Cnc Machining Brass Part: Things You May Want to Know
cnc machining brass part provided by Honscn Co.,Ltd is well-received for its good functionality, beautiful looking and unparalleled reliability. It is exquisitely crafted by our experts who have rich experience and professional expertise across all aspects of the product, including its design, production, required characteristics, etc. It excels its competitors in every aspect.
HONSCN has always been working on how to make our brand stand out so that we have strengthened and reinforced our brand mission - offer more authentic and transparent customer services. We have been seriously carrying out the brand mission and have made the voice of this brand mission being heard consistently so that our brand image becomes highly recognizable on multiple channels.
Through Honscn, we focus on the total customer experience to help grow brands with quality products, such as cnc machining brass part. Fast and efficient turnaround times are guaranteed for both small and large production runs.
Shenzhen Honscn is a professional manufacturer of CNC Machine Parts, Auto Lathe Machine Parts, and Screw Fasteners. We offer OEM and ODM service with any related products for customers. We have a professional team of product design and engineers, as well as a professional QC team, our sales and documentation and logistics departments can finish the requirements of presentation of documents under various payment methods and different transportation modes.
• We can make offcial drawings based on customer request, or customer will provide their drawings for us to quote price and make samples for approval.
• After receiving the samples, customers will do a test for the material, size and tolerance. If customer need to change the size or material, we can arrange second samples for approval. Until customer approved the samples, then we will confirm large order.
Meantime, we will test it before shipping samples. And all tests are strictly carried out according to industry standards.
• If confirmed the sample okay, the customer needs us to provide the Mill Test Crtificate of this product conforming to EU standards, such as CE, RoHS, REACH before placing order. All of our products are in accordance with all the European certification, such as CE, RoHS, REACH, etc., and all of them have prepared standard documents for customers checking.
• We start to prepare the order materials when customer confirm all the details such as material, size, tolerance, surface finish and other details of the final sample.
After the package such as qty, label, shipping mark etc. are provided by customer, we starts to arrange the mass production. After all the goods finished, send pictures to customer for approval. We promise the packag is same as customer requested, mass products are exactly the same as the final samples. The following photos of the shipment, the passing rate of the third-party inspection of our company is 100%.
• After receiving shipment of whole order, customer put it on the market immediately and became the most popular product in the market quickly, no matter from the traditional market, the market of high-end professional fasteners or the online sales in Amazon. We always pay much attention to the quality of our products, which is recognized by customers and repurchased constantly.
• We can make offcial drawings based on customer request, or customer will provide their drawings for us to quote price and make samples for approval.
• After receiving the samples, customers will do a test for the material, size and tolerance. If customer need to change the size or material, we can arrange second samples for approval. Until customer approved the samples, then we will confirm large order.
Meantime, we will test it before shipping samples. And all tests are strictly carried out according to industry standards.
• If confirmed the sample okay, the customer needs us to provide the Mill Test Crtificate of this product conforming to EU standards, such as CE, RoHS, REACH before placing order. All of our products are in accordance with all the European certification, such as CE, RoHS, REACH, etc., and all of them have prepared standard documents for customers checking.
• We start to prepare the order materials when customer confirm all the details such as material, size, tolerance, surface finish and other details of the final sample.
After the package such as qty, label, shipping mark etc. are provided by customer, we starts to arrange the mass production. After all the goods finished, send pictures to customer for approval. We promise the packag is same as customer requested, mass products are exactly the same as the final samples. The following photos of the shipment, the passing rate of the third-party inspection of our company is 100%.
• After receiving shipment of whole order, customer put it on the market immediately and became the most popular product in the market quickly, no matter from the traditional market, the market of high-end professional fasteners or the online sales in Amazon. We always pay much attention to the quality of our products, which is recognized by customers and repurchased constantly.
With the advent of the Industry 4.0 era, CNC processing technology is also changing step by step, in addition to the pursuit of quality breakthroughs, many entrepreneurs are also pursuing automated production! Automation is a future trend in manufacturing. However, as we all know, the cost of manufacturing machine iteration is very expensive, under normal circumstances, the same series of machines do not appear the quality of the general process span will not be iterated machine. So we can avoid the heavy way to improve the production capacity and efficiency of CNC machine tools, and then take a look!
With the change of the development process environment, today's CNC machining machine tool technology has been constantly improving, today's we are already different from yesterday's we, the new era has put forward new challenges to us. What do we need to change to meet the challenge? What is needed is for us to continuously improve our perceptions, our capabilities, our methods and our actions.
1
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The importance of product processing technology
The process of the internal structure of the product is closely related to the processing cost. The processing technology used by the product directly determines the production cost, and the processing efficiency and production capacity will also be affected by it.
From the perspective of product design, if the manufacturing threshold of processing technology can be fundamentally reduced, on this basis, certain processing costs can be reduced, and the processing CT time of CNC machine tools can be shortened, and the processing quality and processing quality can be improved. Efficiency can be improved. Can greatly improve the CNC machining capacity.
2
/
Tool life management control in CNC machining
The life management control of the tool by the CNC system is to calculate the number of tool machining, or to determine the processing time. Therefore, when the tool life reaches the expected number of machining times or time of the system, the CNC automatically stops the action. It is assumed that when manual supervision is not in place, or when the tool is not able to stop changing in the expected situation, the CNC machining process will be affected. Therefore, tool life is a key factor affecting CNC production capacity.
Especially when the CNC machining process of a workpiece is too much, the processing amount is cumbersome, and the dimensional accuracy of the processing is relatively strict, the tools to be used will be more. At this time, the CNC tool library automatically changes the tool, and the knife action is more frequent, and the tool wear is larger, so that the manual tool change and machine adjustment are more frequent.
Therefore, tool wear is an important indicator that affects the normal production rhythm and capacity of CNC. Through technical measures to improve the process, improve the overall life of the tool, not only can save the cost of the tool, but more importantly, can reduce the stopping time of the CNC spindle, so as to improve the efficiency of CNC processing, improve the production quality and capacity.
3
/
CNC optimization program and process parameters
In the process of confirming the product processing technology, it is necessary to fully consider all the functions of CNC CNC machine tools, to shorten the processing route, reduce the number of tool walking and tool changing times, so as to ensure that the processing capacity is improved.
By choosing a reasonable and appropriate cutting amount, give full play to the cutting performance of the tool, optimize the processing parameters of the CNC, ensure the high-speed machining of the spindle, reduce the CT time of parts processing, and ultimately improve the processing efficiency of the product and improve the production quality.
4
/
CNC machining process improvement
When writing CNC machining process, it is not only necessary to focus on the feasibility of processing, but also to consider whether the process of the processing process will have a negative effect on the processing efficiency. Effectively shorten the processing time of CNC CT and improve production capacity can be achieved by arranging a reasonable processing sequence and reducing the number of tool changes.
5
/
The production site is strictly controlled
The development and strict implementation of production SOP is an indispensable part of CNC machining production process. Manual operation behavior should be reasonably standardized to reduce employees' negative emotions and unnecessary waste of time efficiency. Formulate incentive policies to improve the enthusiasm of technicians, so as to achieve the purpose of improving production capacity and product processing quality.
6
/
CNC machining abnormal problem elimination
The inspection work needs to be comprehensive, such as the use of the cylinder, solenoid valve, motor and other electrical parts in the oil environment on the equipment and fixture condition, and the investigation of these parts before the operation can effectively avoid the situation that the production of CNC spindle is forced to stop, so as to improve the utilization rate of the spindle.
Machine iteration is expensive, but there are other methods we can use to do it at a very small cost in exchange for a high yield.
The high-quality management of CNC machining production should be put in the first place, and the above six points can effectively improve the production performance and capacity of the machine tool.
Six industries that rely on cnc machining
Modern CNC (computer numerical control) machines enable the manufacture of precision parts quickly and efficiently. CNC machines manufacture millions of parts around the world every day. All of these parts vary in size, material and purpose.
CNC machining is often used for metal parts and assemblies with complex designs and tight tolerances. Because of the precision and capability of CNC machining, it is one of the most demanding manufacturing methods.
These industries rely heavily on CNC machined parts: automotive, Aerospace & Defense, medical, construction equipment, Power & Energy, and industrial. In this article, we will share how each industry uses precision machined parts.
Automobile industry
The automotive and transportation industry is one of the largest users of CNC machined parts. Cars, trucks, vans and motorcycles all use precision metal parts. Vehicles require thousands of parts, which require high precision and durability.
CNC machining is ideal for many automotive parts because the parts need to be the same and made of hard metals such as steel and stainless steel. Many engine and transmission parts are CNC machined. Few manufacturing processes can match the precision and repeatability offered by CNC machining.
Electric vehicles play an important role in the development of CNC machining, as they require a large number of precision-machined parts.
Medical industry
Similar to the automotive industry, the medical industry requires parts with extremely tight tolerances. There is no room for error in the manufacture of life-saving equipment.
CNC machining provides the medical industry with precision parts, required materials, and fast manufacturing. CNC machines can use specific materials required by the medical industry, such as stainless steel, titanium and copper parts.
