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Classify CNC MACHINE AS PER CNC SYSTEM FUNCTION LEVEL

KYLT Precision CNC Machining — Wed, 30 Oct 2019 05:10:03 +0000

To classify CNC machine as per function level of CNC system.

According to the function level of CNC system, CNC system is usually divided into three categories: low, medium and high. This kind of classification is widely used in China. The boundaries of low, medium and high grades are relative, and the standards of division will be different in different periods. In terms of the current development level, various types of CNC systems can be divided into three categories: low, medium and high-end according to some functions and indicators. Among them, the middle and high-grade are generally called full function CNC or standard CNC.

KYLT Aluminum profile CNC Machining

(1) metal cutting CNC machine

Refers to the use of turning, milling, collision, reaming, drilling, grinding, planing and other cutting processes of CNC machine tools. It can be divided into the following two categories.

① common CNC machine tools such as CNC lathe, CNC milling machine, CNC grinding machine, etc.

② the main feature of machining center is the tool library with automatic tool change mechanism and the workpiece passes through once. After clamping, through automatic replacement of various cutting tools, various processes such as milling (turning) key, reaming, drilling, tapping and other processes are continuously processed on the same machine tool for each processing surface of the workpiece, such as (building / milling type) processing center, turning center, drilling center, etc.

Medical device box by CNC machining

(2) metal forming CNC machine

It refers to the numerical control machine tool with extrusion, punching, pressing, drawing and other forming processes, commonly used including numerical control press, numerical control bending machine, numerical control bending machine, numerical control spinning machine, etc.

(3) special processing CNC machine

It mainly includes CNC WEDM, CNC EDM forming machine, CNC flame cutting machine, CNC laser processing machine, etc.

(4) measurement and drawing CNC machine

There are mainly three coordinate measuring instruments, CNC tool setting instruments, CNC plotter, etc

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CNC machine be Classified by servo control mode

KYLT Precision CNC Machining — Mon, 28 Oct 2019 20:10:07 +0000

Servo control mode to classify CNC machine tool.

(1) open loop control CNC machine tool

The feed servo drive of this kind of machine tool is open-loop, that is, there is no detection feedback device. Generally, its driving motor is a stepping motor. The main feature of stepping motor is that every time the control circuit changes the command pulse signal, the motor will rotate a step angle, and the motor itself has self-locking ability.

The drive circuit is controlled by the pulse distributor, which controls the coordinate displacement by changing the number of pulses, the displacement speed by changing the frequency of pulses, and the direction of displacement by changing the distribution sequence of pulses.

Therefore, this control mode is characterized by convenient control, simple structure and low price. The command signal flow from the CNC system is unidirectional, so there is no stability problem of the control system, but because the error of the mechanical transmission is not corrected by feedback, the displacement accuracy is not high.

Aluminum Turning & Milling Parts

(2) closed loop control CNC machine tool

The feed servo drive of this kind of NC machine tool works in the way of closed-loop feedback control. Its drive motor can be DC or AC servo motor, and need to configure position feedback and speed feedback. In the process of machining, the actual displacement of the moving parts is detected at any time and fed back to the comparator in the numerical control system in time. It is compared with the instruction signal obtained by interpolation operation, and its difference is used as the control signal of servo drive, which drives the displacement parts to eliminate the displacement error.

According to the difference between the installation position of the position feedback detection element and the feedback device used, it can be divided into two control modes: full closed loop and half closed loop.

CNC milled workpiece

① full closed loop control

As shown in the figure, its position feedback device adopts linear displacement detection element (at present, grating ruler is generally used), which is installed on the bed saddle of the machine tool, i.e. directly detecting the linear displacement of the machine tool coordinate. Through the feedback, the transmission error in the whole mechanical transmission chain from the motor to the bed saddle of the machine tool can be eliminated, so as to obtain high static positioning accuracy of the machine tool.

