Guide to Shop Cnc Plastic Turning Parts in HONSCN

"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!

At least 25 per cent of the plastics used in new Volvo car models from 2025 will be from recycled materials, the Chinese-owned company said on Monday in an anti-pollution plan praised by the United Nations.Recycled plastics - such as from fishing nets or old bottles in car dashboards or carpets, would not affect safety or quality, Stuart Templar, director for sustainability at Volvo Cars, told Reuters."We think this makes business sense," he said.Environmentalists 'encouraged' by G7 plastics charter but urge more actionMany big companies are designing products that can be recycled after use to limit pollution. Volvo's plan goes a step further by building ever more recycled materials into its production lines."Volvo Cars is committed to minimising its global environmental footprint," Hkan Samuelsson, president and CEO of Volvo Cars, which is owned by China's Zhejiang Geely Holding Group Co Ltd, said in a statement.Volvo said it was in talks with plastics producers to achieve its "ambition that from 2025, at least 25 per cent of the plastics used in every newly launched Volvo car will be made from recycled material."Volvo sold 570,000 cars last year, with about five per cent of plastics in its cars currently made from recycled materials.Volvo unveiled a test model of its XC60 T8 plug-in hybrid SUV in Gothenburg, Sweden, that it said looks identical to the existing car except that some of its plastic parts were made from recycled materials.Industry wants zero plastic packaging in Canada's landfills by 2040The carpet, for instance, had fibres made from PET plastic bottles, old Volvo car seats were used in sound-absorbing material under the bonnet and fishing nets and ropes were used in the tunnel console - between the passenger and driver seats.The United Nations welcomed Volvo's plan. More than eight million tonnes of plastics end up in the oceans every year, threatening marine life from fish stocks to coral reefs."As far as we are aware this is a first an attempt to source waste as a raw material for a new vehicle," Erik Solheim, head of the UN Environment Programme in Nairobi, told Reuters."We need to see a situation in which plastic waste begins to have more value and the processes to transform it into something new will also advance," he said.'We need to rethink the entire plastics industry': Why banning plastic straws isn't enoughIn 2017, Volvo said that it would electrify all new cars launched after 2019. Last month it said its aim was that fully electric cars would make up half of its global sales by 2025.

