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Machine tools knowledge

KYLT Precision CNC Machining — Wed, 03 Aug 2022 02:43:41 +0000

A good mechanical process engineer must be a good processing equipment application engineer, who is proficient in all kinds of knowledge of the machine tools.

Introduce the most common turning, milling, planing, grinding, boring, drilling, wire cutting and other processing equipment in the mechanical processing industry, and understand the type, scope of application, structural characteristics and processing accuracy of these processing equipment.

work piece clamped by fixture

Lathe

1) Type of lathe

The types of lathes include: instrument lathes, single axle automatic lathes, multi axle automatic or semi-automatic lathes, return wheel or turret lathes, crankshaft and camshaft lathes, vertical lathes, floor and horizontal lathes, profiling and Multi Tool lathes, axle spindles and gear cutting lathes, etc. Vertical lathes and horizontal lathes are commonly used in the machinery industry.

2) Applicable scope of lathe processing

A. The horizontal lathe is suitable for turning inner and outer cylindrical surfaces, conical surfaces, formed rotating surfaces and annular grooves, turning sections and various threads, and can be used for drilling, reaming, reaming, tapping, threading, knurling and other processes.

B. Vertical lathes are applicable to the processing of various rack and shell parts, as well as the processing of internal and external cylindrical surfaces, conical surfaces, end faces, grooves, cutting, drilling, expanding, reaming, etc. of various parts. With the help of additional devices, processing procedures such as threading, end faces, profiling, milling and grinding can also be realized.

3) Machining accuracy of lathe

A. The machining accuracy of the general horizontal lathe is as follows:

Roundness: 0.015mm; Cylindricity: 0.02/150mm; Flatness 0.02/ ¢ 150mm; Surface roughness: 1.6ra/ μ m。

B. The machining accuracy of the vertical lathe is as follows:

Roundness: 0.02mm; Cylindricity: 0.01mm; Flatness 0.03mm.

Final machined Turning Part

Milling machine

1) Type of milling machine

The types of milling machines include: instrument milling machine, cantilever and ram milling machine, gantry milling machine, plane milling machine, profiling milling machine, vertical lifting table milling machine, horizontal lifting table milling machine, bed milling machine, tool milling machine, etc. Vertical machining centers and gantry machining centers are commonly used in the machinery industry.

2) Applicable scope of milling machine processing

There are too many kinds and structures of milling machines, and there are great differences in their applicability. Here we only introduce the most commonly used vertical machining centers and gantry machining centers.

A. Vertical machining center: the vertical machining center is actually a vertical CNC milling machine with a tool library. Its main feature is that it uses multi edge rotary tools for cutting, which can process planes, grooves, gear parts, helical surfaces and various curved surfaces. Especially with the application of numerical control technology, the processing range of this type of machine tools has also been greatly improved, in addition to various milling operations, It can also drill, bore, ream and tap the thread of the workpiece.

B. Gantry machining center: compared with vertical machining center, gantry machining center is a composite application of CNC gantry milling machine and tool magazine. In terms of processing range, the gantry machining center has almost all the processing capabilities of ordinary vertical machining centers, and can adapt to the processing of larger tools in terms of the overall dimensions of parts. At the same time, it also has great advantages in processing efficiency and processing accuracy, especially the practical application of the five axis combined gantry machining center, its processing range has also been greatly improved.

CNC milling

3) Machining accuracy of milling machine:

A. Vertical machining center:

Flatness: 0.025/300mm; Coarse excess: 1.6ra/ μ m。

B. Gantry machining center:

Flatness: 0.025/300mm; Coarse excess: 2.5ra/ μ m。

Planer

1) Type of planer

Compared with lathes and milling machines, the types of planers are much less. The typical types are: cantilever planer, gantry planer, shaper, edge and mold planer, etc. In the machinery industry, shapers and planers are the most widely used and widely used.

2) Application scope of planer processing

The planing motion of the planer is mainly the periodic round-trip linear motion relative to the processing workpiece. Its applicable planing part features are mostly the processing of plane, inclined plane and concave convex surface, and can also be planed for various curved surfaces. However, due to the limitations of its own processing characteristics, the speed of processing and planing is not too high, so the processing efficiency is relatively low.

3) Machining accuracy of planer

The accuracy of planing can generally reach the accuracy level of it10-it7, especially for the machining of long guide rail surface of some large machine tools, which can even replace grinding.