Aluminum Precision Machining Part

However, in the whole control ring, the friction characteristics, rigidity and clearance of many mechanical transmission links are nonlinear, and the dynamic response time of the whole mechanical transmission chain is very large compared with the electrical response time. This brings great difficulty to the stability correction of the whole closed-loop system, and the design and adjustment of the system are also quite complex. Therefore, this kind of full closed-loop control mode is mainly used for CNC coordinate building machine and CNC precision grinder with high precision requirements.

② semi closed loop control

As shown in the figure, its position feedback adopts angle detection element (currently mainly encoder, etc.), which is directly installed at the end of servo motor or lead screw. Because most of the mechanical transmission links are not included in the closed-loop system, it is called to obtain more stable control characteristics. The mechanical transmission errors such as lead screw can not be corrected at any time by feedback, but the software fixed value compensation method can be used to properly improve its accuracy. At present, most CNC machine tools adopt semi closed loop control.

(3) hybrid control CNC machine

The characteristics of the above control methods can be selectively centralized to form a hybrid control scheme. As mentioned before, because the open-loop control mode has good stability, low cost and poor accuracy, while the full closed-loop control mode has poor stability, in order to make up for each other and meet the control requirements of some machine tools, the hybrid control mode should be adopted. There are two kinds of open-loop compensation and half closed-loop compensation.

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cnc machining center CUTTING TOOLS KNOWLEDGE

KYLT Precision CNC Machining — Mon, 28 Oct 2019 00:56:52 +0000

In CNC milling or lathing, Different shapes need use different cutting tools. This article stated some knowledge of cutter in CNC machining.

Aluminum Fast Prototypes by CNC milling

Basic classification of cutting tools

According to the end geometry:

Flat end milling cutter
Flat bottom R angle end milling cutter
Ball end milling cutter
Indexable inlaid end milling cutter

CNC machine cutters

Basic geometry of cutting tools

milling tool body

miller end

milling tool front terminal

For the cutting tools used for finishing, the cutting edge must have good profile accuracy.

Several possible profile deviations of cutting tools

Accurate contour;
The grinding process is not accurate enough, which results in irregular broken surface on the edge.
Radius deviation caused by inaccurate grinding process.

CUTTING TOOLS PROFILE DEVIATIONS

If the requirements for machining workpiece accuracy are very high, standard certified tools should be purchased from the tool manufacturer. KYLT CNC milling, CNC turning processes, adopt famous brand cutter to got high precision machined parts.

KYLT Aluminum CNC machining prototypes making service

On the premise of ensuring that the maximum overhang length of the tool shank and tool system does not exceed the specified value, in order to make the spindle operate accurately, the radial run out error of the tool must be detected at the tool shank and cutting edge respectively. If the radial run out error is too large, it will cause serious vibration of the spindle.

cutter radial run inspection

How to select suitable cutter

1) analyze the specific processing conditions, such as spindle and machine performance, tool clamping system, lubrication mode, etc.

2) analyze the material characteristics of the workpiece;

3) analyze the surface quality, machining accuracy requirements, cost, etc.

4) comprehensively consider various factors and make the optimal choice.

Calculation method of high speed cutting parameters

Three important formulas

Calculation method of high speed cutting parameters

Some important terms and processing parameters in high speed cutting

(1) cutting speed VC

Definition of cutting speed: VC = n * p * deff / 1000

VC refers to the appropriate cutting speed value suitable for high-speed machining of a workpiece material in the case of a specific tool. It refers to the linear speed of the tool.

cutting speed VC

How to set the value of cutting speed VC correctly:

Provided by tool supplier;
Refer to the existing experimental data;
Through a large number of cutting experiments to establish their own database.

VC value is an important basis for setting other cutting parameters correctly!

Effect of cutting speed on surface finish

EFFECT OF CUTTING SPEED ON SURFACE FINISH

Color comparison of iron chips produced at different cutting speeds

(2) effective tool diameter deff

Calculation of effective tool diameter and effective tool diameter.