Seven diverse wood products application reflect the diverse capabilities of CNC machining centers.
For a machine that not so long ago did not even exist, the uses for CNC machining centers have quickly become vast and continue to grow.
Woodworkers today are using these versatile machines for a variety of uses ranging from high-speed, flat-panel production work to very intricate carvings. Combining high speed boring with routing, profiling, cutting and other features, these computer-controlled marvels are being successfully utilized in shops that produce everything from beautiful high-end architectural woodwork to flanges for take up reels.
In the following pages, WOOD & WOOD PRODUCTS interviews woodworkers from around the country who have increased their productivity and accuracy while reducing labor costs through investments in CNC technology. Following are their stories.
SPEAKER MAKER USES CNC MACHINERY TO MAKE IT'S DIVERSE PRODUCT As an OEM supplier of audio speakers, the products that Tiffin, Ohio-based Ameriwood Industries International Inc. manufactures vary in size from small bookshelf-size speakers to large symphonic speakers.
Jim Harrington, plant manager of Ameriwood, said, "We do a variety of sizes and styles. We work with different types of materials, with different thicknesses and locations of holes. No two things are alike." Because of this product diversity, Ameriwood Industries (formerly Tiffin Enterprises) used to perform multiple machining operations for every item. Multiple operations meant that several workers had to handle each part, "and the more you handle it, the more opportunity there is for the product to be damaged," Harrington said.
To minimize parts handling -- and thus reduce their labor costs -- the company made an investment in a CNC machining center from Roger Stiles & Associates.
MACHINING CENTERS Vinyl overlayed particleboard is trimmed, cut-to-size, drilled and routed on the machining center. Computer programs are downloaded from a computer system directly into the machine's controller.
"We used CNC routers for a number of years," Harrington said. "The machining center is taking the place of routing and vertical-type drills." The machining center allows the company to do up to 12 workpieces at a time, Harrington said. After all the machining operations have been completed it is a "totally finished part" without need of further machining, Harrington added.
EFFICIENT PLANT HELPS COMPANY CONTROL COSTS In the past two years, Warvel Products-North Carolina has experienced dramatic price increases for the raw materials used to produce curved plywood components. These components are then sold to contract furniture manufacturers such as Haworth.
"We had 30 percent increases in our raw material costs," said sales manager Robbie Wiltcher, "so we have improved plant efficiency by purchasing machinery and technology that would allow us to absorb as much (of the price increase) as possible without passing these costs on. It is important for us as a vendor to help our customers be as competitive in their markets as possible." One of the ways Warvel did this was through the purchase of a multiple-station, four-axis CNC machining center from C.M.S North America. The machining center allows the company to mount up to six components at a time, and complements the company's existing three and five axis machining centers, Wiltcher said.
This is important, considering the amount of product which is shipped from the company's plant in Linwood, N.C. Approximately 100,000 parts a month are produced at the facility, the majority of which are customized. The company has a catalog with standard components, but Wiltcher said that 80 percent of the company's orders are made per customers specifications.
"The machine is capable of multiple machining tasks," Wiltcher said. "In most cases all that's left to do is light sanding and tee-nut installation where required." Another benefit, Wiltcher added, is the very tight tolerances obtained with the machine. The company supplies curved plywood which must integrate with plastic and steel components in ergonomic chairs.
"It is essential to be able to maintain tight tolerances in the various required operations such as drilling on angles, profiling and notching so that all of the different chair components fit together the way they were engineered. This machine provides all of these things," Wiltcher said.
To increase productivity even further, the company purchased machines and software that complement the machining center, including a digitizing machine. The digitizer will read a template part and the software will create a program which is downloaded into the machining center. The company also uses the system to internally produce its own compound tooling.
"The system has reduced the lead time on new tooling from months to days," said Wiltcher. "All of these capabilities assists our customers in bringing many new products to market rapidly and competitively." HIGH-TECH HELPS HIGH-END ARCHITECTURAL FIRM Powell Cabinet & Fixtures of Sparks, Nev., is a high-end architectural woodworking company whose work ranges from luxurious residences to glistening casinos.
The 42-year-old company, which bills itself as the oldest architectural woodworking company in the state of Nevada, is owned by the father/son team of Roger and Bill Powell.
One of the company's most recent projects was for the new Luxor Casino and Hotel in Las Vegas. The company did a variety of work at the hotel, including a 3 1/2-inch thick, 13-inch wide, solid-mahogany handrail that was built on a 255-foot radius. The handrail also featured solid-cast bronze support pieces and etched glass.
The handrail was manufactured utilizing a Komo VR 512 CNC machining center the company got in January 1993. Prior to that, the company had been doing everything with multiple machines. "The machining center is exceptional on irregular shapes and curves," Bill Powell said.
