Five-axis linkage technology in CNC custom machining: Innovation and advantages

Five-axis linkage technology plays a vital role in CNC custom machining. Five-axis CNC machine tool is a kind of machine tool with high technology content and high precision, which is specially used for machining complex curved surface.

From the structural composition, the five-axis linkage CNC machine tool is usually composed of control media, numerical control device, servo system, machine body, detection device and other parts. Compared with conventional CNC machine tools, in addition to X, Y, Z three linear motion axis, but also set two rotation axis, to complete the feed movement. Most of the five-axis CNC machine tools are "3+2" structure, that is, X, Y, Z three linear motion axes plus A, B, C three rotation axes rotating around X, Y, Z axis respectively. Classified from the general direction, there are three forms of spindles + dual-axis swinging milling head linkage (X, Y, Z, A, B), three straight spindles + dual-axis rotary table linkage (X, Y, Z, A, C), three straight spindles + single-axis swinging milling head + single-axis rotary table linkage (X, Y, Z, B, C).

In terms of working principle, the working process of CNC machine tools is controlled by digital instructions. Before processing, it is necessary to use the specified instruction code according to the part drawing to prepare the numerical control machining program and input it into the numerical control device. The numerical control device generates the corresponding control signal after decoding and operation, including position signal, motion control signal and logic control signal. After the signal transformation and power amplification by the servo system, the position signal and motion control command drive the servo motor to move precisely and drive the moving parts of the machine tool to process automatically according to the program. The logic control instructions output by the built-in programmable controller controlled by the numerical control device, after power amplification, directly drive the executive components according to the pre-specified logical sequence, control the spindle start and stop, speed change, reversing, workpiece tightening or loosening and other auxiliary actions to achieve the automatic operation of numerical control machine tools. In addition, the detection device detects the actual position and speed value of the coordinate axis in real time, and feeds back to the numerical control device or servo system after the signal conversion, compares with the command value, and compensates for the error adjustment, so that the moving parts run to the correct position. More special is that in the processing of the five-axis CNC machine tool, the five degrees of freedom that control the movement of the workpiece and the tool can also move at the same time, so as to process any surface.

One of the outstanding advantages of five-axis linkage technology is the ability to process complex shapes in a single setting. In traditional machining methods, complex shaped workpieces often need to be clamped and adjusted multiple times, which not only consumes a lot of time, but also increases costs, and is prone to operator errors. The five-axis linkage technology can complete the processing of complex shapes at one time through the coordinated movement of five axes. For example, in the aerospace industry, the finishing of complex cavity workpieces can be processed using the tool side edge to obtain a smoother machining surface, avoiding the errors that may be caused by multiple clamping, greatly saving time and cost, and also reducing the operator's mistakes that may occur during multiple clamping.

Five-axis machining has significant advantages in tool use. Because the five-axis linkage technology can lower the tool head towards the working direction and the tool towards the surface, shorter tools can be used. Shorter tools enable higher cutting speeds because the cutting point line speed of the tool is higher at the same spindle speed. At the same time, the shorter tool can also reduce the vibration of the tool and improve the stability and accuracy of the processing. According to statistics, the use of five-axis machining technology can reduce the vibration of the tool by more than 30%, thereby extending the service life of the tool and reducing the wear of the tool.

Five-axis machining provides the ability to process extremely complex parts from the solid. For some parts with complex shapes and high precision requirements, such as automobile engine cylinder block, key parts of aircraft, etc., traditional processing methods are often difficult to meet the requirements. The five-axis linkage technology can complete multi-angle and multi-plane processing on a machine tool, whether it is shaped processing, hollow processing or drilling, oblique hole, oblique cutting and other processes, can be easily realized. For example, in mold manufacturing, five-axis machining can process particularly complex surfaces on three-dimensional blanks without the use of specially cast blanks, saving a lot of time and cost. For small batch processing, this method is faster and more economical, and can be completed in only 1 to 2 weeks, while traditional casting and processing may take 2 months or more.

