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Precision machinery parts processing plays a crucial role in various industries, including aerospace, automotive, medical, and manufacturing.Precision machinery parts have specific requirements to ensure optimal performance.One crucial aspect is the material used for processing. If the hardness of the material being processed surpasses that of the lathe tool, it can potentially cause irreparable damage.Therefore, it is essential to select materials that are compatible with precision machining.
1. Material Strength and Durability
One of the key requirements of precision machinery parts processing is material strength and durability.Machinery parts often undergo significant stress and pressure during operation, and the selected materials must be able to withstand these forces without deforming or breaking.For example, aerospace components require materials with high strength-to-weight ratios, such as titanium alloys, to ensure structural integrity and reliability.
2. Dimensional Stability
Precision machinery parts must maintain their dimensional stability even under extreme operating conditions.The materials used in their processing should possess low thermal expansion coefficients, allowing the parts to retain their shape and size without warping or distorting due to temperature fluctuations.Steels with low thermal expansion coefficients, such as tool steel or stainless steel, are commonly preferred for precision machinery parts subjected to varying thermal conditions.
3.Wear and Corrosion Resistance
Precision machinery parts often interact with other components or environments that can cause wear and corrosion.The materials chosen for their processing should exhibit excellent wear resistance to withstand constant friction and minimize surface damage.Additionally, corrosion resistance is crucial to ensure the longevity of the parts, especially in industries where exposure to moisture, chemicals, or harsh environments is common.Materials such as hardened steel, stainless steel, or certain grades of aluminum alloys are frequently utilized to enhance wear and corrosion resistance.
4.Machinability
Efficient and precise machining is a critical factor in the manufacturing of precision machinery parts.The material selected for processing should possess good machinability, allowing it to be easily cut, drilled, or shaped into the desired form with minimal tool wear.Materials like aluminum alloys with excellent machinability properties are often preferred for their versatility and ease of shaping into complex geometries.
5.Thermal Conductivity
Thermal management is significant in precision machinery parts processing, as excessive heat can adversely affect performance and increase the risk of failure.Materials with high thermal conductivity, such as copper alloys or certain grades of aluminum, help dissipate heat efficiently, preventing localized temperature rise and ensuring optimal operating conditions.
6.Cost-Effectiveness
While meeting the specific requirements is crucial, cost-effectiveness is also an important consideration in precision machinery parts processing.The selected materials should strike a balance between performance and cost, ensuring that the final product remains economically viable without compromising quality.Conducting a cost-benefit analysis and considering factors like material availability, processing complexity, and overall project budget can aid in making informed decisions regarding material selection.
Precision parts processed with stainless steel have the advantages of corrosion resistance, long service life and good mechanical and dimensional stability, and austenitic stainless steel precision parts have been widely used in medical, instrumentation and other precision machinery fields.
The reasons why stainless steel material affects the machining accuracy of parts
The exceptional strength of stainless steel, coupled with its impressive plasticity and noticeable work hardening phenomenon, result in a significant disparity in cutting force when compared to carbon steel. In fact, the cutting force required for stainless steel surpasses that of carbon steel by more than 25%.
At the same time, the thermal conductivity of stainless steel is only one-third of that of carbon steel, and the cutting process temperature is high, which makes the milling process deteriorate.
The growing machining hardening trend observed in stainless steel materials demands our serious attention. During milling, the intermittent cutting process leads to excessive impact and vibration, resulting in substantial wear and collapse of the milling cutter. Furthermore, the use of small-diameter end milling cutters poses a higher risk of breakage. Significantly, the decrease in tool durability during the milling process adversely affects the surface roughness and dimensional accuracy of precision parts machined from stainless steel materials, rendering them unable to meet the required standards.
Stainless steel precision parts processing precision solutions
In the past, traditional machine tools had limited success in machining stainless steel parts, particularly when it came to small precision components. This posed a major challenge for manufacturers. However, the emergence of CNC machining technology has revolutionized the machining process. With the aid of advanced ceramic and alloy coating tools, CNC machining has successfully taken on the complex task of processing numerous stainless steel precision parts. This breakthrough has not only improved the machining accuracy of stainless steel components but has also significantly enhanced the efficiency of the process. As a result, manufacturers can now rely on CNC machining to achieve precise and efficient production of stainless steel precision parts.