CNC machining is also an ideal choice to support crisis response. In early 2020, many CNC workshops shifted part of their work to manufacturing basic medical equipment such as parts for ventilators. CNC machines have a wide range of functions and can be easily programmed to make new parts.
Industrial equipment industry
CNC machines make parts for other manufacturing operations. The industrial sector includes packaging equipment, electronics and other general industrial equipment. Overall, the industry accounts for about 25% of CNC machined parts.
Industrial equipment often requires high-precision parts that can operate in high-stress environments. The consistency and custom machining capabilities offered by CNC machining are necessary for the industry.
Aerospace and defense industries
The aerospace industry is worth an estimated $300 billion and shows no signs of slowing down. We usually think of aerospace as = airplanes, but there are also thousands of satellites and rockets that require thousands of precision parts.
The aerospace and defense industry relies on CNC machining to manufacture complex precision parts that leave no margin for error. The tight tolerances, rapid prototyping and scalability of CNC machines are ideally suited to meet the needs of this industry.
Construction industry
The construction industry needs reliable, high-strength parts that can operate in harsh environments. CNC machine tools can process large and small metal parts needed for construction equipment.
CNC machining is the best manufacturing method for difficult metal alloys. High-strength steel alloys are commonly used to make parts for cranes, lifting equipment, bulldozers and other construction equipment. Gears, pump equipment, and high-strength fasteners are just a few examples of NC machined parts.
Energy industry
The gas, oil and energy industry is another huge market that relies on many #CNC machined components. Precision valves, bushings and sensor devices all require precision machined parts.
To keep vital energy infrastructure operating at peak efficiency, components need to fit perfectly together.
Parts used in harsh environments require high precision and high corrosion and heat resistance. Salt water and chemicals can destroy many metal parts, so the industry needs metals such as Hastelloy, which often require modern CNC machine tool cutting tools.
In general, CNC machining process plays an irreplaceable role in modern manufacturing industry, and its high precision, high efficiency and flexibility bring great development opportunities and competitive advantages to all walks of life. With the continuous progress of technology and the continuous expansion of applications, CNC machining technology will continue to play an important role in the future manufacturing industry, and make new contributions to the progress and development of human society.#Honscn #cnc
With the change of the development process environment, today's CNC machining machine tool technology has been constantly improving, today's we are already different from yesterday's we, the new era has put forward new challenges to us. What do we need to change to meet the challenge? What is needed is for us to continuously improve our perceptions, our capabilities, our methods and our actions.
1
/
The importance of product processing technology
The process of the internal structure of the product is closely related to the processing cost. The processing technology used by the product directly determines the production cost, and the processing efficiency and production capacity will also be affected by it.
From the perspective of product design, if the manufacturing threshold of processing technology can be fundamentally reduced, on this basis, certain processing costs can be reduced, and the processing CT time of CNC machine tools can be shortened, and the processing quality and processing quality can be improved. Efficiency can be improved. Can greatly improve the CNC machining capacity.
2
/
Tool life management control in CNC machining
The life management control of the tool by the CNC system is to calculate the number of tool machining, or to determine the processing time. Therefore, when the tool life reaches the expected number of machining times or time of the system, the CNC automatically stops the action. It is assumed that when manual supervision is not in place, or when the tool is not able to stop changing in the expected situation, the CNC machining process will be affected. Therefore, tool life is a key factor affecting CNC production capacity.
Especially when the CNC machining process of a workpiece is too much, the processing amount is cumbersome, and the dimensional accuracy of the processing is relatively strict, the tools to be used will be more. At this time, the CNC tool library automatically changes the tool, and the knife action is more frequent, and the tool wear is larger, so that the manual tool change and machine adjustment are more frequent.
Therefore, tool wear is an important indicator that affects the normal production rhythm and capacity of CNC. Through technical measures to improve the process, improve the overall life of the tool, not only can save the cost of the tool, but more importantly, can reduce the stopping time of the CNC spindle, so as to improve the efficiency of CNC processing, improve the production quality and capacity.
3
/
CNC optimization program and process parameters
In the process of confirming the product processing technology, it is necessary to fully consider all the functions of CNC CNC machine tools, to shorten the processing route, reduce the number of tool walking and tool changing times, so as to ensure that the processing capacity is improved.
By choosing a reasonable and appropriate cutting amount, give full play to the cutting performance of the tool, optimize the processing parameters of the CNC, ensure the high-speed machining of the spindle, reduce the CT time of parts processing, and ultimately improve the processing efficiency of the product and improve the production quality.
4
/
CNC machining process improvement
When writing CNC machining process, it is not only necessary to focus on the feasibility of processing, but also to consider whether the process of the processing process will have a negative effect on the processing efficiency. Effectively shorten the processing time of CNC CT and improve production capacity can be achieved by arranging a reasonable processing sequence and reducing the number of tool changes.
5
/
The production site is strictly controlled
The development and strict implementation of production SOP is an indispensable part of CNC machining production process. Manual operation behavior should be reasonably standardized to reduce employees' negative emotions and unnecessary waste of time efficiency. Formulate incentive policies to improve the enthusiasm of technicians, so as to achieve the purpose of improving production capacity and product processing quality.
6
/
CNC machining abnormal problem elimination
The inspection work needs to be comprehensive, such as the use of the cylinder, solenoid valve, motor and other electrical parts in the oil environment on the equipment and fixture condition, and the investigation of these parts before the operation can effectively avoid the situation that the production of CNC spindle is forced to stop, so as to improve the utilization rate of the spindle.
Machine iteration is expensive, but there are other methods we can use to do it at a very small cost in exchange for a high yield.
The high-quality management of CNC machining production should be put in the first place, and the above six points can effectively improve the production performance and capacity of the machine tool.
Six industries that rely on cnc machining
Modern CNC (computer numerical control) machines enable the manufacture of precision parts quickly and efficiently. CNC machines manufacture millions of parts around the world every day. All of these parts vary in size, material and purpose.
CNC machining is often used for metal parts and assemblies with complex designs and tight tolerances. Because of the precision and capability of CNC machining, it is one of the most demanding manufacturing methods.
These industries rely heavily on CNC machined parts: automotive, Aerospace & Defense, medical, construction equipment, Power & Energy, and industrial. In this article, we will share how each industry uses precision machined parts.
Automobile industry
The automotive and transportation industry is one of the largest users of CNC machined parts. Cars, trucks, vans and motorcycles all use precision metal parts. Vehicles require thousands of parts, which require high precision and durability.
CNC machining is ideal for many automotive parts because the parts need to be the same and made of hard metals such as steel and stainless steel. Many engine and transmission parts are CNC machined. Few manufacturing processes can match the precision and repeatability offered by CNC machining.
Electric vehicles play an important role in the development of CNC machining, as they require a large number of precision-machined parts.
Medical industry
Similar to the automotive industry, the medical industry requires parts with extremely tight tolerances. There is no room for error in the manufacture of life-saving equipment.
CNC machining provides the medical industry with precision parts, required materials, and fast manufacturing. CNC machines can use specific materials required by the medical industry, such as stainless steel, titanium and copper parts.
CNC machining is also an ideal choice to support crisis response. In early 2020, many CNC workshops shifted part of their work to manufacturing basic medical equipment such as parts for ventilators. CNC machines have a wide range of functions and can be easily programmed to make new parts.
Industrial equipment industry
CNC machines make parts for other manufacturing operations. The industrial sector includes packaging equipment, electronics and other general industrial equipment. Overall, the industry accounts for about 25% of CNC machined parts.
Industrial equipment often requires high-precision parts that can operate in high-stress environments. The consistency and custom machining capabilities offered by CNC machining are necessary for the industry.
Aerospace and defense industries
The aerospace industry is worth an estimated $300 billion and shows no signs of slowing down. We usually think of aerospace as = airplanes, but there are also thousands of satellites and rockets that require thousands of precision parts.
The aerospace and defense industry relies on CNC machining to manufacture complex precision parts that leave no margin for error. The tight tolerances, rapid prototyping and scalability of CNC machines are ideally suited to meet the needs of this industry.
Construction industry
The construction industry needs reliable, high-strength parts that can operate in harsh environments. CNC machine tools can process large and small metal parts needed for construction equipment.
CNC machining is the best manufacturing method for difficult metal alloys. High-strength steel alloys are commonly used to make parts for cranes, lifting equipment, bulldozers and other construction equipment. Gears, pump equipment, and high-strength fasteners are just a few examples of NC machined parts.
Energy industry
The gas, oil and energy industry is another huge market that relies on many #CNC machined components. Precision valves, bushings and sensor devices all require precision machined parts.
To keep vital energy infrastructure operating at peak efficiency, components need to fit perfectly together.
Parts used in harsh environments require high precision and high corrosion and heat resistance. Salt water and chemicals can destroy many metal parts, so the industry needs metals such as Hastelloy, which often require modern CNC machine tool cutting tools.