In terms of drilling, five-axis machine tools have obvious advantages. Drilling a series of holes with different compound angles is time-consuming, and using a three-axis machine to drill oblique holes requires a different tooling for each hole. With five-axis machining, the head can be automatically oriented along the correct axis of each hole, thus completing the drilling operation faster and saving a lot of drilling time. For example, when processing complex automobile parts or aircraft structural parts, the five-axis machine tool can quickly and accurately complete the drilling work of a large number of inclined holes, which greatly improves the production efficiency.

Most manufacturers that specialize in manufacturing controls for five-axis machines can also provide a feature that allows basic machining operations on diagonal surfaces to be programmed, even for manual programmers. This makes the five-axis machining more convenient and fast in programming operation, reducing the difficulty and complexity of programming. For some small machining enterprises or individual studios, manual programming is still a common programming method, and this function of the five-axis machine can make it easier for them to process complex parts, improving production efficiency and processing quality.

In the aerospace industry, five-axis linkage technology plays a crucial role. The design of key parts in the aerospace field usually includes a large number of theories such as fluid mechanics, aerodynamics and material mechanics, and its surface shape is complex, requiring high machining accuracy. Five-axis machining technology enables efficient and precise machining of these complex shaped components, such as turbine blades. The shape of turbine blade is complicated, and the traditional machining method is difficult to meet the accuracy requirements. However, the five-axis linkage machining can complete the machining of multiple faces in a single clamping, reducing the error brought by multiple loading and improving the machining accuracy. At the same time, the five-axis linkage processing technology can also reduce production costs. For example, the use of five-axis CNC machine tools to process aircraft landing gear, wings, wing ribs, frame and beam structural parts can improve production efficiency, reduce processing time and labor costs, and increase production benefits. According to statistics, the use of five-axis linkage processing technology can increase the production efficiency of aerospace parts by more than 30%.

In the automobile manufacturing industry, the five-axis linkage technology has a wide range of applications. The five-axis machining machine can effectively manufacture complex and fine automotive parts, such as engine block, cylinder head, crankshaft, connecting rod, etc. Through precise cutting and complex surface machining, the precision and surface quality of the parts are guaranteed. At the same time, the five-axis machining center can also realize multi-sided simultaneous processing, which greatly improves the production efficiency. In the field of automobile repair, five-axis linkage technology can also play an important role. For example, a damaged car body frame can be accurately repaired using a five-axis linkage machining center to ensure the strength and safety of the body. In addition, five-axis machining technology can also reduce the cost of automobile manufacturing. Lower production costs by improving processing accuracy and efficiency, reducing scrap rates and rework times.

In the manufacturing of die parts, the five-axis linkage technology can improve the efficiency and accuracy of the process. The characteristics of the five-axis machining center to change the direction of the tool shaft can not only improve the machining accuracy and surface quality of the mold, but also enhance the application of the universal tool, thereby reducing the replacement of the tool. For example, the use of five-axis machining center to process die parts can complete the processing of multiple angles in a single clamping, avoiding the error brought by multiple loading. At the same time, the five-axis machining center can also use a shorter tool, improve the rigidity of the tool, and quickly complete the processing of the entire part, without the need for a second loading card, and the surface quality of the part is also good. In addition, the five-axis machining center can also reduce the adjustment time. In the processing of complex mold parts, the traditional processing method needs to frequently adjust the position of the tool and the workpiece, and the five-axis linkage machining can automatically adjust the processing Angle and position through the coordinated movement of the five coordinate axes, reducing the adjustment time and improving the production efficiency.

