Dalian precision machining has high requirements for cutting tools and materials. Cutting tools need to have high hardness, high wear resistance, and good thermal stability. Common tool materials include hard alloys, ceramics, cubic boron nitride (CBN), and diamond. The processing materials are selected according to the performance requirements of the parts, such as aluminum alloy, titanium alloy, stainless steel, hard alloy, etc.

The core equipment of precision machining is CNC machine tools, which control the machining process through computer programs and can achieve high-precision and high-efficiency machining. Common CNC machine tools include CNC lathes, CNC milling machines, CNC grinders, and machining centers. These machine tools have high rigidity, high stability, and high repeatability positioning accuracy, which can meet the machining needs of complex parts.

What are the methods to control precision machining errors in Dalian?

Error prevention

Improve the accuracy of machine tools

When selecting high-precision machine tools, especially for the processing of key components, it is necessary to ensure that the spindle rotation accuracy, guide rail straightness and parallelism, transmission chain accuracy and other indicators of the machine tool meet the processing requirements.

Regularly maintain and check the accuracy of the machine tool, promptly detect and repair problems such as wear and looseness, and adjust and calibrate the accuracy of key components.

Optimize fixture design and manufacturing

Design a reasonable fixture structure to improve the positioning and clamping accuracy of the fixture, ensure that the workpiece can be accurately positioned and fixed during the machining process, and reduce positioning errors and clamping deformation.

Adopting high-precision fixture manufacturing and assembly processes to ensure the manufacturing accuracy and assembly quality of fixtures, regular inspection and calibration of fixtures are carried out, and worn positioning and clamping components are replaced in a timely manner.

Reasonable selection of cutting tools and tool management

Select appropriate tool types, tool materials, and tool geometry parameters based on processing materials, processing techniques, and processing requirements to improve the cutting performance and machining accuracy of the tool.

Establish a tool management system to monitor and manage the service life and wear of tools in real time, replace worn tools in a timely manner, use tool presetters and other equipment to accurately measure and adjust tools, and ensure the installation accuracy of tools.

Control processing parameters

Through process experiments and simulation analysis, optimize cutting parameters such as cutting speed, feed rate, cutting depth, etc., to reduce the impact of cutting force and cutting heat on machining accuracy.

For some complex parts processing, a multi process and multi-step processing technology is adopted to gradually complete the machining of the parts, and the machining accuracy is strictly controlled in each process to avoid the accumulation of errors.

Improve processing environment

Arrange precision machining in a constant temperature, humidity, and clean processing environment to reduce the impact of environmental factors such as temperature, humidity, and dust on machining accuracy.

Perform vibration isolation treatment on processing equipment and processing sites to prevent external vibrations from interfering with the processing process. Use vibration isolation materials such as air springs and rubber pads to reduce the transmission of vibrations.

Improve the skills of operators

Strengthen the training and assessment of operators, improve their technical level and proficiency in operation, so that they can correctly operate machine tools and equipment, and strictly follow the process specifications for processing.

Operators should have good quality awareness and sense of responsibility, and be careful and meticulous in the processing process. They should pay attention to observing the processing status, timely discover and handle problems that arise during the processing.

error compensation

Hardware compensation

Install error compensation devices on machine tool equipment, such as installing ball screw error compensation devices in the feed system of the machine tool. By detecting the pitch error of the ball screw, adjust the feed rate in real time and compensate for the pitch error.

Using online detection equipment such as laser interferometers, grating rulers, etc., real-time detection of the size and shape of the workpiece during the machining process is carried out. Based on the detection results, the machining parameters of the machine tool are adjusted in a timely manner to achieve error compensation.

software compensation

Using computer software to model and analyze machining errors, writing compensation programs based on the error model, and automatically adjusting tool paths or machining parameters through a numerical control system during the machining process to achieve error compensation.

By using artificial intelligence and machine learning algorithms, machining errors are predicted and compensated. Through learning and analyzing a large amount of machining data, an error prediction model is established to predict machining errors in advance and take corresponding compensation measures.

The core of precision machining lies in "precision", which not only requires machining equipment to have high precision and stability, but also requires strict control of factors such as temperature, vibration, and tool wear during the machining process to ensure machining quality. In addition, precision machining also involves complex process design, material selection, tool selection, and optimization of machining parameters.

Utilizing technologies such as artificial intelligence, big data, and the Internet of Things to achieve automation and intelligence in the manufacturing process. The intelligent machining system can monitor the machining status in real time, automatically adjust machining parameters, optimize machining paths, improve machining efficiency and quality, and reduce labor costs and intensity. Automated CNC machine tools can automatically complete the processing of complex parts according to preset programs, reducing the influence of human factors.