In general, CNC machining process plays an irreplaceable role in modern manufacturing industry, and its high precision, high efficiency and flexibility bring great development opportunities and competitive advantages to all walks of life. With the continuous progress of technology and the continuous expansion of applications, CNC machining technology will continue to play an important role in the future manufacturing industry, and make new contributions to the progress and development of human society.#Honscn #cnc
The requirements of lightweight, safety and decoration in modern automobile manufacturing industry drive the development of traditional welding technology in the field of automobile plastics. In recent years, with the application of a variety of high-end technologies such as ultrasonic, vibration friction and laser technology in the field of automobile plastic parts manufacturing, the technical level and supporting capacity of domestic automobile parts manufacturing industry have been greatly improved.As for the welding and welding process of automotive interior parts, hot plate welding, laser welding, ultrasonic welding, non-standard ultrasonic welding machine, vibration friction machine, etc. have been developed. In the process, one-time overall or complex structure welding can be realized, and the optimal design requirements can be achieved on the basis of simplifying mold design and reducing molding cost.For typical interior and exterior trim parts, large components with high surface quality and complex structure, such as instrument panel, door panel, column, glove box, engine intake manifold, front and rear bumper, must select corresponding welding technology, and adopt appropriate welding process according to the requirements of interior structure, performance, materials and production cost. All these applications can not only complete the corresponding manufacturing process, but also ensure the excellent quality and perfect shape of products.
Hot plate welding machine: the hot plate welding machine equipment can control the horizontal or vertical movement of the hot plate welding die, and the transmission system is driven by pneumatic, hydraulic drive or servo motor. The advantages of hot plate welding technology are that it can be applied to workpieces of different sizes without area limitation, applicable to any welding surface, allowing plastic allowance compensation, ensuring welding strength, and adjusting welding procedures according to the needs of various materials (such as adjusting welding temperature, welding time, cooling time, input air pressure, welding temperature and switching time, etc.), In the welding process, the equipment can maintain good stability, ensure consistent welding effect and accuracy of workpiece height after machining.
Another feature of the horizontal hot plate welding machine is that it can rotate at 90 for cleaning. The processing period of hot plate welding machine can generally be divided into: original position (the hot plate does not move with the upper and lower molds), heating period (the hot plate moves between the upper and lower molds, and the heat of the hot plate moves down the upper and lower molds to dissolve the welding surfaces of the upper and lower workpieces), transfer period (the upper and lower molds return to the original position, and the hot plate exits), welding and cooling period (the upper and lower dies are joined to make the workpiece welded at the same time and cooled for forming), and return to the original position (the upper and lower dies are separated, and the welded workpiece can be taken out).
In the early automobile industry, these welding equipment were relatively common, but with the continuous improvement of the requirements for the structure, shape and service life of the parts themselves, the requirements for their processing equipment are higher and higher. Moreover, because the size of the equipment is limited to the size of the welded parts, the equipment and equipment driving mode should be selected according to the size of the parts in the design. The most important thing is the parts The heating area is large and there is large deformation. In addition, the welding process distinguishes the polarity and non polarity of welding plastics, resulting in the gradual replacement of hot plate welding by ultrasonic welding and laser welding. The main parts used for welding in China include automotive plastic fuel tank, battery, tail lamp, glove box, etc.
Laser welding: laser welding technology is widely used in today's medical device manufacturing industry. Only a few manufacturers in the automotive industry use laser welding air inlet pipe, etc. because it is a new welding technology, it is not very mature to a certain extent, but it is believed that it will be widely used in the near future because of its remarkable welding characteristics. Its advantage is that it can weld TPE / TP Or TPE products; under the condition of no vibration, nylon, workpiece with sensitive electronic parts and three-dimensional welding surface can be welded, which can save cost and reduce waste products.
In the welding process, the resin melts less, the surface can be welded tightly, and there is no flash or glue overflow. It is allowed that rigid plastic parts can be welded without glue overflow and vibration. Generally, workpieces with soft or irregular welding surfaces can be welded evenly regardless of the size of workpieces, especially for large-scale production of high-tech micro parts. However, laser conduction is limited. "Quasi synchronous" laser welding technology uses a scanning mirror to transmit the laser beam to the welding surface at the speed of 10m / s according to the welding shape. It can walk on the welding surface as many as 40 times in 1s. The plastic around the welding surface melts and the two workpieces are welded after pressurization.
Laser welding can be roughly divided into: solid Nd-YAG system (laser beam is generated by crystal) and diodesystem (high power diode laser) , CAD data programming. All materials can be laser welded with body materials, among which acrylonitrile butadiene styrene is most suitable for laser welding with other materials, nylon, polypropylene and polyethylene can only be welded with their own body materials, and other materials have general applicability for laser welding.fqj
Hot plate welding machine: the hot plate welding machine equipment can control the horizontal or vertical movement of the hot plate welding die, and the transmission system is driven by pneumatic, hydraulic drive or servo motor. The advantages of hot plate welding technology are that it can be applied to workpieces of different sizes without area limitation, applicable to any welding surface, allowing plastic allowance compensation, ensuring welding strength, and adjusting welding procedures according to the needs of various materials (such as adjusting welding temperature, welding time, cooling time, input air pressure, welding temperature and switching time, etc.), In the welding process, the equipment can maintain good stability, ensure consistent welding effect and accuracy of workpiece height after machining.
Another feature of the horizontal hot plate welding machine is that it can rotate at 90 for cleaning. The processing period of hot plate welding machine can generally be divided into: original position (the hot plate does not move with the upper and lower molds), heating period (the hot plate moves between the upper and lower molds, and the heat of the hot plate moves down the upper and lower molds to dissolve the welding surfaces of the upper and lower workpieces), transfer period (the upper and lower molds return to the original position, and the hot plate exits), welding and cooling period (the upper and lower dies are joined to make the workpiece welded at the same time and cooled for forming), and return to the original position (the upper and lower dies are separated, and the welded workpiece can be taken out).
In the early automobile industry, these welding equipment were relatively common, but with the continuous improvement of the requirements for the structure, shape and service life of the parts themselves, the requirements for their processing equipment are higher and higher. Moreover, because the size of the equipment is limited to the size of the welded parts, the equipment and equipment driving mode should be selected according to the size of the parts in the design. The most important thing is the parts The heating area is large and there is large deformation. In addition, the welding process distinguishes the polarity and non polarity of welding plastics, resulting in the gradual replacement of hot plate welding by ultrasonic welding and laser welding. The main parts used for welding in China include automotive plastic fuel tank, battery, tail lamp, glove box, etc.
Laser welding: laser welding technology is widely used in today's medical device manufacturing industry. Only a few manufacturers in the automotive industry use laser welding air inlet pipe, etc. because it is a new welding technology, it is not very mature to a certain extent, but it is believed that it will be widely used in the near future because of its remarkable welding characteristics. Its advantage is that it can weld TPE / TP Or TPE products; under the condition of no vibration, nylon, workpiece with sensitive electronic parts and three-dimensional welding surface can be welded, which can save cost and reduce waste products.
In the welding process, the resin melts less, the surface can be welded tightly, and there is no flash or glue overflow. It is allowed that rigid plastic parts can be welded without glue overflow and vibration. Generally, workpieces with soft or irregular welding surfaces can be welded evenly regardless of the size of workpieces, especially for large-scale production of high-tech micro parts. However, laser conduction is limited. "Quasi synchronous" laser welding technology uses a scanning mirror to transmit the laser beam to the welding surface at the speed of 10m / s according to the welding shape. It can walk on the welding surface as many as 40 times in 1s. The plastic around the welding surface melts and the two workpieces are welded after pressurization.
Laser welding can be roughly divided into: solid Nd-YAG system (laser beam is generated by crystal) and diodesystem (high power diode laser) , CAD data programming. All materials can be laser welded with body materials, among which acrylonitrile butadiene styrene is most suitable for laser welding with other materials, nylon, polypropylene and polyethylene can only be welded with their own body materials, and other materials have general applicability for laser welding.fqj
"CNC machining often has many advantages. From the perspective of automotive, aerospace and consumer applications, it is widely used in the manufacturing of components in these fields. And, in a way, it has similar properties to metal."
Polyformaldehyde, or POM, is a fascinating plastic resin that is widely used in various industrial fields. The aerospace, automotive and electronics industries are important consumers of this polymer. The processing of polyformaldehyde, especially when used in the manufacturing field, can achieve fast and efficient processing. In addition, it benefits users due to its high mechanical strength, stiffness, machinability and variety of grade choices.
This article contains the following key details of POM CNC machining, as well as its basic characteristics in terms of functions, applications, advantages, etc. Let's get started.
What is POM?
POM, a homopolymer, is also known as Delrin. It is widely adopted as an engineering grade thermoplastic for manufacturing prototypes for industrial use. It usually comes in two forms: copolymers or homopolymers. From complex prototypes to flexible machine parts, it brings economic benefits to manufacturing.
