In the precision machining process in Dalian, online measurement technology can be used to monitor the machining accuracy in real time. For example, equipping a laser measuring instrument or contact probe on a CNC machining center can measure the size and shape of the workpiece during the machining process, and feed back the measurement data to the control system. The control system adjusts machining parameters in a timely manner based on feedback data, such as tool feed rate, cutting depth, etc., to ensure that machining accuracy meets requirements.

Precision machining requires operators to have exquisite skills and experience, proficient in various machining processes and operating methods of mechanical equipment. At the same time, it is also necessary to have a good work attitude and a meticulous work spirit to ensure that every detail is perfect. During the processing, it is necessary to strictly follow safety operating procedures to ensure the safety of operators and equipment.

What are the quality control methods for precision machining in Dalian?

Method for controlling machining accuracy

Error prevention strategy

Optimizing the machining process system: In precision machining, the machining process system includes machine tools, cutting tools, fixtures, and workpieces. To prevent errors, it is necessary to ensure the accuracy and stability of the machine tool. For example, for high-precision lathes, it is necessary to regularly check and adjust the geometric accuracy of the machine tool, including the rotation accuracy of the spindle and the straightness of the guide rail. Choose appropriate tool materials and geometric parameters, such as using hard alloy or superhard material tools when cutting high hardness materials, and optimize the parameters of the tool's rake angle, rake angle, etc. to reduce errors caused by tool wear. The design of fixtures should ensure the correct positioning and clamping of workpieces to prevent displacement during the machining process.

Control processing environmental factors: Environmental factors have a significant impact on precision machining accuracy. Temperature is one of the important factors, and precision machining is usually carried out in a constant temperature workshop. For example, for optical lens processing that requires high precision, the workshop temperature should be controlled within ± 0.5 ℃, and the humidity should also be maintained within a certain range to prevent dimensional errors caused by material expansion or contraction. In addition, to reduce the interference of vibration on machining, the machine tool should be installed on a vibration isolation foundation to avoid the transmission of vibration from nearby equipment to the machine tool.

Error compensation technology

Software compensation method: Compensating for machining errors through software algorithms is a commonly used method. In CNC machining systems, error compensation software modules are used to correct the tool's motion trajectory based on pre measured or modeled error data. For example, for the thermal deformation error of machine tools, temperature sensors are installed in key parts of the machine tool to collect real-time temperature data. Based on the relationship model between thermal deformation and temperature, the compensation amount for each coordinate axis direction is calculated, and then the tool path is compensated in real-time in the CNC program, effectively reducing the machining error caused by thermal deformation.

Hardware compensation methods: In addition to software compensation, hardware compensation methods can also be used. For example, in some high-precision grinding machines, compensation devices are installed between the grinding wheel frame and the worktable to compensate for the wear of the grinding wheel and the shape error of the workpiece. When the wear of the grinding wheel causes the machining size to increase, the compensation device can automatically adjust the relative position between the grinding wheel and the workpiece to ensure machining accuracy. For the clearance error of mechanical transmission systems, hardware measures such as double nut clearance and gear clearance can be used for compensation.

Real time monitoring and feedback control

Application of online measurement system: During the machining process, the online measurement system is used to monitor the size and shape accuracy of the workpiece in real time. For example, installing a laser measuring instrument or contact probe on a precision CNC milling machine can measure the dimensions of the workpiece at any time during the machining process and feedback the measurement data to the CNC system. The CNC system determines whether the machining accuracy meets the requirements based on feedback information. If it exceeds the tolerance range, the machining parameters such as tool feed rate and cutting depth are adjusted in a timely manner to achieve real-time control of machining accuracy.

Application of adaptive control technology: Adaptive control technology can automatically adjust control strategies according to changes in the machining process. For example, in cutting, when the hardness of the workpiece material is uneven, the adaptive control system can sense changes in cutting force, automatically adjust cutting speed and feed rate, and ensure the stability of machining accuracy. Meanwhile, adaptive control can also monitor the wear of cutting tools. When the tool wear reaches a certain level, it automatically adjusts the machining parameters or prompts for tool replacement to ensure machining quality.

Surface quality control methods

Optimization of cutting parameters

Cutting speed adjustment: Cutting speed has a significant impact on surface quality. Appropriately increasing the cutting speed can make the cutting process smoother, reduce the formation of chip deposits, and thus improve surface roughness. For example, when turning aluminum alloy parts, increasing the cutting speed from 100m/min to around 300m/min can reduce the surface roughness Ra value from 1.6 μ m to around 0.8 μ m. However, excessive cutting speed may lead to increased tool wear, so it is necessary to consider the properties of both the tool material and the workpiece material comprehensively to choose the appropriate cutting speed.

Feed rate and cutting depth control: Reducing feed rate and cutting depth can help achieve better surface quality. Generally speaking, the smaller the feed rate, the lower the surface roughness. In precision cutting, the feed rate can be controlled between 0.05-0.1mm/r. The cutting depth should not be too large. In the precision machining stage, the cutting depth is usually controlled within 0.1-0.3mm to reduce the impact of cutting force on surface quality.

Precision machining is a high-precision manufacturing process commonly used to produce various precision components and equipment. This processing method requires operators to have a high level of skills and experience, while using precision mechanical equipment and tools to achieve precise processing. Precision machining can be applied to various industries, such as automotive manufacturing, aerospace, electronic equipment manufacturing, and more.

In the future, precision machining will develop towards intelligence, and building an intelligent machining system is the key. The intelligent processing system integrates technologies such as artificial intelligence, big data, and the Internet of Things. By installing sensors on processing equipment, real-time data is collected during the machining process, such as tool wear, equipment vibration, machining accuracy, etc. These data are transmitted to cloud servers through the Internet of Things, and intelligent decision-making and optimization of the processing process are carried out using big data analysis and artificial intelligence algorithms. For example, automatically adjusting cutting parameters based on tool wear, or predicting equipment failures and conducting maintenance in advance.