As an industry-leading manufacturer in precision machinery parts processing, HONSCN understands the significance of material requirements in delivering exceptional products. We prioritize using high-quality materials that meet all specific requirements, guaranteeing superior performance, durability, and reliability. Our team of experienced professionals meticulously evaluates each project's unique needs, selecting the most suitable materials to ensure customer satisfaction and industry-leading solutions.
In conclusion, precision machinery parts processing demands careful consideration of the materials used. From strength and durability to wear resistance and machinability, each requirement plays a vital role in achieving high-quality products. By understanding and meeting these specific material requirements, manufacturers can produce precision machinery parts that excel in performance, reliability, and longevity. Trust HONSCN for all your precision machinery parts processing needs, as we strive to deliver excellence through meticulous material selection and exceptional manufacturing expertise.
Project introduction
Customer products
This product is a mechanical part, and the processing structure is complex, so the size and relative position requirements are high. Therefore, the accessory needs to scan the data of the first industrial part in 3D, detect the quality error between the data and the design document, and analyze the mapping cost of mechanical parts to ensure the smooth progress of production.
Customer difficulties
After the customer's castings are processed, how to detect them has become a difficult problem. The customer has no way to detect the complex structure, many internal dimensions, important processing positions and relative positions.
Nanjing Ningrui handheld 3D laser scanner
The customer recognizes that the measuring equipment
The customer learned about our hand-held 3D laser scanner of Nanjing Ningrui metrology through the introduction of a friend, and checked the relevant knowledge on the Internet. He thought it was too suitable for the mapping of mechanical parts they wanted, so he found us.
Introduction to 3D laser scanner
When the portable 3D scanner T-scan works, the six beam laser is used to obtain the three-dimensional point cloud on the object surface. The operator can hold the equipment in his hand and adjust the distance and angle between the instrument and the measured object in real time. The operation is flexible, convenient and easy to learn. When scanning large volume objects, it can cooperate with the global photogrammetry system to eliminate the cumulative error and scan the size, shape and working environment of the scanned objects efficiently and accurately.
Operation of handheld 3D laser scanner and photogrammetry on products
Solution
The hand-held three-dimensional scanner is a mechanical mapping equipment. Firstly, the positioning mark points should be quickly pasted on the scanned products, and then the three-dimensional data of workpiece surface shape can be obtained quickly and accurately by using the mark points pasted on the workpiece surface through non-contact three-dimensional laser scanning; After the scanner obtains the high-precision data, the obtained data is compared with the existing digital analog, so as to obtain the product deviation and carry out cost analysis.
Scanning process
It takes 7 minutes to paste the marked points;
Data post-processing and comparison for 45 minutes.
Process display
3. Data comparison
summary
The grooved parts of the rotor body in the machine conform to the fit of the rotor gear and change the old comparison method. The use of 3D laser scanner is not only convenient and fast, but also can more accurately grasp the accuracy of each position, which brings better service to customers.
Reverse / comparative product presentation LW
As a machine tool mainly used to process box and shell parts, the machining center is worth hundreds of thousands to millions. It is generally the key equipment in the key processes of the enterprise. Once the machine is shut down, the loss is often great. Therefore, in order to give full play to the benefits of the machine tool, we must pay attention to the maintenance and repair work. Because most of the daily electrical faults of CNC machine tools are electrical faults, electrical maintenance and repair are more important.1) CNC system control part2) Servo motor and spindle motor
Focus on noise and temperature rise. If the noise or temperature rise is too large, find out whether it is a mechanical problem such as bearing or the parameter setting of its matching amplifier, and take corresponding measures to solve it. For example, if there is abnormal sound during the movement of the servo shaft, and there is no obvious parameter change after verification, it is suspected that the mechanical noise may be caused by the lead screw, coupling and non concentricity with the servo motor. Disconnect the motor from the coupling and operate the motor separately. If the motor still has noise, adjust the speed loop gain and position loop gain appropriately, Make the motor silent. If there is no noise, judge that it is the concentricity between the lead screw and the coupling, re correct the concentricity, and then connect with the motor. The problem can be eliminated.