Product designers can benefit from its structural integrity, color diversity and stiffness characteristics. In addition, its reliability and resilience in wet environments make it suitable for Marine, medical and aerospace applications. POM, usually has some other name, such as; Acetal (acetal), polyacetal (polyacetal), polyformaldehyde, etc.
Why use POM for CNC machining?
POM formaldehyde or polyacetal has significant advantages when used in machining. Benefit from leading technologies such as precision machining POM or CNC machining; For example; Milling, drilling, punching and punching. In addition, its versatility in various grades is very beneficial for machining experts. Delrin is also compatible with advanced cutting technologies; Examples include laser cutting and extrusion processes.
Some of the main features of CNC machining include:
It is lightweight, wear-resistant and has low friction properties.
POM's low friction capability means it can be used in high-precision rotating parts, such as automotive bushings, bearings and gears.
POM is similar to acrylic because of its inherent optical transparency and crystallinity.
Delrin comes in a variety of textures, colors and grades.
POM CNC machining is essential for high volume production and runs efficiently.
It has a lower heat absorption rate compared to other grade polymers such as nylon and polyethylene.
Evolved into CNC POM prototyping, CNC machining plays a key role in prototyping.
Delrine or POM is also known as metallic plastic or super steel because of its high rigidity and strength.
POM can be efficiently milling, drilling, grooving and cutting with CNC machining.
Manufacturers can use it for a variety of applications such as aerospace, automotive and consumer goods.
Design engineers can benefit from its dimensional stability and achieve tighter tolerances of ±0.0005 inches.
Rapid prototyping with CNC machining is feasible.
CNC lathes are also available for POM machining.
It describes low-cost solutions and offers economic benefits when produced in large volumes.
POM is a common technique; For example; CNC machining, injection molding, and 3D printing.
Prototypes and complex geometric shapes are easier to manufacture with POM CNC machining.
POM numerical control machining method
Plastic CNC machining can be deployed through various technologies; For example; CNC milling, CNC drilling, lathes, grinding, blanking and punching. Its ease of processing greatly affects its use in these processes. In addition, it has also received a lot of attention for its high elongation. Now, let's discuss the method to get the best results POM CNC machining.
The process begins with computer-aided design and programming to improve accuracy, quality, and optimization levels. After the virtual configuration, the instructions are forwarded to the CNC machine in the following form: G code for further processing prospects.
A cutting operation is then performed on the workpiece material (POM) to obtain the optimal dimensions and dimensions. It is recommended to use coolant when machining Delrin at high speed to prevent ineffective processing operations such as chip buildup or overheating.
The following are some of the techniques commonly used to process strong polyformaldehyde or POM.
1.POM CNC milling
CNC milling is often used to machine POM parts. Tools with sharp edges help to get the best Angle, as well as surface finish. Therefore, it is reasonable to use a single slot milling cutter to process Delrin. These cutters prevent chip buildup during machining operations.
2.POM CNC drilling
Standard twist and center drills are best suited for processing polyformaldehyde resins. These materials have strong, sharpened edges that ultimately allow for smooth milling operations on Delrin. The optimal cutting speed of the drilled POM must be approximately 1500rpm and the lip torsion Angle 118°.
3.POM CNC turning
POM CNC turning operation is similar to brass turning operation. The best results can be achieved by maintaining high speed turning at the same rate as the medium feed rate. In order to prevent interference and excessive chip accumulation problems, a chip-breaker must be used for precision turning operations.
4. Blanking and punching
Blanking and stamping, both methods are preferred for small and medium-sized complex parts. During operation, cracks in the sheet can lead to major problems of improper processing. To eliminate this problem, it is best to preheat the Delrin plate and use a manual or high punch.
Highlights: "During POM CNC machining, it is important to keep the POM tight or hold the POM and use a hard steel or carbide tool.
List of Delrin grades for CNC machining
The two most common acetal grades are very useful for CNC machining; Polyformaldehyde resin 150, polyformaldehyde resin; 100 (AF). Let's evaluate their compatibility;
1. Delrin 150
Derlin 150 belongs to the acetal homopolymer family. It has high mechanical strength, stiffness and wear resistance. Thanks to these unique features, it is ideal for CNC machining of gears, bushings, gaskets and automotive interior and exterior finishes. In addition, its stability under high temperature conditions makes it ideal for irrigation and conveyor parts.
2. Delrin 100(A)
Delrin 100 A is integrated with polytetrafluoroethylene (PTFE) for enhanced mechanical stability and viscosity. It is widely used in gear systems or components that require low friction characteristics. In addition, it has strong moisture and chemical resistance. In addition, it eliminates the self-lubricating (oil or grease) characteristic, making it different from other Delrin grades.
Surface treatment options for POM
The desired surface finish plays a key role in the machining process. When it comes to surface treatment, two options are usually employed: machining and sandblasting. Here is a brief introduction to these;
After processing
CNC machining often leaves a bumpy surface or texture on the surface of the acetal part. When rough or textured parts are needed to improve the frictional properties of the parts, the surface treatment is preferred. The typical roughness range that can be achieved by machining is about 32 to 250 microinches (0.8 to 6.3 microns).
Pearl burst
In most cases, machining tools leave marks on acetal parts. Sandblasting is often used to prevent tool marks and enhance the visual effect of Delrin machined parts. It works by releasing glass beads or fine particles onto the surface of machined parts under high pressure. In addition, it improves durability and provides a valuable, smooth, matte, aesthetically pleasing and satin-polished appearance to polyformaldehyde resin machine parts.
There are other techniques; For example; Anodizing, polishing, painting and stamping. However, most design engineers prefer the above two options due to economic feasibility.
What are the limitations of Delrin CNC machining?
However, there are huge benefits to using Delrin for CNC machining. Besides, it also has some disadvantages. Here are Delrin's limitations;
Adhesion: Although acetal has excellent chemical resistance, it often presents challenges in bonding with strong adhesives. To overcome this problem, designers may need to employ post-treated surface options for best results.
Thermal sensitivity: Thermal sensitivity is a noteworthy issue for design manufacturers. The ability of acetone alcohols to withstand high temperature conditions is very significant. However, it is well suited for applications where mechanical stability is critical. But in some cases, when it is exposed to high temperature conditions, there will be deformation or distortion problems. Compared with nylon, nylon shows higher strength and structural strength even in harsh environments.
High flammability: The processing of polyformaldehyde resin faces the challenge of flammability. It is sensitive to temperatures above 121 degrees Celsius. It is recommended to always use a coolant, such as air coolant, to maintain the temperature during the processing operation. In order to overcome or control flammability problems, it is also necessary to use A Class A fire extinguisher when processing POM.
Delrin NC machining applications
From automotive interiors to aerospace components, Drin is used in a wide range of applications. Let's take a look at some of its key applications in manufacturing;
Medical industry
POM is an important material for medical components or equipment. As an engineered thermoplastic, it meets the strict quality standards of the FDA or ISO. Its applications range from enclosures and housings to complex functional components; For example; Disposable syringes, surgical tools, valves, inhalers, prosthetics and medical implants.
Automobile industry
Derlin supplies a wide range of automotive components to the automotive industry. Its high mechanical strength, low friction, and wear resistance allow engineers to use it to make important car, motorcycle, and electric vehicle parts. Some common examples include: articulated housings, locking systems, and fuel transmitter units.
Consumer appliances
When it comes to convenient applications, polyformaldehyde processing describes several significant benefits. Manufacturing experts use it to make zippers, cooking utensils, washing machines and clips.
Industrial machinery parts
Derlin's great strength enables it to be used in industrial parts manufacturing. Its ability to withstand wear and low friction characteristics makes it ideal for components such as springs, fan wheels, gears, housings, scrapers and rollers.
As an industry pioneer, Honscn is always at the forefront of market developments. We know that in the fierce market competition, only by constantly honing ourselves can we create indestructible competitiveness. Therefore, we adhere to technological innovation and integrate scientific management into every production link to ensure that every step is accurate. We not only focus on the pulse of the domestic market, but also in line with international standards, with a global perspective to examine the industry trend, grasp the pulse of The Times. With an open mind, embrace the world, with excellent quality, win the future!
Please feel free to contact us to discuss your project needs!
Polyformaldehyde, or POM, is a fascinating plastic resin that is widely used in various industrial fields. The aerospace, automotive and electronics industries are important consumers of this polymer. The processing of polyformaldehyde, especially when used in the manufacturing field, can achieve fast and efficient processing. In addition, it benefits users due to its high mechanical strength, stiffness, machinability and variety of grade choices.
This article contains the following key details of POM CNC machining, as well as its basic characteristics in terms of functions, applications, advantages, etc. Let's get started.
What is POM?
POM, a homopolymer, is also known as Delrin. It is widely adopted as an engineering grade thermoplastic for manufacturing prototypes for industrial use. It usually comes in two forms: copolymers or homopolymers. From complex prototypes to flexible machine parts, it brings economic benefits to manufacturing.
Product designers can benefit from its structural integrity, color diversity and stiffness characteristics. In addition, its reliability and resilience in wet environments make it suitable for Marine, medical and aerospace applications. POM, usually has some other name, such as; Acetal (acetal), polyacetal (polyacetal), polyformaldehyde, etc.