Grinding machine

1) Type of grinder

There are many kinds of grinding machines, which can be divided into: instrument grinding machines, cylindrical grinding machines, internal grinding machines, grinding machines, coordinate grinding machines, guide rail grinding machines, tool edge grinding machines, surface and end grinding machines, crankshaft camshaft spline and roll grinding machines, tool grinding machines, superfinishing machines, internal honing machines, external and other honing machines, polishing machines, abrasive belt polishing and grinding machines. There are many types of tool grinding and grinding machines, indexable blade grinding machines, grinding machines, ball bearing ring groove grinding machines, roller bearing ring raceway grinding machines, bearing ring superfinishing machines, blade grinding machines, roller processing machines, steel ball processing machines, valve piston and piston ring grinding machines, automobile and tractor grinding machines, etc. Here we will specifically talk about cylindrical grinder and surface grinder.

2) Applicable scope of grinding machine processing

A. Cylindrical grinding machines and cylindrical grinding machines are mainly used to process cylindrical surfaces, conical surfaces or other external surfaces of rotating bodies and shaft shoulder end faces. Because of their good processing adaptability and processing accuracy, they are widely used in the processing of some high-precision parts in machining.

B. The surface grinder is mainly used to process the surface of parts such as plane, step surface and side.

3) Machining accuracy of grinding machine

A. Machining accuracy of cylindrical grinder:

Roundness and cylindricity: 0.003mm; Surface roughness: 0.32ra/ μ m。

B. Machining accuracy of surface grinder:

Parallelism: 0.01/300mm; Surface roughness: 0.8ra/ μ m。

Boring machine

1) Type of boring machine

Boring machines can be divided into the following types: deep hole boring machines, coordinate boring machines, vertical boring machines, horizontal milling and boring machines, fine boring machines, boring machines for automobile and tractor repair, etc. The most commonly used boring machine is coordinate boring machine.

2) Application scope of boring machine

Coordinate boring machine is a kind of precision machine tool with precision coordinate positioning device, which is mainly used for boring hole systems with high requirements for size, shape and position accuracy. It can be used for drilling, reaming, reaming, end face, grooving, milling surface and other processing, as well as coordinate measurement, precision calibration, marking and other work.

3) Machining accuracy of boring machine

The aperture accuracy processed by coordinate boring machine is generally it6-7, and the surface roughness is 0.4-0.8ra/ μ m。

Drilling machine

1) Type of drilling machine

Drilling machines can be divided into the following types: coordinate boring machines, deep hole drilling machines, radial drilling machines, bench drilling machines, vertical drilling machines, horizontal drilling machines, milling drilling machines, center hole drilling machines, etc. The most common is radial drilling machine.

2) Applicable scope of drilling machine processing

We mainly describe the rocker drill. Drilling machine is to drill various types of holes. In addition to drilling, it can also realize processing procedures such as reaming, reaming, drilling, tapping and so on. Its main disadvantage is that the accuracy of hole system position is not high. Therefore, we usually do not choose drilling machine to realize some parts that require high accuracy of hole system position.

3) Machining accuracy of drilling machine

Because there is basically no machining accuracy, just drilling a hole.

Aluminum CNC Milling & Tapping Part

Wire cutting

1) Type of wire cutting

Wire EDM cutting machines can be divided into high-speed reciprocating wire cut electrical discharge machining (commonly known as “fast wire cutting”) Low speed one-way walk Wire cut electrical discharge machining (commonly known as “slow wire”) and vertical wire electrical discharge machining machine tool with rotation wire.

2) Machining accuracy of WEDM

The wire speed of fast wire EDM is 6 ~ 12 mm / s. the electrode wire moves back and forth at high speed, and the cutting accuracy is poor. Medium wire EDM is a new technology developed in recent years, which realizes the function of frequency conversion and multiple cutting based on fast wire EDM. The wire speed of slow wire EDM is 0.2mm/s, and the electrode wire makes low-speed unidirectional movement, with high cutting accuracy.

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KYLT Precision CNC machining services (milling & turning service), Fast prototyping, Fixture/Jig/Tooling making, Aluminum die casting & plastic injection parts. Email:cnkylt@aliyun.com +008615195010186

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Aluminum rapid prototyping – precision part making by cnc milling machine

KYLT Precision CNC Machining — Wed, 21 Apr 2021 01:11:58 +0000

Aluminum rapid prototyping （also named: aluminum prototyping, fast prototyping, quick prototyping). Rapid prototyping is a quick method to got a finished part from design, then to check and test the desingned part function.

ALUMINUM RAPID PROTOTYPING

Aluminum alloy is a reasonable material and widely used in industry.