EFFECTIVE TOOL DIAMETER

(3) feed rate of each edge FZ

Definition of feed per blade:

FEED RATE OF EACH EDGE

How to set the feed rate of each edge of the tool correctly:

Provided by cutting tool supplier;
Refer to the experimental data of other people’s research;
Through a large number of cutting experiments.

Whether the feed rate of each cutting edge is set correctly or not has a very important influence on the reasonable distribution of cutting load on the tool.

(4) axial and radial feed rate AP & AE

Calculation of axial feed:

Calculation of axial feed rate calculating example

The actual results will be affected by the spindle, tool and material.

The effect of AE and FZ on the finish

fz & ae cutting relationship

cutting finished surfaces

(5) calculation method of cutting parameters in high speed machining

CALCULATION METHOD OF CUTTING PARAMETERS IN HIGH SPEED MACHINING

(6) setting principle of CNC MACHINING parameters

In the process of high-speed machining, the machining parameters must be optimized and can not be set at will;
The value of cutting speed VC must be set correctly;
The feed rate of each edge FZ must be set correctly.

Reasonable value can not only bring the cutting efficiency of the tool to the limit, make full use of the tool, improve the machining quality and efficiency, but also will not affect the service life of the tool, so as to achieve the purpose of saving cost and achieving real high-speed machining.

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roughing Machining & final machining

KYLT Precision CNC Machining — Sat, 14 Sep 2019 23:46:45 +0000

CNC machining works for Mold, Fixture, Prototype or other metal work pieces. Roughing machining and Final Machining are the necessarily processes.

What is Roughing Machining?

Roughing machining: Cut-out more materials from original blocks, bars by cutting tool.

Machine tool (CNC lathe, CNC milling machine, CNC router etc) adopts maximum load. Normally, the largest cutting tool should be selected, the largest feeding amount and fastest feeding speed be chosen. When use same cutting tool, the feed is inversely proportional to the cutter feeding amount.

Normally, the load of machine tools is not a problem. The principle of cutter selection is mainly based on whether the two-dimensional angle and three-dimensional arc of the product are too small. After choosing a good cutting tool, the length of the tool can be determined. The principle is that the length of the tool is larger than the machining depth. For large machining workpieces, the interference of the chuck should be considered.

CNC router rough machining

What is Final Machining?

Final Machining: The purpose of final machining is to meet the surface finish requirements and appropriate allowance reserved.

The final machining should be chosen large cutter and adopt fast cutting speed. Because the fine machining needs a long time, and a suitable feeding amount and feeding speed should be used.

Final machined Turning Part

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CNC NC Programming Routine

KYLT Precision CNC Machining — Thu, 05 Sep 2019 01:24:55 +0000

Do you know how to deal with these problems in CNC machining?

CNC NC Programming Routine explain your question! More information about CNC machine or router control panel buttons & keys, please read: “what are the mean of CNC machine buttonS & keys?“

cnc machine programming plc

CNC NC Programming Routine, Normal Machining problems & Solution

Overcutting of Machining workpiece:

over cutting Reason:

Ballistic cutter, tool strength is not too long or too small, resulting in tool bouncing cutting tool.
The operator operates improperly.
Cutting allowance is not uniform. (e.g. 0.5 on the side and 0.15 on the bottom of the curved surface)
Improper cutting parameters (such as too big tolerance, too fast SF setting, etc.).

Improve methods:

The principle of using knives/cutters: big or small, short or short.
Add angle clearing procedures, and keep the margin as evenly as possible. (The side and bottom margins remain the same.)
Reasonably adjust the cutting parameters and round the corner with large margin.
Using SF function of machine tool, the operator can adjust the speed slightly to achieve the best effect of machine tool cutting.

Centering problems ( to find the position of the machining workpiece in the coordinate system of the CNC machine center.

