultaneous cutting process, which enables one piece of equipment to complete the machining of the workpiece, and the accuracy and efficiency are also improved.
With a non-rotating tool, it is necessary to control the swivel position around the spindle, which requires six-coordinate control. In terms of efficiency improvement, the cutting speed and the feed speed are consistent due to the use of non-rotating tools in the six-coordinate control process, which solves the problem of the shape and position that can not be processed by high-speed machining and the rotary tool cannot be improved by increasing the spindle speed. problem. It also makes it possible to complete all the cutting operations without changing the process and one-time loading.
(c) Grinding the main body
For the multi-axis of the grinding machine, in the past, how to automate in the operation of products such as centerless grinding machines has been carried out more. Also being developed is a product that completes inner, outer and end grinding with a single machine. With the increase in the speed of numerical control devices, the compounding function of the grinding machine is also advancing. For example, European manufacturers are trying to add thread grinding and spline grinding to an ordinary universal grinding machine, which is to develop the grinding machine.
Composite processing of different forms
As a composite machining that performs various types of machining according to different principles, it also combines grinding and grinding processes for cutting and finishing, heat treatment, bonding, cutting, etc. after processing, and is equipped with a laser function. Products that are processed and assembled at the same time.
The product under development is also a unique multi-tasking machine that combines the turning function, the milling function and the gear processing function. As a composite with the laser, the turning function and the laser quenching function are combined. lathe. New varieties that are still being developed in Europe include a combined machining machine that combines the mechanical milling function with the three-dimensional machining function of the laser.
Bring various benefits
The most important feature of component production with a multi-tasking machine is the integration of the processing of several different machine tools, which allows the process to be easily integrated with a single machine. And bring the following benefits:
1 Improve production efficiency: Multi-tasking machine tools can be loaded with one-off tools to complete the processing required by several different machine tools in the past, so that the entire working hours and processing time of the processing will be reduced. In the past, there were ideas for rationalization through integration processes. For example, if the main shaft is disposed on both the left and right sides, the first and second processes are continuously performed on the two main axes of the opposite surface. Of course, the effects of mass production will be better. For multi-variety and low-volume production, composite processing machines are still beneficial.
2 Reduction procedure: Since it is no longer necessary to convert from one process to another process by one machine, the workpiece is loaded and disassembled at the time of six conversions.
3 Maintain high precision: Since it is not necessary to reload the workpiece, it is not necessary to care about the positioning problem, so that the accuracy is easily maintained.
4 Saving energy and reducing costs: Compared with the need to purchase several different equipment for processing, a composite machine is very suitable. Energy is also saved compared to starting several devices, and operating costs are reduced by reducing the use of electricity.
5 save space: no need to have a few machines with special machine functions, which can save space on the spot - and so on.
Solve various problems
The structure of the composite machining machine is more complicated. Due to the ever-increasing functions and processing contents, the processing, vibration and heat generation are different, which requires the design of the mechanical structure to keep up with the different situations. Moreover, multi-tasking machines need to be able to achieve their performance while achieving a more acceptable level of structure and price. In this way, the application technology of the composite processing can be fully utilized.
In addition, the "problems" surrounding the composite processing machine are roughly divided into the following aspects.
1 Market narrowing: In the past, a series of processing that required two or three equipments was completed, and now only one piece of equipment can be completed. This is 1.5 times the price of the original equipment for the machine tool manufacturer. Still can't avoid the fear that the market will be narrow. Of course, due to the emergence of multi-tasking machine tools, some of the processing fields that were not available in the past can now be deepened, and thus a new market has been obtained.
2 With the complexity of machine tools and the variety of special accessories, maintenance is complicated: as the mechanical structure becomes more complex, the corresponding measures for maintenance and failure are complicated. Maintenance parts are fundamentally different from conventional general-purpose equipment, and it is more troublesome to sell and repair overseas. As a result, there has been a call for a new after-sales service system.
3 Programming complication: It is necessary to avoid the interference of the tool and the workpiece, realize high-precision control, and have to perform complicated control processing, which is bound to make the programming complicated and bulky, which requires high-speed calculation processing and simplification of the operation sequence. Work hard. Also, such a high-performance machine tool is also intelligent, and it must be easy for the operator to use.
4 Strengthening service and maintenance: This is related to 2, and in the future, it will be more demanding to reduce costs and improve efficiency. The continuous operation of equipment for 24 hours will also increase. In this way, 24-hour uninterrupted service and remote diagnosis will become common sense and will require prompt and accurate repair services.
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