3) Measurement feedback elementIncluding encoder, grating ruler, etc., check whether the connection of detection elements is loose and whether they are polluted by oil or dust.4) Electrical control part
Check whether the three-phase power supply voltage is normal; Check whether the electrical components are well connected; Check whether various switches are effective with the aid of CRT display diagnosis screen; Check whether all relays and contactors work normally and whether the contacts are in good condition; Whether the thermal relay, arc suppressor and other protective elements are effective; Check whether the temperature of components inside the electrical cabinet is too high. For poor contact of contactor contact, the contactor can be disassembled, the high-temperature oxide on the contact surface can be scraped off with a small file, then the sundries can be wiped out with absorbent cotton and alcohol, reassembled, and then the contact can be conducted with a multimeter.
5) Improve utilization
If the machining center is idle for a long time, when it needs to be used, first of all, each moving link of the machine tool will affect its static and dynamic transmission performance due to grease solidification, dust and even rust, reduce the accuracy of the machine tool, and the blockage of the oil circuit system is a big trouble; From the electrical point of view, the electrical control system hardware is composed of tens of thousands of electronic components, and their performance and life are very discrete. If it is not used for a long time, when power is suddenly transmitted, the components will be damaged in high current and strong voltage. Therefore, in a period of time without machining task, it is best to run the machine tool at a low speed, and at least power on the NC system frequently, or even every day.
I have encountered this situation: a horizontal machining center, using FANUC system. After running the warm-up program, it processed and found that the qualified parts were processed in the morning, and the processed parts were unqualified by noon. After inspection by the on-site processing personnel, the positioning and fixture on the machine tool are not deformed or loose. However, when the spindle box is not processed and stationary, it will deviate downward by 0.1mm along the direction of the gravity axis. The technician judges that the temperature compensation fails or the temperature sensor has poor contact. However, the phenomenon still occurs after replacing the temperature sensor and temperature module and re entering CNC parameters and temperature compensation parameters. After expert consultation, it was finally found that it was not the sensor problem, but that there was a 2-meter-long and 1-meter-wide skylight facing the main shaft and column on the machine tool. At noon, the sun directly shines on the main shaft and column, resulting in thermal deformation. After the skylight is covered, the spindle box returns to normal. This is a typical maintenance error caused by improper maintenance. Therefore, proper daily maintenance provides convenience for overall maintenance in the future.
1. Fault phenomenonWhen changing the knife, the manipulator is stuck and cannot change the knife. The position of the manipulator for changing the knife is offset, and the knife is changed.2 fault analysis and treatment
2.1 tool change principleThe machining center is a rotary tool magazine, and the tool change mechanism is cam type. The tool change process is as follows:(1) Write m06t01 to start the tool change and tool selection cycle.
(2) The spindle will stop at the oriented spindle stop point, the coolant stops, and the z-axis moves to the tool change position (second reference point).(3) Select the tool. After NC compiles it to PLC according to the t command, start selecting the tool. The tool magazine motor rotates and rotates the target tool number to the tool change point of the tool magazine. Note that the t command is the tool sleeve position of the tool magazine at this time.(4) The tool change motor drives the cam mechanism to rotate 90 from the parking position to grasp the tool in the effective tool sleeve and the tool in the spindle. At the same time, detect the change of the proximity switch state of the cam mechanism, the PMC output sends out the tool loosening command, the tool magazine tool sleeve tool loosening and the spindle tool loosening solenoid valve are powered on, the cam continues to rotate, drive the manipulator down, push down the tool handle and prepare for exchange. As shown in Figure 1.
(5) The manipulator rotates 180 to exchange the tool, the cam continues to move upward, install the tool into the spindle, and install the tool on the original spindle into the tool sleeve at the tool change position of the tool magazine. At the same time, the detection switch sends a tool tightening command to PMC, the solenoid valve loses power, the shaft tool handle is clamped, the butterfly spring retracts, and the spindle tool is clamped.(6) Change to the manipulator, continue to rotate 90 , and stop completing a set of tool change actions.2.2 fault analysis
Change the tool to the fourth step of 2.1. The tool change manipulator is stuck, and the spindle has been loosened for blowing, but the tool cannot be pulled out. Cut off the power and manually turn the tool change motor. After completing a tool change action, manually load and unload the tool, the action is normal, and the problems of spindle tightening tool are preliminarily eliminated. When the tool change process is performed again, the manipulator gets stuck and the manipulator claw at the tool magazine falls off. After the tool change is found, the manipulator installs the tool on the spindle and the position is offset, as shown in Figure 2.