Why use POM for CNC machining?
POM formaldehyde or polyacetal has significant advantages when used in machining. Benefit from leading technologies such as precision machining POM or CNC machining; For example; Milling, drilling, punching and punching. In addition, its versatility in various grades is very beneficial for machining experts. Delrin is also compatible with advanced cutting technologies; Examples include laser cutting and extrusion processes.
Some of the main features of CNC machining include:
It is lightweight, wear-resistant and has low friction properties.
POM's low friction capability means it can be used in high-precision rotating parts, such as automotive bushings, bearings and gears.
POM is similar to acrylic because of its inherent optical transparency and crystallinity.
Delrin comes in a variety of textures, colors and grades.
POM CNC machining is essential for high volume production and runs efficiently.
It has a lower heat absorption rate compared to other grade polymers such as nylon and polyethylene.
Evolved into CNC POM prototyping, CNC machining plays a key role in prototyping.
Delrine or POM is also known as metallic plastic or super steel because of its high rigidity and strength.
POM can be efficiently milling, drilling, grooving and cutting with CNC machining.
Manufacturers can use it for a variety of applications such as aerospace, automotive and consumer goods.
Design engineers can benefit from its dimensional stability and achieve tighter tolerances of ±0.0005 inches.
Rapid prototyping with CNC machining is feasible.
CNC lathes are also available for POM machining.
It describes low-cost solutions and offers economic benefits when produced in large volumes.
POM is a common technique; For example; CNC machining, injection molding, and 3D printing.
Prototypes and complex geometric shapes are easier to manufacture with POM CNC machining.
POM numerical control machining method
Plastic CNC machining can be deployed through various technologies; For example; CNC milling, CNC drilling, lathes, grinding, blanking and punching. Its ease of processing greatly affects its use in these processes. In addition, it has also received a lot of attention for its high elongation. Now, let's discuss the method to get the best results POM CNC machining.
The process begins with computer-aided design and programming to improve accuracy, quality, and optimization levels. After the virtual configuration, the instructions are forwarded to the CNC machine in the following form: G code for further processing prospects.
A cutting operation is then performed on the workpiece material (POM) to obtain the optimal dimensions and dimensions. It is recommended to use coolant when machining Delrin at high speed to prevent ineffective processing operations such as chip buildup or overheating.
The following are some of the techniques commonly used to process strong polyformaldehyde or POM.
1.POM CNC milling
CNC milling is often used to machine POM parts. Tools with sharp edges help to get the best Angle, as well as surface finish. Therefore, it is reasonable to use a single slot milling cutter to process Delrin. These cutters prevent chip buildup during machining operations.
2.POM CNC drilling
Standard twist and center drills are best suited for processing polyformaldehyde resins. These materials have strong, sharpened edges that ultimately allow for smooth milling operations on Delrin. The optimal cutting speed of the drilled POM must be approximately 1500rpm and the lip torsion Angle 118°.
3.POM CNC turning
POM CNC turning operation is similar to brass turning operation. The best results can be achieved by maintaining high speed turning at the same rate as the medium feed rate. In order to prevent interference and excessive chip accumulation problems, a chip-breaker must be used for precision turning operations.
4. Blanking and punching
Blanking and stamping, both methods are preferred for small and medium-sized complex parts. During operation, cracks in the sheet can lead to major problems of improper processing. To eliminate this problem, it is best to preheat the Delrin plate and use a manual or high punch.
Highlights: "During POM CNC machining, it is important to keep the POM tight or hold the POM and use a hard steel or carbide tool.
List of Delrin grades for CNC machining
The two most common acetal grades are very useful for CNC machining; Polyformaldehyde resin 150, polyformaldehyde resin; 100 (AF). Let's evaluate their compatibility;
1. Delrin 150
Derlin 150 belongs to the acetal homopolymer family. It has high mechanical strength, stiffness and wear resistance. Thanks to these unique features, it is ideal for CNC machining of gears, bushings, gaskets and automotive interior and exterior finishes. In addition, its stability under high temperature conditions makes it ideal for irrigation and conveyor parts.
2. Delrin 100(A)
Delrin 100 A is integrated with polytetrafluoroethylene (PTFE) for enhanced mechanical stability and viscosity. It is widely used in gear systems or components that require low friction characteristics. In addition, it has strong moisture and chemical resistance. In addition, it eliminates the self-lubricating (oil or grease) characteristic, making it different from other Delrin grades.
Surface treatment options for POM
The desired surface finish plays a key role in the machining process. When it comes to surface treatment, two options are usually employed: machining and sandblasting. Here is a brief introduction to these;
After processing
CNC machining often leaves a bumpy surface or texture on the surface of the acetal part. When rough or textured parts are needed to improve the frictional properties of the parts, the surface treatment is preferred. The typical roughness range that can be achieved by machining is about 32 to 250 microinches (0.8 to 6.3 microns).
Pearl burst
In most cases, machining tools leave marks on acetal parts. Sandblasting is often used to prevent tool marks and enhance the visual effect of Delrin machined parts. It works by releasing glass beads or fine particles onto the surface of machined parts under high pressure. In addition, it improves durability and provides a valuable, smooth, matte, aesthetically pleasing and satin-polished appearance to polyformaldehyde resin machine parts.
There are other techniques; For example; Anodizing, polishing, painting and stamping. However, most design engineers prefer the above two options due to economic feasibility.
What are the limitations of Delrin CNC machining?
However, there are huge benefits to using Delrin for CNC machining. Besides, it also has some disadvantages. Here are Delrin's limitations;
Adhesion: Although acetal has excellent chemical resistance, it often presents challenges in bonding with strong adhesives. To overcome this problem, designers may need to employ post-treated surface options for best results.
Thermal sensitivity: Thermal sensitivity is a noteworthy issue for design manufacturers. The ability of acetone alcohols to withstand high temperature conditions is very significant. However, it is well suited for applications where mechanical stability is critical. But in some cases, when it is exposed to high temperature conditions, there will be deformation or distortion problems. Compared with nylon, nylon shows higher strength and structural strength even in harsh environments.
High flammability: The processing of polyformaldehyde resin faces the challenge of flammability. It is sensitive to temperatures above 121 degrees Celsius. It is recommended to always use a coolant, such as air coolant, to maintain the temperature during the processing operation. In order to overcome or control flammability problems, it is also necessary to use A Class A fire extinguisher when processing POM.
Delrin NC machining applications
From automotive interiors to aerospace components, Drin is used in a wide range of applications. Let's take a look at some of its key applications in manufacturing;
Medical industry
POM is an important material for medical components or equipment. As an engineered thermoplastic, it meets the strict quality standards of the FDA or ISO. Its applications range from enclosures and housings to complex functional components; For example; Disposable syringes, surgical tools, valves, inhalers, prosthetics and medical implants.
Automobile industry
Derlin supplies a wide range of automotive components to the automotive industry. Its high mechanical strength, low friction, and wear resistance allow engineers to use it to make important car, motorcycle, and electric vehicle parts. Some common examples include: articulated housings, locking systems, and fuel transmitter units.
Consumer appliances
When it comes to convenient applications, polyformaldehyde processing describes several significant benefits. Manufacturing experts use it to make zippers, cooking utensils, washing machines and clips.
Industrial machinery parts
Derlin's great strength enables it to be used in industrial parts manufacturing. Its ability to withstand wear and low friction characteristics makes it ideal for components such as springs, fan wheels, gears, housings, scrapers and rollers.
As an industry pioneer, Honscn is always at the forefront of market developments. We know that in the fierce market competition, only by constantly honing ourselves can we create indestructible competitiveness. Therefore, we adhere to technological innovation and integrate scientific management into every production link to ensure that every step is accurate. We not only focus on the pulse of the domestic market, but also in line with international standards, with a global perspective to examine the industry trend, grasp the pulse of The Times. With an open mind, embrace the world, with excellent quality, win the future!
Please feel free to contact us to discuss your project needs!
The processing methods of holes include drilling, reaming, reaming, boring, drawing, grinding and finishing of holes. The following small series for you to introduce several hole processing technology in detail, crack the hole processing problems.
The hole is an important surface on the box, bracket, sleeve, ring, and disk parts, and it is also a surface often encountered in machining. In the case of the same processing accuracy and surface roughness requirements, it is difficult to process the hole than the outer round surface, low productivity and high cost.
This is because: 1) the size of the tool used in hole processing is limited by the size of the hole being processed, and the rigidity is poor, which is easy to produce bending deformation and vibration; 2) When machining the hole with a fixed-size tool, the size of the hole processing often directly depends on the corresponding size of the tool, and the manufacturing error and wear of the tool will directly affect the processing accuracy of the hole; 3) When machining holes, the cutting area is inside the workpiece, the chip removal and heat dissipation conditions are poor, and the processing accuracy and surface quality are not easy to control.