In the field of medical equipment manufacturing, five-axis linkage technology has a wide range of applications in the production of complex and fine medical components. For example, the manufacturing of surgical instruments, implants, artificial joints, artificial hearts and other high-precision medical equipment requires five-axis linkage processing technology. Five-axis machining can accurately process the shape and size of these complex components to meet the custom needs of medical equipment. At the same time, the five-axis linkage processing technology can also ensure the quality and safety of medical equipment. For example, in the processing of artificial joints, five-axis linkage machining can ensure the surface accuracy and dimensional accuracy of the joint, and improve the suitability and service life of the joint. In addition, five-axis machining technology can also improve the production efficiency of medical equipment. Through a single clamping to complete the processing of multiple surfaces, reduce the processing time and labor costs, improve the production efficiency.

In the energy industry, the five-axis linkage technology also has important applications. For example, in the production of wind turbine blades, oil drilling equipment components, solar equipment precision components, etc., five-axis linkage processing technology can process complex shapes and high-precision dimensions. For wind turbine blades, five-axis machining can ensure the surface accuracy and aerodynamic performance of wind blades, and improve the power generation efficiency of wind turbines. In the manufacturing of oil drilling equipment components, five-axis linkage machining can process high-strength and high-precision parts to ensure the reliability and safety of drilling equipment. In the manufacturing of precision components of solar equipment, five-axis linkage machining can process high-precision reflectors and concentrators and other components to improve the conversion efficiency of solar equipment. In addition, the five-axis machining technology can also reduce the manufacturing cost of energy equipment. Lower production costs by improving processing accuracy and efficiency, reducing scrap rates and rework times.

In the context of intelligent manufacturing, the development trend of five-axis linkage technology in CNC custom machining has shown diversified characteristics. With the continuous progress of science and technology and the change of market demand, the five-axis linkage technology is developing in the direction of high precision, high efficiency, intelligence and compound.

With the increasingly high requirements for product accuracy in the manufacturing industry, the five-axis linkage technology continues to improve the processing accuracy and processing stability by using high-precision servo systems, advanced algorithms and precision tools. At the same time, the error compensation technology and adaptive control technology in the machining process are also widely used to improve the machining precision and reduce the error. For example, at present, the processing accuracy of some advanced five-axis CNC machine tools has reached the micron level, and it is expected to be further improved to the nanometer level in the future.

With the intensification of market competition, manufacturing enterprises need to continuously improve production efficiency and shorten the processing cycle. Five-axis linkage technology by using high-speed cutting technology, multi-axis linkage technology, automatic loading and unloading technology and other means, greatly improve the processing efficiency and production automation. At the same time, the process parameters and tool paths are constantly optimized to reduce processing time and improve processing efficiency. According to statistics, the use of five-axis linkage technology can increase the processing efficiency by more than 30%.

With the continuous development of artificial intelligence technology, the five-axis linkage technology will gradually realize intelligence. By integrating artificial intelligence technology, big data analysis technology, Internet of Things technology and other means, adaptive processing, intelligent diagnosis, remote monitoring and other functions can be achieved to further improve processing efficiency and processing quality. At the same time, intelligent technology can also help enterprises achieve personalized customization and flexible production to meet the diversified needs of the market. For example, some intelligent five-axis CNC machine tools can automatically adjust processing parameters according to the material, shape and processing requirements of the workpiece to achieve the optimal processing effect.

With the continuous development of the manufacturing industry and the diversification of products, more and more parts need to be multi-axis linkage processing and composite processing. Five-axis linkage technology through the use of composite technology and multi-axis linkage technology, can achieve a single clamping to complete the processing of multiple surfaces, reduce the number of parts clamping and adjustment time, improve processing efficiency and processing accuracy. At the same time, the composite technology can also help enterprises to achieve a multi-purpose machine, reduce equipment investment costs and production costs. For example, some five-axis linkage machining centers can integrate milling, drilling, tapping and other processing functions to achieve composite processing.

Although the five-axis linkage technology faces some challenges in the development process, such as high technical difficulty, high cost, talent shortage and other problems, with the continuous progress of science and technology and the continuous growth of market demand, the five-axis linkage technology has broad prospects in CNC custom processing. In the future, the five-axis linkage technology will continue to innovate and develop, providing strong support for the transformation and upgrading of the manufacturing industry.Get an instant quote