Reason analysis of centering problems in NC machining process:

Operator’s manual operation is inaccurate.
There are burrs around the die.
There is magnetism in the middle bar.
The four sides of the die are not vertical.

Improve centering operation:

Manual operation should be carefully checked repeatedly, and the points should be as high as possible at the same point.
Use oil stone or file to deburr the periphery of the die and wipe it clean with rags, and finally confirm it by hand.
Demagnetize the middle bar before dividing the die. (Ceramic can be used to divide the middle bar or other parts.)
Calibration check whether the four sides of the die are vertical. (Verticality error needs to be checked with fitter scheme.)

Cut tool setting problem:

Reason analysis of cutting tool setting :

Operator’s manual operation is inaccurate.
Error in tool clamping.
The blade on the flying knife is wrong (the flying knife itself has some errors).
There are errors between R knife and flat bottom knife and flying knife.

Improve methods of cutter setting:

Manual operation should be checked repeatedly and carefully, and the knife should be checked at the same point as possible.
Clean the tool with air gun or rag when clamping.
A blade can be used when measuring the tool rod and smooth bottom of the blade on the flying knife.
The error between the flat and flying knives of R-knife can be avoided by setting up a tool-setting program separately.

machine collision – Programming:

Reason of machine collision:

Insufficient or no safety height (knife or chuck hitting workpiece when fast feed G00).
Writing errors of tool on program sheet and actual program tool.
Writing errors in tool length (edge length) and actual depth of machining on program sheet.
Writing errors of Z-axis number of depth and actual Z-axis number on program sheet.
Error of coordinate setting in programming.

Improve method:

Accurate measurement of workpiece height also ensures that the safety height is above the workpiece.
The tool on the program sheet should be consistent with the actual program tool (try to use the automatic program sheet or the picture to produce the program sheet).
Measure the actual depth of the workpiece. Write clearly the length of the tool and the length of the edge on the program sheet (the general tool clamp length is 2-3MM higher than the workpiece, and the length of the blade avoids void is 0.5-1.0MM).
Take the actual Z-axis number on the workpiece and write it clearly on the program sheet. (This operation is usually written for manual operation to be checked repeatedly).

cut tool collision – Operator:

Reason:

Deep Z-axis tool alignment error.
Errors in the number of collisions and operations (e.g. the number taken unilaterally has no radius of feed, etc.).
Use wrong knife (e.g. D4 knife and D10 knife).
Program error (e.g. A7.NC goes A9.NC).
The handwheel is rocking in the wrong direction during manual operation.
Manual fast feed in wrong direction (e.g. – X press + X).

Improve:

Deep Z-axis tool alignment must pay attention to the position of tool alignment. (Bottom, top, analysis, etc.).
The number of collisions and operands in points should be checked repeatedly after they are completed.
When clamping the tool, it should be checked repeatedly against the program sheet and program before loading.
Procedures should go one by one in order.
When using manual operation, the operator himself should strengthen the operation proficiency of the machine tool.
When moving rapidly by hand, Z-axis can be raised to the workpiece and moved.

Surface Accuracy:

Reason:

The cutting parameters are unreasonable and the workpiece surface is rough.
The cutting edge is not sharp.
Tool clamping is too long and blade avoidance is too long.
Scrap removal, air blowing, oil flushing is not good.
Programming cutter-walking mode, (you can consider milling as far as possible).
Workpiece has burrs.

Improve:

Cutting parameters, tolerances, allowances and speed feed should be set reasonably.
Tools require operators to inspect and replace them irregularly.
When clamping the tool, the operator is required to clamp it as short as possible and the blade avoidance is not too long.
For flat knife, R knife and round nose knife, the setting of speed feed should be reasonable.
Workpieces have burrs: the root of our machine tools, cutting tools, the way we move the knife has a direct relationship. So we need to understand the performance of machine tools and repair burred edges.

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