Drilling and reaming
Drilling
Drilling is the first process of machining holes on solid materials, and the diameter of the drilling hole is generally less than 80mm. There are two ways of drilling: one is the bit rotation; The other is workpiece rotation. The error generated by the above two drilling methods is not the same, in the drilling method of the bit rotation, due to the asymmetry of the cutting edge and the insufficient rigidity of the bit and the bit deflection, the center line of the hole will be skewed or not straight, but the aperture is basically unchanged; On the contrary, in the drilling method of workpiece rotation, the bit deflection will cause the aperture to change, but the center line of the hole is still straight.
Commonly used drilling knives have: twist drill, center drill, deep hole drill, etc., of which the most commonly used is twist drill, its diameter specification is Φ0.1-80mm.
Due to structural limitations, the bending stiffness and torsional rigidity of the drill bit are low, coupled with poor centering, the drilling accuracy is low, generally only IT13 ~ IT11; The surface roughness is also large, Ra is generally 50~12.5μm; However, the metal removal rate of drilling is large and the cutting efficiency is high. Drilling is mainly used for processing holes with low quality requirements, such as bolt holes, thread bottom holes, oil holes, etc. For holes with high machining accuracy and surface quality requirements, they should be achieved by reaming, reaming, boring or grinding in subsequent processing.
Reaming
Reaming is to further process the hole that has been drilled, cast or forged with a reaming drill to enlarge the aperture and improve the processing quality of the hole. Reaming can be used either as a pre-processing before finishing the hole or as the final processing of the hole with low requirements. Reaming drill is similar to twist drill, but has more teeth and no cross edge.
Compared with drilling, reaming has the following characteristics:
(1) the number of reaming drill teeth (3~8 teeth), good guidance, cutting is relatively stable; (2) reaming drill without cross edge, cutting conditions are good;
(3) The processing allowance is small, the chip sink can be made shallower, the drill core can be made thicker, and the tool body strength and rigidity are better. The precision of reaming is generally IT11~IT10, and the surface roughness Ra is 12.5~6.3μm. Reaming is often used to process holes with smaller diameters. When drilling a large diameter hole (D ≥30mm), often use a small drill bit (diameter of 0.5 to 0.7 times of the aperture) to pre-drill, and then use the corresponding size of the hole reaming drill, which can improve the processing quality and production efficiency of the hole.
In addition to processing cylindrical holes, reaming drills of various special shapes (also known as countersinks) can be used to process various countersunk seat holes and countersinks. The front face of the countersink is often equipped with a guide post, guided by a machined hole.
Reaming
Reaming is one of the finishing methods of holes, which is widely used in production. For smaller holes, reaming is a more economical and practical machining method than internal grinding and fine boring.
1. Reamer
Reamer is generally divided into two kinds of hand reamer and machine reamer. The handle part of the hand reamer is straight handle, the working part is longer, and the guiding function is better. The hand reamer has two kinds of structures: integral and adjustable outside diameter. The machine reamer has two kinds of structure with handle and sleeve. The reamer can not only process round holes, but also taper reamer can process taper holes.
2. Reaming process and its application
Reaming allowance has a great influence on the quality of reaming, the allowance is too large, the load of the reamer is large, the cutting edge is soon blunted, it is not easy to obtain a smooth machining surface, and the dimensional tolerance is not easy to guarantee; The margin is too small to remove the knife marks left by the previous process, and naturally there is no role in improving the quality of hole processing. Generally, the margin of coarse hinge is 0.35~0.15mm, and the fine hinge is 01.5~0.05mm.
To avoid chip nodules, reaming is usually processed at a lower cutting speed (v <8m/min for steel and cast iron with HSS reamers). The value of feed is related to the aperture to be machined, the larger the aperture, the larger the feed value, the feed rate of high-speed steel reamer processing steel and cast iron is usually 0.3~1mm/r.
Reaming must be cooled, lubricated and cleaned with appropriate cutting fluid to prevent chip buildup and remove chips in time. Compared with grinding and boring, the reaming productivity is higher and the accuracy of the hole is easily guaranteed. However, reaming can not correct the position error of the hole axis, and the position accuracy of the hole should be guaranteed by the previous process. Reaming is not suitable for processing step holes and blind holes.
The dimensional accuracy of reaming is generally IT9 ~ IT7, and the surface roughness Ra is generally 3.2~ 0.8μm. For medium-size holes with high precision requirements (such as IT7 precision holes), the driller - reamer - reamer process is a typical processing scheme commonly used in production.
Boring
Boring is a machining method in which the prefabricated hole is enlarged with a cutting tool. The boring work can be carried out either on the boring machine or on the lathe.
1. Boring method
There are three different machining methods for boring.
(1) The workpiece rotates and the tool makes feed movement
Boring on the lathe mostly belongs to this boring method. The characteristics of the process are: the axis line of the hole after processing is consistent with the rotation axis of the workpiece, the roundness of the hole mainly depends on the rotation accuracy of the machine tool spindle, and the axial geometry error of the hole mainly depends on the position accuracy of the tool feed direction relative to the rotation axis of the workpiece. This boring method is suitable for machining holes with coaxial requirements on the surface of the outer circle.
(2) The tool rotates and the workpiece is fed
The boring machine spindle drives the boring tool to rotate, and the table drives the workpiece to feed.
(3) The tool rotates and makes feed motion
Using this kind of boring boring method, the overhanging length of the boring bar is changed, the force deformation of the boring bar is also changed, the aperture near the headstock is large, and the aperture away from the headstock is small, forming a cone hole. In addition, with the increase of the overhang length of the boring bar, the bending deformation of the main shaft caused by its own weight also increases, and the axis of the machined hole will have a corresponding bending. This boring method is only suitable for machining short holes.
2. Diamond boring
Compared with general boring, diamond boring is characterized by a small amount of back cutting, small feed, high cutting speed, it can obtain a high processing accuracy (IT7 ~ IT6) and a very smooth surface (Ra is 0.4~ 0.05μm). Diamond boring was originally processed with diamond boring tools, and is now commonly processed with cemented carbide, CBN and artificial diamond tools. Mainly used for processing non-ferrous metal workpieces, can also be used for processing cast iron and steel parts.
The commonly used cutting parameters of diamond boring are: pre-boring of 0.2~0.6mm and final boring of 0.1mm; The feed rate is 0.01~0.14mm/r; The cutting speed is 100~250m/min when processing cast iron, 150~300m/min when processing steel, and 300~2000m/min when processing non-ferrous metals.
In order to ensure that the diamond boring machine can achieve high machining accuracy and surface quality, the machine tool (diamond boring machine) must have high geometric accuracy and stiffness, the main shaft of the machine tool supports the commonly used precision angular contact ball bearing or static pressure plain bearing, and the high-speed rotating parts must be accurately balanced; In addition, the movement of the feed mechanism must be very smooth to ensure that the table can do smooth low-speed feed movement.
The machining quality of diamond boring is good, the production efficiency is high, and it is widely used in the final processing of precision holes in a large number of mass production, such as the engine cylinder hole, the piston pin hole, the main shaft hole on the spindle box of the machine tool. However, it should be noted that when machining ferrous metal products with diamond boring, only the boring tool made of cemented carbide and CBN can be used, and the boring tool made of diamond can not be used, because the carbon atoms in diamond have a large affinity with the iron group elements, and the tool life is low.
3. Boring tool
Boring tool can be divided into single-edge boring tool and double-edge boring tool.
4. Boring process characteristics and application range
Compared with the drilling, expanding and reaming process, the bore size is not limited by the tool size, and the boring has a strong error correction ability, and the deviation error of the original hole axis can be corrected by multiple cutting, and the boring can maintain a higher position accuracy with the positioning surface.
Compared with the outer circle of the boring, due to the poor rigidity of the tool bar system, large deformation, poor heat dissipation and chip removal conditions, the hot deformation of the workpiece and the tool is relatively large, and the processing quality and production efficiency of the boring are not as high as the outer circle of the car.
In summary, it can be seen that the processing range of boring is wide, and holes of different sizes and different precision levels can be processed. For holes and hole systems with large aperture, high size and position accuracy requirements, boring is almost the only processing method. The machining accuracy of boring is IT9 ~ IT7. Boring can be carried out on the boring machine, lathe, milling machine and other machine tools, which has the advantages of flexibility and flexibility, and is widely used in production. In mass production, boring die is often used to improve boring efficiency.
Honing hole
1. Honing principle and honing head
Honing is the method of finishing the hole by using a honing head with a grinding rod (whetstone). When honing, the workpiece is fixed, and the honing head is rotated by the spindle of the machine tool and moves in a reciprocating straight line. In honing processing, the grinding strip acts on the workpiece surface with a certain pressure, and cuts an extremely thin layer of material from the workpiece surface. In order to make the movement of the abrasive particle not repeat, the number of revolutions per minute of the turning movement of the honing head and the number of reciprocating strokes per minute of the honing head should be prime.