"It is more adaptable than to have a journeyman do it by hand. The radius work takes more time to program, but instead of having a journeyman woodworker spend several days on something, the machine will produce the same product in significantly less time." Powell added that there is a learning curve to the machine. "The purchase of the machine is just the first step," Powell said.
"The time that it takes to learn how to program and operate it is a major expense, as is the tooling and all the programming updates that are needed to keep up-to-speed." But while these factors need to be taken into account, Powell said he thinks it is becoming essential for companies to invest in high-technology equipment. According to Powell, one of the reasons the company purchased the machining center was because "the quantity of qualified, journeyman cabinetmakers that can produce this type of work is diminishing. You have to rely on the technical aspects of the industry to help fill that void," he said.
COMPANY GROWS A STEP AT A TIME When Denny Beuter and Bob Bloss formed Diamond Cut Inc. eight years ago they had a plan. The two men wanted their South Bend, Ind.-based company to become a leader in the field of commercial sound equipment. A daunting task made all the more difficult considering they did not own any sophisticated equipment.
"We went on the premise that we needed extremely good equipment to make a really good product," said Beuter. "But in order to get good equipment you have to have a product with enough volume to keep the machine running." What Beuter and Bloss did was to start slowly, acquiring equipment and producing parts for other companies. "We would do cutting and edging, anything to get work into the plant," Beuter said. "To sell machine time you have to do everything a little bit better than what the (source) companies can do in their own shop. We got real good, real fast, because otherwise we had to eat the cost of the job." From doing this job-shop-type-work, the next step was doing contract work. "My partner (Bloss), whose background is in the speaker business, went out (to speaker companies) and said, 'We can make speakers boxes for you and we can do them with high precision,'" Beuter said.
Diamond Cut began producing speaker cabinets for such companies as JBL and Panasonic. The product Panasonic wanted the company to produce necessitated an equipment upgrade. "The Panasonic people wanted a (speaker) box that was trapezoid shape," Beuter said. "This product would have been almost impossible to make with the router we were using." Beuter and Bloss chose a U-26 Morbidelli machining center from Tekna Machinery. The machine not only allows them to produce the trapezoidal shapes, it also has reduced labor costs. "For example, we had one full-time worker on the payroll whose only job was to make jigs, Beuter said. "I have no more jigs." While Diamond Cut has grown, with sales projected to reach around $2 million in 1994, the company continues to move toward that plan. In 1993, the company started a proprietary line of heavy-duty commercial sound equipment under the moniker, Bull Frog.
The Bull Frog equipment is sold throughout the United States and a number of countries around the world. "For 24-hours a day, for the last three months, we have been so busy with our own proprietary work that we have not been able to do any outside work, Beuter said.
"Hopefully by the end of the year we will be completely out of contract work." BOOTH MAKER FINDS SIGN TO SUCCESS Utilizing a variety of materials, Farmington Displays of Farmington, Conn., creates trade show displays for companies in industries as diverse as food, computers and guns.
Farmington Displays, which was founded in 1973 by Paul DiTommaso Sr., counts 278 companies as its clients. On average, Farmington Displays' clients update their booths every three to five years.
"We have a pretty good job flow," said general manager Sal DiTommaso, son of Paul Sr. and one of three sons and a daughter currently working for the company. "Not everybody is building their booth at the same time." Farmington Displays boasts an impressive client list, including General Electric, NEC and gun manufacturer Smith & Wesson. In the traditionally very labor-intensive field of display manufacturing, the company stands out for its use of high-technology equipment. More than three years ago, after extensive research on available machinery, the company began its investment in CNC machinery.
"The first thing that sparked my interest in obtaining CNC machinery was watching one of my men cutting out an eight-foot circle," said Sal DiTommaso. "It was so archaic, I just said there had to be another way to do it." Farmington Display's plant now features two Heian CNC routers and a computerized panel saw from Stiles Machinery, as well as a computerized graphic/design laboratories linked together as a Local Area Network.
The Heian machining centers have allowed the company to branch out into areas such as manufacturing signage and store fixtures. Farmington Displays had always created graphics for signs, but the CNC routers allow the company to manufacture them in-house. Additionally, the company is now doing contract machining for other, non-competing manufacturers.
To create their distinctive products, the company utilizes a variety of materials. On its CNC routers, the company utilizes everything from acrylics to solid woods. On a separate metal machining center the company works with brass and other metallic alloys. "We don't farm anything out," DiTommaso said. "We try to keep everything in-house so that we have complete quality control over the finished product." FAMILY-OWNED LUMBER YARD SEIZES CHANCE TO DIVERSIFY ITS BUSINESS In 1922, Hans Lars founded Hansen Lumber in Galesburg, Ill. Over the next 70 or so years, the business would be handed down from family-member to family-member, and would remain a traditional lumber yard.