With the developing on aluminum alloy materials, high-strength aluminum alloy with its excellent comprehensive performance in the use of commercial aircraft has reached its structural quality of more than 80%, so get the global aviation industry generally attention. Aluminum began to gradually applied to life, military, science and technology.

aluminum prototyping by CNC milling

Aluminum alloy functions:

low in density but high in strength
close to or superior to high quality steel
good plasticity
excellent process ability
excellent welding characteristics and electroplating
good corrosion resistance
high toughness and deformation after manufacturing
defects and easily polished
easy to color film
excellent anodizing finished and other excellent features(painting, powder coating, plating etc)

aluminum die casting part with powder coating

Over ten years experience with aluminum prototype machining, Our CNC engineer experienced in complex structure part machining and skill to manufacture quality aluminium prototype parts. From One prototype to Mass production, We will quote and reply with 24hr.

ALUMINUM RAPID PROTOTYPING:

ALUMINUM FAST PROTOTYPING

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KYLT Precision CNC machining for Medical devices making

KYLT Precision CNC Machining — Mon, 10 Feb 2020 01:04:34 +0000

Medical devices making such as operating forceps, they are by WEDM, EDM, CNC milling, Polishing etc, metal making and manufacturing processes. In fact, the medical devices making processes normally involve: metal making processes and plastic injection processes.

what is medical devices?

Medical devices are those equipment, instrumentation, equipment, calibration and other related similar items which used in the human body directly or indirectly.

operating forceps making

The treatment of the human body is mainly obtained through physical methods, not through pharmacology, immunization, metabolic methods. The state has strict legal regulations on the manufacture and application of medical devices, so it has clear provisions on the design, safety, stability and effectiveness of medical devices. Medical device parts processing accuracy directly affects the safety and reliability of medical devices, the CNC precision machining applications to ensure the precision of processing parts.

medical devices making

What is KYLT medical device making services?

KYLT as the terminal medical devices spare parts producer,provide WEDM,EDM,Precision CNC, Lathing,Tapping machining service as per clients drawings.

Here is forceps part, which making processed by WEDM(Wire Cut Electro Discharge Machining) firstly,then use CNC precision machining to got the drawing requirement.

operating forceps spare part making

Medical devices materials which by CNC machined involve: iron, steel, stainless steel, aluminum,titanium alloy etc.

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Any questions about medical devices spare parts machining and making, please feel free contact with KYLT:

www.marketingthiink.com
www.kyltcn.com
+008615195010186
cnkylt@aliyun.com

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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.

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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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How to improve the machining quality of CNC machine

KYLT Precision CNC Machining — Wed, 23 Oct 2019 04:41:09 +0000

In order to got good machining quality of Machined work-pieces, the precision of CNC lathe, CNC router, CNC milling machine is the key element.

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Measures to improve the machining quality of CNC machine:

Ways to improve machining accuracy

There are many methods and measures to reduce errors in production practice. From the technical point of view of eliminating or reducing errors, these measures can be divided into the following categories.

Aluminum CNC machining prototype

(1) error prevention technology

Error prevention technology refers to taking corresponding measures to reduce or eliminate errors, that is to say, reducing error sources or changing the quantitative conversion relationship between error sources and machining errors.

In order to reduce or eliminate geometric errors, the following measures can be adopted:

The following carriage is used to eliminate the influence of radial force, and the reverse cutting is used to change the compression effect of axial force into tensile effect, and the elastic center is used to eliminate the possible bending deformation.

Solar panel holder by CNC machining and assembly

(2) error compensation technology

Error compensation technology refers to the existing conditions. Based on the analysis and measurement of these errors, an additional error is artificially introduced into the process system to offset the original error of the process system. In order to reduce or eliminate the machining error of parts.

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(3) reduce the influence of cumulative error of CNC system

In the process of fast moving and interpolating operation, the CNC system will produce accumulated error. When it reaches a certain value, it will make the machine tool produce moving and positioning error, which will affect the machining accuracy. The following measures can reduce the cumulative error of CNC system.

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Try to program in absolute mode. The absolute mode is based on a fixed point (workpiece coordinate origin). Each program and the whole processing process are based on this. The incremental programming is based on the previous point, and the continuous execution of multiple programs will inevitably produce accumulated errors.

When the machine tool returns to the reference point, the coordinates will be cleared when inserting the command of returning to the reference point, thus eliminating the accumulated error of the numerical control system operation. It is beneficial to ensure the machining accuracy to insert the instruction back to the reference point properly in a long program. When there is a tool change request, you can return to the reference point to change the tool, thus killing two birds with one stone.

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Machined parts surface quality

KYLT Precision CNC Machining — Wed, 23 Oct 2019 04:39:02 +0000

The machining quality of machined parts includes not only the machining accuracy, but also the surface quality after machining. The working performance of mechanical products, especially its reliability and durability, largely depends on the surface quality of its main parts. With the development of science and technology, the machine is developing towards the direction of high speed and heavy load, high temperature and high pressure. And the requirements for the surface quality of parts are higher and higher.