The cross Angle of the honing track is related to the reciprocating speed and circular speed of the honing head, and the size of the Angle affects the processing quality and efficiency of the honing. In order to facilitate the discharge of broken abrasive particles and chips, reduce the cutting temperature and improve the processing quality, sufficient cutting fluid should be used when honing.
In order to make the machined hole wall can be uniformly machined, the stroke of the sand bar at both ends of the hole must exceed a section of overpass. In order to ensure the uniform honing allowance and reduce the influence of the spindle rotation error on the machining accuracy, the floating connection between the honing head and the spindle of the machine tool is mostly adopted.
The radial expansion adjustment of honing head grinding rod has various structural forms such as manual, pneumatic and hydraulic.
2. Honing process characteristics and application range
(1) honing can obtain higher dimensional accuracy and shape accuracy, the processing accuracy is IT7~IT6, the roundness and cylindricity error of the hole can be controlled within the range, but honing can not improve the position accuracy of the hole to be machined.
(2) Honing can obtain a higher surface quality, the surface roughness Ra is 0.2~0.25μm, the surface metal metamorphic defect layer depth is very small 2.5~25μm.
(3) Compared with the grinding speed, the circular speed of the honing head is not high (vc=16~60m/min), but due to the large contact area between the sand bar and the workpiece, the reciprocating speed is relatively high (va=8~20m/min), so the honing still has a high productivity.
Honing is widely used in the machining of engine cylinder holes and precision holes in various hydraulic devices in a large number of mass production, and can process deep holes with a length-diameter ratio greater than 10. However, honing is not suitable for processing holes on non-ferrous metal workpieces with large plasticity, nor can it process holes with keyways, spline holes, etc.
Lacon
1. Broach and broach
Drawing is a high productivity finishing method, which is carried out on a broaching machine with a special broach. Broaching machine divided into horizontal broaching machine and vertical broaching machine two kinds, the horizontal broaching machine is the most common.
Broaching only uses low-speed linear motion (main motion). The number of teeth of the broach working at the same time should generally be not less than 3, otherwise the broach is not stable, and it is easy to produce ring ripples on the surface of the workpiece. In order to avoid generating too much broaching force and causing the broach to break, the number of teeth of the broach working at the same time should not exceed 6 to 8.
There are three different broaching methods, which are described as follows:
(1) Layered broaching
This broaching method is characterized by the broach cutting the workpiece machining allowance layer by layer in sequence. In order to facilitate chip breaking, the cutter teeth are ground with interleaved chip grooves. The broach designed according to the layered broaching method is called the ordinary broach.
(2) block broaching
The characteristic of this broaching method is that each layer of metal on the machined surface is cut by a set of tool teeth that are basically the same size but interlaced with each other (usually each set consists of 2-3 tool teeth). Each tooth cuts only part of a layer of metal. Broach designed according to the block broach method is called rotary broach.
(3) Comprehensive broaching
In this way, the advantages of layering and block broaching are concentrated. Block broaching is used in the rough cutting part and layer broaching is used in the fine cutting part. In this way, the broach length can be shortened, productivity can be increased, and better surface quality can be obtained. The broach designed according to the comprehensive broach method is called the comprehensive broach.
2. Process characteristics and application range of drawing holes
(1) The broach is a multi-edge tool, which can finish the roughing, finishing and finishing of the hole in a sequence in one broaching stroke, and has high production efficiency.
(2) The drawing accuracy mainly depends on the accuracy of the broach, under normal conditions, the drawing accuracy can reach IT9~IT7, and the surface roughness Ra can reach 6.3~ 1.6μm.
(3) When drawing a hole, the workpiece is positioned by the machined hole itself (the leading part of the broach is the positioning element of the workpiece), and the drawing hole is not easy to ensure the mutual position accuracy of the hole and other surfaces; For the processing of rotary parts whose inner and outer circular surfaces have coaxial requirements, it is often necessary to first pull holes, and then process other surfaces with holes as the positioning reference.
(4) broach can not only process round holes, but also process forming holes and spline holes.
(5) broach is a fixed size tool, complex shape, expensive, not suitable for processing large holes.
Drawing holes are commonly used in a large number of mass production to process holes on small and medium-sized parts with a diameter of 10~80mm and a hole depth of not more than 5 times the aperture.
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The hole is an important surface on the box, bracket, sleeve, ring, and disk parts, and it is also a surface often encountered in machining. In the case of the same processing accuracy and surface roughness requirements, it is difficult to process the hole than the outer round surface, low productivity and high cost.
This is because: 1) the size of the tool used in hole processing is limited by the size of the hole being processed, and the rigidity is poor, which is easy to produce bending deformation and vibration; 2) When machining the hole with a fixed-size tool, the size of the hole processing often directly depends on the corresponding size of the tool, and the manufacturing error and wear of the tool will directly affect the processing accuracy of the hole; 3) When machining holes, the cutting area is inside the workpiece, the chip removal and heat dissipation conditions are poor, and the processing accuracy and surface quality are not easy to control.
Drilling and reaming
Drilling
Drilling is the first process of machining holes on solid materials, and the diameter of the drilling hole is generally less than 80mm. There are two ways of drilling: one is the bit rotation; The other is workpiece rotation. The error generated by the above two drilling methods is not the same, in the drilling method of the bit rotation, due to the asymmetry of the cutting edge and the insufficient rigidity of the bit and the bit deflection, the center line of the hole will be skewed or not straight, but the aperture is basically unchanged; On the contrary, in the drilling method of workpiece rotation, the bit deflection will cause the aperture to change, but the center line of the hole is still straight.
Commonly used drilling knives have: twist drill, center drill, deep hole drill, etc., of which the most commonly used is twist drill, its diameter specification is Φ0.1-80mm.
Due to structural limitations, the bending stiffness and torsional rigidity of the drill bit are low, coupled with poor centering, the drilling accuracy is low, generally only IT13 ~ IT11; The surface roughness is also large, Ra is generally 50~12.5μm; However, the metal removal rate of drilling is large and the cutting efficiency is high. Drilling is mainly used for processing holes with low quality requirements, such as bolt holes, thread bottom holes, oil holes, etc. For holes with high machining accuracy and surface quality requirements, they should be achieved by reaming, reaming, boring or grinding in subsequent processing.
Reaming
Reaming is to further process the hole that has been drilled, cast or forged with a reaming drill to enlarge the aperture and improve the processing quality of the hole. Reaming can be used either as a pre-processing before finishing the hole or as the final processing of the hole with low requirements. Reaming drill is similar to twist drill, but has more teeth and no cross edge.
Compared with drilling, reaming has the following characteristics:
(1) the number of reaming drill teeth (3~8 teeth), good guidance, cutting is relatively stable; (2) reaming drill without cross edge, cutting conditions are good;
(3) The processing allowance is small, the chip sink can be made shallower, the drill core can be made thicker, and the tool body strength and rigidity are better. The precision of reaming is generally IT11~IT10, and the surface roughness Ra is 12.5~6.3μm. Reaming is often used to process holes with smaller diameters. When drilling a large diameter hole (D ≥30mm), often use a small drill bit (diameter of 0.5 to 0.7 times of the aperture) to pre-drill, and then use the corresponding size of the hole reaming drill, which can improve the processing quality and production efficiency of the hole.
In addition to processing cylindrical holes, reaming drills of various special shapes (also known as countersinks) can be used to process various countersunk seat holes and countersinks. The front face of the countersink is often equipped with a guide post, guided by a machined hole.
Reaming
Reaming is one of the finishing methods of holes, which is widely used in production. For smaller holes, reaming is a more economical and practical machining method than internal grinding and fine boring.
1. Reamer
Reamer is generally divided into two kinds of hand reamer and machine reamer. The handle part of the hand reamer is straight handle, the working part is longer, and the guiding function is better. The hand reamer has two kinds of structures: integral and adjustable outside diameter. The machine reamer has two kinds of structure with handle and sleeve. The reamer can not only process round holes, but also taper reamer can process taper holes.
2. Reaming process and its application
Reaming allowance has a great influence on the quality of reaming, the allowance is too large, the load of the reamer is large, the cutting edge is soon blunted, it is not easy to obtain a smooth machining surface, and the dimensional tolerance is not easy to guarantee; The margin is too small to remove the knife marks left by the previous process, and naturally there is no role in improving the quality of hole processing. Generally, the margin of coarse hinge is 0.35~0.15mm, and the fine hinge is 01.5~0.05mm.
To avoid chip nodules, reaming is usually processed at a lower cutting speed (v <8m/min for steel and cast iron with HSS reamers). The value of feed is related to the aperture to be machined, the larger the aperture, the larger the feed value, the feed rate of high-speed steel reamer processing steel and cast iron is usually 0.3~1mm/r.
Reaming must be cooled, lubricated and cleaned with appropriate cutting fluid to prevent chip buildup and remove chips in time. Compared with grinding and boring, the reaming productivity is higher and the accuracy of the hole is easily guaranteed. However, reaming can not correct the position error of the hole axis, and the position accuracy of the hole should be guaranteed by the previous process. Reaming is not suitable for processing step holes and blind holes.