It remained solely a lumber yard until two years ago when Hansen Lumber seized an opportunity to diversify. The company was asked to do some circular panel cutting for a Galesburg-based manufacturer of wooden reels. Approximately a year later that manufacturer, who believed the reel industry was going to dominated by the use of plastics, first contemplated shuttering the facility and then offered to sell the business -- and its client list -- to Hansen Lumber.
The family-owned company, currently being run by Shard Hansen, the founder's grandson, with help from his daughter Karen (the fourth-generation family member in the business), decided to purchase the company, and quickly realized the need to upgrade its equipment.
"Taking up wire or rope around a reel must be done at very high feed rates, especially if it is a small diameter wire, because unless your doing it at a 1,000 feel a minute it would take forever to wind," said Hansen, "so the arbor hole has to be exact. If the arbor hole is off center the whole thing will be jerking." A little more than a year ago the company purchased a CNC machining center from Accu-Router. The machine features two vertical routers, which can machine 1 1/2 inch southern yellow pine industrial grade plywood used for the flanges on the reels and maintains tight tolerances.
Prior to working with the machining center, the company would have to cut out a square and in subsequent steps radius the panel down to the required size and shape.
Having a high-technology machining center not only provides for accuracy, it also helps to utilize the plywood. "Our flanges range in size from eight inches to 48 inches round," said Hansen.
"When we are cutting the circles, we can nest them in such a fashion that we get great yield and waste is very nominal." CNC EQUIPMENT HELPS CARVING COMPANY MAKE BEAUTIFUL MUSIC Investing, not only in new equipment, but also in the training of its workforce has helped this Thomasville, N.C.-based carving company increase its capacity while reducing its overhead.
Founded in 1968, Piedmont Carving carves furniture parts -- specializing in chair parts -- and parts for such musical instruments as the cello and guitar.
Over the last few years, the company has sold some of its older carving machines and invested that money in computerized machinery including CNC Robot Carvers from Thermwood Corp.
"We used to have 13 carving machines and we would run all of them in one shift," said Gay Jones, who along with her twin brother Ray, and her father, company-founder Jimmy, own the business. "We sold three carving machines and still are projecting to triple our capacity with the robotic carvers." The company has reduced its labor costs in part by computerizing its carving, but also by cross training its 29 employees so that they can work on other machines in the shop.
Learning to efficiently use the CNC robot was a difficult challenge for the company, Gay Jones said, "but I'm glad we did because it gives us an advantage over companies who are just now getting into robotic carving." Piedmont Carving bought its first robotic carver four years ago. The company is planning to purchase additional machines.
One of the benefits of computerized machinery is consistency. This is important when Piedmont is crafting its furniture and musical instrument components.
"Chair parts have to fit together perfectly when they're sent to the manufacturer," Jones said. "With the robotic carving everything stays so consistent. This consistency is also very important when we are doing the musical instruments because the craftsmanship that goes into the part can affect the sound." CARVING WOOD PARTS 20 AT A TIME Intricate handcarvings are being quickly and accurately duplicated by Carving Research Inc. of Huntersville, N.C., using a 20-head Kitako CNC Machining Center distributed by Tekmatex Inc.
Carving Research is a 2-year-old, 12-employee company with projected 1994 sales of $840,000. The company supplies intricate wood carvings to such major residential furniture makers as Henredon Furniture Industries Inc. and Baker Furniture Co.
What once had to be done one at a time by master handcarvers can now be done 20 at a time by the company. This results not only in time savings but cost savings as well, without sacrificing the look of the product, according to company owner Tom Bowker. An example of the speed of the machine is a rice carved bed post; typically it would take a master handcarver approximately six to eight hours to complete, "while we can do it in an hour," Bowker said.
To produce the carvings, an initial handcarved template is made. This carving is sent to Tekmatex, where a digitizing machine creates a computer program which can be downloaded into the machining center. Once this program is completed, an infinite number of a given carving can be created with precision.
There are certain "essential ingredients" to creating the carvings, said Bowker. Tooling is one of the most important. Because of the nature of the product, the Carving Research utilizes unique tooling, including a razor-sharp veining bit developed by Oertli Woodworking Tools Inc. that leaves such a clean cut, that secondary carvings are not necessary, Bowker said. Another example is a 1/16-inch flat-bottom or straight router bit which is used on many of the carvings.
"Nobody else uses anything like that," Bowker said.
"Because of the intricacies of many of the carvings, we have to use a wider variety of tooling including some carbide tooling, than what you would use if running a normal carving operation. Many of our bits have to be small because you have to get in and do a cut and make it look like it was done with a chisel.