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Surface quality Concept of Machining parts

Machined parts Surface quality refers to the state of surface layer after machining, which includes surface roughness, waviness and physical and mechanical properties of surface layer.

(1) surface roughness and waviness

Surface roughness refers to the micro geometry error of machined surface. It is usually formed by the moving track of cutting tools in machining, and the ratio of wave distance to wave height is generally less than 50.

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(2) physical and mechanical properties of surface layer

The surface layer is cold hardening. It refers to the phenomenon that the strength and hardness of the surface layer of the workpiece are improved after machining, also known as cold hardening or strengthening; the metallographic structure of the surface layer changes. It refers to the phenomenon that the high temperature produced in cutting (especially grinding) changes the metallographic structure of the surface metal of the workpiece and reduces the surface hardness; the residual stress of the surface layer. It refers to the residual stress on the surface layer of the workpiece caused by the cutting force and cutting heat in the cutting process, which affects the fatigue strength of the parts.

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Factors affecting Machined parts surface roughness

In machining, there are two main reasons for the formation of surface roughness:

1.The cutting residual area geometric factor formed by the relative movement track of the blade and workpiece;

2.The factor physical factor related to the nature of the material to be processed and the cutting mechanism, which refers to the plastic deformation, friction, chip accretion, scale thorn and vibration in the process system.

Aluminum Fast Prototypes by CNC milling

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Main factors affecting machining accuracy

KYLT Precision CNC Machining — Wed, 23 Oct 2019 00:08:34 +0000

For NC turning, CNC machining or prototypes making processes, Machining accuracy is the key factor of machined parts quality.

CNC machined plastic parts and assembly for solar panel holding

In the work-piece machining process, what factors affect the machining parts accuracy?

(1) machining principle error

Machining principle error refers to the error produced by machining with approximate forming movement or approximate shape cutter. In the NC machining of curve or curve. The forming movement of the tool relative to the workpiece is approximate. Furthermore, when the NC machine tool interpolates the straight line or the circular arc, it uses the small straight line segment of the parallel coordinate axis to approach the ideal straight line or the circular arc. There are processing principle errors here.

Aluminum CNC machining prototype

(2) machine error

The error of machine tool is caused by the manufacture, installation and wear of machine tool. Among all kinds of errors of machine tools, the main ones that affect the machining accuracy of workpieces are the rotary error of main pump and the error of guide rail.

CNC lathing parts

(3) fixture error

The main causes of the fixture error are the low manufacturing accuracy, low assembly accuracy and the wear of the working surface during the use of the fixture. The fixture error will directly affect the position accuracy and dimension accuracy of the workpiece surface, especially the position accuracy of the machined surface.

(4) CUTTING tool error

The manufacturing error and wear in use are the main causes of tool error. The influence of cutter error on machining accuracy varies with the type and material of cutter. For example, the dimensional accuracy of fixed size cutter (such as drill, reamer, etc.) will directly affect the dimensional accuracy of workpiece. For example, the shape accuracy of forming tools (such as forming turning tools, forming milling tools, etc.) will directly affect the shape accuracy of the workpiece.

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Machining precision accuracy of NC & CNC machining parts

KYLT Precision CNC Machining — Tue, 22 Oct 2019 20:20:04 +0000

The machining parts quality includes Machining precision accuracy and Surface quality. Especially for NC lathing parts and CNC machining parts, they are require tight tolerance and good surface.

Precision Accuracy CNC lathing parts

What is machining precision accuracy?

Machining accuracy refers to the degree of conformity between the actual value and the ideal value of the geometric parameters (size, geometry and mutual position) of the parts after machining. The deviation between the actual value and the ideal value is the machining error. The machining error reflects the machining accuracy.

The machining accuracy of parts includes three aspects:

Dimensional accuracy
Geometric accuracy
Mutual position accuracy

There is a connection between these three factors.

Precision Accuracy CNC WEMD, Milling & Assembly part

In machining, the formation of the size, geometry and relative position between the surfaces of the parts mainly depends on the mutual position relationship between the workpiece and the tool in the process of cutting movement. The workpiece and cutter are installed on the fixture and machine tool, and are constrained by the fixture and machine tool.

Precision Accuracy CNC machining prototype

In machining, machine tool, fixture, cutter and workpiece constitute a complete system, which is called process system. The problem of machining accuracy of parts is essentially the accuracy of the whole process system.

Therefore, the designer should reasonably specify the machining parts precision accuracy according to their usage. According to the design requirements and production conditions, the technologists should adopt appropriate process methods to improve the productivity and reduce the cost as much as possible on the premise of ensuring the processing accuracy.

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