The dimensional accuracy of reaming is generally IT9 ~ IT7, and the surface roughness Ra is generally 3.2~ 0.8μm. For medium-size holes with high precision requirements (such as IT7 precision holes), the driller - reamer - reamer process is a typical processing scheme commonly used in production.
Boring
Boring is a machining method in which the prefabricated hole is enlarged with a cutting tool. The boring work can be carried out either on the boring machine or on the lathe.
1. Boring method
There are three different machining methods for boring.
(1) The workpiece rotates and the tool makes feed movement
Boring on the lathe mostly belongs to this boring method. The characteristics of the process are: the axis line of the hole after processing is consistent with the rotation axis of the workpiece, the roundness of the hole mainly depends on the rotation accuracy of the machine tool spindle, and the axial geometry error of the hole mainly depends on the position accuracy of the tool feed direction relative to the rotation axis of the workpiece. This boring method is suitable for machining holes with coaxial requirements on the surface of the outer circle.
(2) The tool rotates and the workpiece is fed
The boring machine spindle drives the boring tool to rotate, and the table drives the workpiece to feed.
(3) The tool rotates and makes feed motion
Using this kind of boring boring method, the overhanging length of the boring bar is changed, the force deformation of the boring bar is also changed, the aperture near the headstock is large, and the aperture away from the headstock is small, forming a cone hole. In addition, with the increase of the overhang length of the boring bar, the bending deformation of the main shaft caused by its own weight also increases, and the axis of the machined hole will have a corresponding bending. This boring method is only suitable for machining short holes.
2. Diamond boring
Compared with general boring, diamond boring is characterized by a small amount of back cutting, small feed, high cutting speed, it can obtain a high processing accuracy (IT7 ~ IT6) and a very smooth surface (Ra is 0.4~ 0.05μm). Diamond boring was originally processed with diamond boring tools, and is now commonly processed with cemented carbide, CBN and artificial diamond tools. Mainly used for processing non-ferrous metal workpieces, can also be used for processing cast iron and steel parts.
The commonly used cutting parameters of diamond boring are: pre-boring of 0.2~0.6mm and final boring of 0.1mm; The feed rate is 0.01~0.14mm/r; The cutting speed is 100~250m/min when processing cast iron, 150~300m/min when processing steel, and 300~2000m/min when processing non-ferrous metals.
In order to ensure that the diamond boring machine can achieve high machining accuracy and surface quality, the machine tool (diamond boring machine) must have high geometric accuracy and stiffness, the main shaft of the machine tool supports the commonly used precision angular contact ball bearing or static pressure plain bearing, and the high-speed rotating parts must be accurately balanced; In addition, the movement of the feed mechanism must be very smooth to ensure that the table can do smooth low-speed feed movement.
The machining quality of diamond boring is good, the production efficiency is high, and it is widely used in the final processing of precision holes in a large number of mass production, such as the engine cylinder hole, the piston pin hole, the main shaft hole on the spindle box of the machine tool. However, it should be noted that when machining ferrous metal products with diamond boring, only the boring tool made of cemented carbide and CBN can be used, and the boring tool made of diamond can not be used, because the carbon atoms in diamond have a large affinity with the iron group elements, and the tool life is low.
3. Boring tool
Boring tool can be divided into single-edge boring tool and double-edge boring tool.
4. Boring process characteristics and application range
Compared with the drilling, expanding and reaming process, the bore size is not limited by the tool size, and the boring has a strong error correction ability, and the deviation error of the original hole axis can be corrected by multiple cutting, and the boring can maintain a higher position accuracy with the positioning surface.
Compared with the outer circle of the boring, due to the poor rigidity of the tool bar system, large deformation, poor heat dissipation and chip removal conditions, the hot deformation of the workpiece and the tool is relatively large, and the processing quality and production efficiency of the boring are not as high as the outer circle of the car.
In summary, it can be seen that the processing range of boring is wide, and holes of different sizes and different precision levels can be processed. For holes and hole systems with large aperture, high size and position accuracy requirements, boring is almost the only processing method. The machining accuracy of boring is IT9 ~ IT7. Boring can be carried out on the boring machine, lathe, milling machine and other machine tools, which has the advantages of flexibility and flexibility, and is widely used in production. In mass production, boring die is often used to improve boring efficiency.
Honing hole
1. Honing principle and honing head
Honing is the method of finishing the hole by using a honing head with a grinding rod (whetstone). When honing, the workpiece is fixed, and the honing head is rotated by the spindle of the machine tool and moves in a reciprocating straight line. In honing processing, the grinding strip acts on the workpiece surface with a certain pressure, and cuts an extremely thin layer of material from the workpiece surface. In order to make the movement of the abrasive particle not repeat, the number of revolutions per minute of the turning movement of the honing head and the number of reciprocating strokes per minute of the honing head should be prime.
The cross Angle of the honing track is related to the reciprocating speed and circular speed of the honing head, and the size of the Angle affects the processing quality and efficiency of the honing. In order to facilitate the discharge of broken abrasive particles and chips, reduce the cutting temperature and improve the processing quality, sufficient cutting fluid should be used when honing.
In order to make the machined hole wall can be uniformly machined, the stroke of the sand bar at both ends of the hole must exceed a section of overpass. In order to ensure the uniform honing allowance and reduce the influence of the spindle rotation error on the machining accuracy, the floating connection between the honing head and the spindle of the machine tool is mostly adopted.
The radial expansion adjustment of honing head grinding rod has various structural forms such as manual, pneumatic and hydraulic.
2. Honing process characteristics and application range
(1) honing can obtain higher dimensional accuracy and shape accuracy, the processing accuracy is IT7~IT6, the roundness and cylindricity error of the hole can be controlled within the range, but honing can not improve the position accuracy of the hole to be machined.
(2) Honing can obtain a higher surface quality, the surface roughness Ra is 0.2~0.25μm, the surface metal metamorphic defect layer depth is very small 2.5~25μm.
(3) Compared with the grinding speed, the circular speed of the honing head is not high (vc=16~60m/min), but due to the large contact area between the sand bar and the workpiece, the reciprocating speed is relatively high (va=8~20m/min), so the honing still has a high productivity.
Honing is widely used in the machining of engine cylinder holes and precision holes in various hydraulic devices in a large number of mass production, and can process deep holes with a length-diameter ratio greater than 10. However, honing is not suitable for processing holes on non-ferrous metal workpieces with large plasticity, nor can it process holes with keyways, spline holes, etc.
Lacon
1. Broach and broach
Drawing is a high productivity finishing method, which is carried out on a broaching machine with a special broach. Broaching machine divided into horizontal broaching machine and vertical broaching machine two kinds, the horizontal broaching machine is the most common.
Broaching only uses low-speed linear motion (main motion). The number of teeth of the broach working at the same time should generally be not less than 3, otherwise the broach is not stable, and it is easy to produce ring ripples on the surface of the workpiece. In order to avoid generating too much broaching force and causing the broach to break, the number of teeth of the broach working at the same time should not exceed 6 to 8.
There are three different broaching methods, which are described as follows:
(1) Layered broaching
This broaching method is characterized by the broach cutting the workpiece machining allowance layer by layer in sequence. In order to facilitate chip breaking, the cutter teeth are ground with interleaved chip grooves. The broach designed according to the layered broaching method is called the ordinary broach.
(2) block broaching
The characteristic of this broaching method is that each layer of metal on the machined surface is cut by a set of tool teeth that are basically the same size but interlaced with each other (usually each set consists of 2-3 tool teeth). Each tooth cuts only part of a layer of metal. Broach designed according to the block broach method is called rotary broach.
(3) Comprehensive broaching
In this way, the advantages of layering and block broaching are concentrated. Block broaching is used in the rough cutting part and layer broaching is used in the fine cutting part. In this way, the broach length can be shortened, productivity can be increased, and better surface quality can be obtained. The broach designed according to the comprehensive broach method is called the comprehensive broach.
2. Process characteristics and application range of drawing holes
(1) The broach is a multi-edge tool, which can finish the roughing, finishing and finishing of the hole in a sequence in one broaching stroke, and has high production efficiency.
(2) The drawing accuracy mainly depends on the accuracy of the broach, under normal conditions, the drawing accuracy can reach IT9~IT7, and the surface roughness Ra can reach 6.3~ 1.6μm.
(3) When drawing a hole, the workpiece is positioned by the machined hole itself (the leading part of the broach is the positioning element of the workpiece), and the drawing hole is not easy to ensure the mutual position accuracy of the hole and other surfaces; For the processing of rotary parts whose inner and outer circular surfaces have coaxial requirements, it is often necessary to first pull holes, and then process other surfaces with holes as the positioning reference.
(4) broach can not only process round holes, but also process forming holes and spline holes.
(5) broach is a fixed size tool, complex shape, expensive, not suitable for processing large holes.
Drawing holes are commonly used in a large number of mass production to process holes on small and medium-sized parts with a diameter of 10~80mm and a hole depth of not more than 5 times the aperture.
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