It is said that in the career of a machine tool worker, no matter how careful it is, it is impossible to avoid a knife collision accident.This has nothing to do with whether the worker is serious and practical and stable, just like a person can not avoid mistakes in the growth process, in the growth process of a machine tool worker, the knife seems to be a hurdle that cannot be bypassing.



Bumping tool, refers to the tool in the process of moving with the workpiece, chuck or tailstock accidental collision machine accident, is the most likely accident for CNC lathe operation novices.

Knife collision will cause workpiece scrap, tool damage, serious damage to the accuracy of the machine tool, destroy the machine parts, and even endanger the personal safety of the machine tool processing personnel.

The occurrence of knife collision accidents is mainly caused by programming errors in the programming process or workers' operational errors in the processing link.

For workers, the general programming link is not easy to make mistakes, and many people have knife collision accidents, often caused by mistakes in the process of machine tool operation.

Because the CNC machining center is locked by software, in the simulation processing, when the automatic operation button is pressed, it is not intuitive to see whether the machine is locked in the simulation interface.

There is often no tool in the simulation, and if the machine tool is not locked to run, it is easy to bump the knife.

Therefore, before the simulation processing should go to the running interface to confirm whether the machine is locked.



Why do CNC machining centers bump knives?


1. Forget to turn off the empty running switch during processing.

Because in the program simulation, in order to save time, the empty run switch is often turned on.

Empty operation means that all moving axes of the machine are running at the speed of G00.

If the operation switch is not turned off during the processing time, the machine tool ignores the given feed speed, and runs at the speed of G00, resulting in knife and machine tool accidents.

2. No reference point is returned after running the simulation empty.

In the verification program when the machine is locked motionless, and the tool relative to the workpiece processing in the simulation operation (absolute coordinates and relative coordinates change), then the coordinates do not match the actual position, must use the method of returning the reference point to ensure that the mechanical zero coordinates are consistent with the absolute and relative coordinates.

If the machining operation is carried out without finding the problem after the verification procedure, it will cause the collision of the tool.

3. The direction of overshoot release is not correct.

When the machine overruns, it should press and hold the overruns release button, and move in the opposite direction manually or by hand, that is, it can be eliminated.

However, if the direction of lifting is reversed, it will cause damage to the machine tool.

Because when the overrange release is pressed, the overrange protection of the machine tool will not work, and the stroke switch of the overrange protection is already at the end of the stroke.

At this time, it is possible to cause the workbench to continue to move in the direction of excess, and eventually pull the lead screw, causing damage to the machine tool.

4. The cursor position of the specified line is incorrect.

When a specified line is run, it is usually executed downward from the cursor position.

For the lathe, it is necessary to call the tool offset value of the tool used, if the tool is not called, the tool running the program segment may not be the desired tool, and it is very likely to cause a collision accident due to different tools.

Of course, in the machining center, CNC milling machine must first call the coordinate system such as G54 and the length compensation value of the knife.

Because the length compensation value of each knife is not the same, it is possible to cause knife collision if it is not called.



As a high-precision machine tool, anti-collision is very necessary, requiring the operator to develop the habit of being careful and careful, operating the machine tool according to the correct method, and reducing the occurrence of machine tool collision.

With the development of technology, advanced technologies such as tool damage detection, machine tool anti-impact detection, and machine tool adaptive processing have emerged during processing, which can better protect CNC machine tools.

There are 9 reasons for this:

(‍1) Programming error

The process arrangement is wrong, the process undertaking relationship is not carefully considered, and the parameter setting is wrong.