After the tool is removed, it is found that the action is normal. The reason for this situation may be the offset between the manipulator and the spindle, or the deviation of the accuracy of the manipulator axis relative to the spindle axis, and the inaccurate positioning of the spindle will also lead to the offset of the tool change position. Implement the tool change action step by step, check the accurate positioning of the spindle, and eliminate the fault caused by inaccurate positioning. According to the table, the mechanicalThe axial position and rotation center distance of hand, knife sleeve and spindle are consistent, so the fault of mechanical jamming of mechanical mobile phone is also eliminated.
Recently, this machine tool mainly processes stainless steel and other material workpieces, with large cutting volume and heavy load. It runs under re cutting for a long time. It is found that the manipulator is not loose and the telescopic action of the manipulator claw is flexible. However, it is found that the adjustment block on the manipulator is worn. It is disassembled and observed that the adjustment block is mainly used to clamp the tool handle. After re repair and processing, try again, The offset disappears at the spindle position. The main cause of this fault is the large impact of the manipulator and frequent tool change, resulting in the loosening and wear of the clamping claw, as shown in Figure 3.
Brand of moisture meter: Boshi Model: bos-180a series Test item: automotive plastic sheet
The water content of plastics is a key reason affecting the production process, commodity appearance and commodity characteristics of resin materials such as polyethylene (PE) and polypropylene (PP). In the injection molding process, if the plastic raw materials with excessive water content are used for production and manufacturing, it will cause some production and processing problems and affect the product quality, such as cracking of the surface layer, reflection, wear resistance, reduction of material mechanical properties such as service performance and tensile strength, etc. Therefore, the control of water content is particularly important for the production of high-quality plastic products.
Testing water content is a necessary step in the production of plastic materials. Testing moisture content is basically divided into national standard method and rapid moisture tester method. Boshi plastic rapid moisture tester is a widely used instrument and equipment at present.(auto plastic parts)Test steps:
1. First, take out the moisture meter, place it and power it on, then break the test material into small pieces, pour out about 6 grams of plastic pieces and pour them into the stainless steel tray. In order to dry and dry the plastic thoroughly during the test, we spread the fine pieces of plastic parts into a scattered form so that the temperature can penetrate into the plastic parts. Use tweezers to lay small pieces of plastic parts evenly. In order to avoid the zoom and blackening of small pieces of plastic parts after baking, we set the temperature at 105 , press the "start" key to start the test for 1 minute and 49 seconds, and then the test ends, and the test data displays 0.3%;
2. In order to obtain more stable data results, wait for the moisture meter of plastic parts to cool down before the second test. When the temperature of the instrument itself drops below 40 , also take about 6 grams of small pieces of plastic parts into the stainless steel tray, and lay the small pieces of plastic parts evenly. This time, we set the temperature at 105 , press the "start" key to start the test, and the test ends after 1 minute and 38 seconds, The test data showed 0.29%;Test data:From the above tests, we found that the moisture of these plastic sheets was well controlled and the moisture distribution was relatively uniform, which promoted the plastic parts to be completely dry after the test, and the moisture data results were also very good.
matters needing attention:1. Small pieces of plastic sheets shall be small enough to ensure the complete drying of water in plastic parts, and shall be evenly spread on the tray as far as possible, rather than simply stacked together.2. Do not set the temperature too high to prevent the plastic parts from melting in case of high temperature. The moisture meter of plastic parts has its use environmental restrictions. Please use it under the environmental conditions specified in the product operation manual. Do not operate in harsh environments.
3. As the instrument is a precision instrument, do not knock the workbench or vibrate the instrument during heating, otherwise the measurement will be inaccurate.4. After the test, do not touch the tray for the Yi first time to avoid scalding.Editing: JQ