Example :

A. The coordinate is set to zero at the base, but the top is 0 in practice;

B. The safety height is too low, resulting in the tool can not completely lift out the workpiece;

C. The second opening margin is less than the previous knife;

D. After the program is written, the path of the program should be analyzed and checked;

(2) Program single remarks error

Example:

A. The number of unilateral touches is written in four sides;

B. The clamping distance of the vise or the protruding distance of the workpiece is wrong;

C. The extension length of the tool is unknown or wrong, resulting in knife collision;

D. Procedure sheet should be as detailed as possible;

E. The principle of new for old should be adopted when the procedure is changed:Destroy the old program.

(‍3) Tool measurement error

Example:

A. The tool bar is not considered in the tool data input;

B. The tool is too short;

C. Tool measurement should use scientific methods, as far as possible with more accurate instruments;

D. The length of the tool should be 2-5mm longer than the actual depth.

(4) Program transmission error

Program number call error or program modification, but still use the old program processing; The site processor must check the detailed data of the program before processing; For example, the time and date the program was written and simulated with bear.

(5) Wrong knife selection

(6) the blank exceeds expectations, and the blank is too large and does not conform to the blank set by the program

(7) The workpiece material itself has defects or high hardness

(8) clamping factors, pad interference and the procedure is not considered

(‍9) Machine tool failure, sudden power failure, lightning strike caused tool collision, etc

Honscn has more than ten years of cnc machining experience, specializing in cnc machining, hardware mechanical parts processing, automation equipment parts processing. Robot parts processing, UAV parts processing, bicycle parts processing, medical parts processing, etc. It is one of the high-quality suppliers of cnc machining. At present, the company has more than 20 sets of cnc machining centers, grinding machines, milling machines, high-quality high-precision testing equipment, to provide customers with precision and high-quality cnc spare parts processing services.

5-axis CNC machining is an advanced manufacturing process that adds two rotating axes (A, B or A, C) to the three linear axes (X, Y, Z). This type of processing has many advantages. It can realize the multi-sided machining of complex shape parts, greatly improve the machining accuracy and efficiency, and reduce the number of clamping and error. For parts with deep cavity, reverse buckle, complex surface and other features, 5-axis CNC machining can easily cope with. In the aerospace, automotive, mold and other industries, 5-axis CNC machining is widely used in the manufacture of high-precision key parts, such as engine impellers, aviation structural parts, automotive molds and so on.



How to optimize 5-axis cnc machining？




Here are some ways to optimize 5-axis CNC machining:


1. Tool path planning:


Efficient tool path algorithm to reduce empty travel and unnecessary tool movement.
Optimize the cutting and cutting mode of the tool, avoid sudden stop and turn, reduce tool wear and machine vibration.

2. Tool selection:


Select the appropriate tool material, geometry and size according to the machining material and process requirements.
Consider using multi-edge tools to improve cutting efficiency.

3. Cutting parameters optimization:


Precise setting of parameters such as cutting speed, feed speed and cutting depth to achieve the best cutting results and efficiency.
Combine tool and material characteristics to determine optimal parameters through testing and simulation.

4. Clamping method:


Ensure that the workpiece is firmly mounted, reducing displacement and vibration during machining.
The use of appropriate fixtures to improve clamping efficiency and accuracy.

5. Programming optimization:


Simplify programming code, reduce redundant instructions, and improve program execution efficiency.
Use macros and subroutines to improve programming flexibility and versatility.

6. Machine maintenance:


Regular maintenance and calibration of the machine to ensure the accuracy and performance of the machine.
Replace the worn parts in time to ensure the normal operation of the machine.

7. Processing sequence:


Reasonable arrangement of processing procedures, first rough processing, then semi-finishing and finishing.
Avoid repeated clamping and positioning errors.

8. Simulation and verification:


Perform tool path simulation before machining to check for interference and errors.
Verify the feasibility and rationality of the processing technology.

9. Personnel training:


Improve the skill level and process knowledge of the operators so that they can skillfully operate the machine and optimize the machining process.

10. Adopt advanced control system:


Upgrade the machine control system to support more advanced machining functions and optimization algorithms.

We can use the above methods to optimize 5-axis CNC machining according to the actual situation.





What factors should be considered to optimize 5-axis cnc machining?




Optimizing 5-axis CNC machining requires consideration of the following factors:




Workpiece design and geometry: including complexity, feature size and tolerance requirements, which affect machining strategy and tool path selection.


Material characteristics: the hardness, toughness, thermal conductivity and other properties of the material determine the selection of cutting parameters and tools.


Tool selection: The material, geometry, blade number, diameter, etc. of the tool should be matched with the processing task to ensure cutting efficiency and quality.


Cutting parameters: such as cutting speed, feed rate, cutting depth, etc., need to be optimized according to material and tool characteristics to improve processing efficiency and avoid excessive tool wear.


Machine tool performance: including the accuracy, rigidity, stroke, speed range of the machine tool, etc., to give full play to the advantages of the machine tool and avoid exceeding its capacity.


Clamping method: to ensure that the workpiece clamping is stable, accurate, and will not interfere with the processing, and to facilitate loading and unloading, improve production efficiency.


Tool path planning: Optimize the feed and retreat mode of the tool, reduce empty travel and unnecessary movement, and reduce processing time.


Cooling and lubrication: Suitable cooling and lubrication methods can reduce the cutting temperature, extend the tool life, and improve the surface quality.


Programming technology: Efficient and accurate programming code helps to reduce errors and improve machine operation efficiency.


Post-processing program: ensure that the generated CNC code can be executed accurately by the machine tool.


Processing sequence: reasonable arrangement of roughing, semi-finishing and finishing sequence to improve processing efficiency and ensure processing quality.


Processing cost: under the premise of ensuring quality, minimize tool loss, energy consumption and processing time to control costs.


Production batch: Batch size will affect the processing strategy and the selection of tooling fixtures.


Quality requirements: Strict surface roughness, dimensional accuracy and form and position tolerances require finer processing parameters and process control.


These factors are related to each other, and comprehensive consideration can achieve the optimization of 5-axis CNC machining.





What performance can be improved by optimizing 5-axis CNC machining?




Optimizing 5-axis CNC machining can significantly improve performance in the following areas:




Machining accuracy: Through more accurate tool path planning, optimized cutting parameters and good machine tool calibration, machining errors can be significantly reduced, and dimensional accuracy and form and position tolerance accuracy of parts can be improved.


Surface quality: Suitable tool selection, cutting parameter adjustment and effective cooling lubrication can obtain a smoother and lower roughness surface to meet higher surface quality requirements.


Processing efficiency: reducing empty stroke, optimizing tool path, improving cutting speed and feed speed and other measures can greatly shorten processing time and improve production efficiency.


Tool life: Reasonable cutting parameters and tool path can reduce tool wear and damage, extend the service life of the tool, reduce the cost of the tool.


Machine tool stability: Optimizing the processing process can reduce the vibration and shock of the machine tool, enhance the stability of the machine tool operation, and reduce the incidence of failure.


Material utilization: More accurate processing and reasonable layout planning can reduce the waste of materials and improve the utilization rate of materials.


Production flexibility: can adapt to the processing needs of different parts more quickly, adjust the processing technology and parameters, and improve the flexibility and response speed of production.


Energy consumption: By improving processing efficiency and reducing unnecessary machine tool actions, reduce energy consumption, achieve energy saving and reduce production costs.


To sum up, optimizing 5-axis CNC machining is of great significance for improving product quality, reducing costs, and enhancing the competitiveness of enterprises.

Honscn has obvious advantages in CNC aluminum processing. First of all, the precision is high, can make aluminum parts with accurate size and complex shape, and the quality is barbar. Then there is high efficiency, automatic processing, saving manpower and time. Complex shapes are no problem, anything can be done. Full use of materials, no waste, cost can be reduced. And the processed things have good repeatability and stable quality. It is also easy to modify the design, and it is flexible to change the procedure.