High-speed cutting is a relative concept. Generally, high speed is defined as significantly more than 5 to 10 times the normal cutting speed. It usually refers to high spindle speed (10000~100000r/min) and high feed/rapid speed. Milling at 40 to 180 m/min. Faced with the increasingly fierce international competition in the manufacturing industry, High Speed ​​Cut has become a very important technical research direction. High-speed machining is widely used in aerospace manufacturing, mold manufacturing, auto parts processing and precision parts processing industries in the world, and has become a technical direction for companies to compete for.
The advantages of high-speed cutting technology High-speed cutting is not only the improvement of cutting speed, but also the advancement of manufacturing technology and further innovation, including major advances in technologies such as drive, tool materials, coatings, tools, testing and safety. By achieving a multiple increase in cutting speed and feed rate, the overall machining efficiency of the manufacturing industry can be significantly improved.
The advantages of the high speed cutting process are as follows:
1. Shorter production time With high-speed machining, the cutting speed and feed rate are doubled, the overall machining efficiency is significantly improved, and the machining time is significantly shortened.
2. Reducing manufacturing costs Higher levels of productivity inevitably lead to a reduction in manufacturing costs. High-speed cutting equipment and tools enable the lowest manufacturing costs in mass production.
3. High-speed cutting absorbs energy using high-speed machining, which reduces heat generation during machining, especially in milling. Due to the reduction of heat generation, the workpiece temperature is small, the processing size is stable, and the damage to the tool and equipment is small. On the other hand, high-speed cutting can process hard materials, which is unmatched by ordinary machine tools.
4. Improve the processing quality of the workpiece by high-speed machining, the machining accuracy and the quality of the cutting surface can be greatly improved, the surface roughness of the parts can reach micron level, reducing and eliminating the auxiliary working hours such as grinding and polishing.
High speed machining in engine manufacturing
Nowadays, with the continuous adoption of new processes, the continuous development of super-hard material tools, coated tools and alloy material tools, high-speed machining has become more and more important in ordinary processing. High-speed machining centers, high-speed external milling, and high-speed grinding of CBN grinding wheels in engine manufacturing are common. In the high-speed machining application, the engine manufacturing industry mainly uses the spindle to realize the high speed of the spindle and the high linear movement speed of the linear motor. The purpose is to replace the multi-spindle with a single spindle machining center with high spindle speed and high-speed linear feed motion. It is difficult to achieve a combination of high spindle speed and high speed feed. The maximum spindle speed is generally 60 000r/min and the maximum feed rate is about 100m/min. The electric spindle incorporates many cutting-edge technologies, such as high-speed bearings with composite ceramic materials or electromagnetic suspension, high-speed motor technology, timed quantitative oil and gas lubrication, and automatic tool changers. There are also some companies that use hollow-through coolants, larger diameters, and larger lead ball screws to reduce costs without the use of linear motors. SAIC-GM-Wuling Engine Factory uses high-speed machining centers such as high-speed machining centers and CBN grinding wheels to achieve high-speed milling and grinding.
1. Milling
At present, milling technology is generally used for machining large cylinders and cylinder heads in engines. For example, milling of a cast iron cylinder in a high-speed milling center (see Figure 1) uses a cubic boron nitride (CBN) insert with a cutting speed of 700 to 1500 m/min.
The production efficiency of milling is greatly improved. For the cylinder head of aluminum alloy material, a face milling cutter is used for high-speed machining. With the PCD insert, the diameter of the milling cutter is gradually reduced and it is developed to multi-station duplex machining. The SAIC-GM-Wuling engine plant uses the EX-CELL-O high-speed milling center from MAG, Germany, and has a total of 104 units in the cylinder block of the engine block. The machining center structure is shown in Figure 2. The X-axis machining range is 0-630mm, the Y-axis machining range is 0-630mm, the Z-axis machining range is 0-710mm, and the B-axis can achieve 306° rotation, W-axis. The inspection device is broken for a magazine with 20 tool positions and the corresponding drill bit. The main shaft is Weiss electric spindle, the speed is infinitely adjustable, the maximum is 16 000r/min, the driving power is 30kW, the maintenance-free internal cooling tool holder is used, the tensioning force is up to 18 000N, and the permanent magnet chip is used to track the tool life, size and compensation amount. information. The equipment is equipped with an automatic cooling station and a cutting waste flushing recovery device, which can eliminate the mechanical failure caused by chip scattering and reduce the strength of the machine cleaning and maintenance work, thereby improving the equipment operating rate.
The milling, drilling and tapping processes of the cylinder block and cylinder head line are all completed by the 104 EX-CELL-O machining centers. Figure 2 shows the machining and application of the engine head.
Extrusion aluminium, also known as aluminum extrusion, is a manufacturing process used to create durable and versatile aluminum-based products. The process involves pushing molten aluminum through a die under high pressure or pulling it through the die using a ram. The resulting product is a smooth surface, uniform cross-section, and precise dimensions.
The extrusion process can create complex shapes and intricate designs, making it popular in various industries such as architecture, automotive, and aerospace. Common extruded aluminum products include window frames, door frames, curtain walls, and structural components.
One advantage of extrusion aluminum is its versatility. It can be modified and finished to suit different requirements, such as anodizing to provide extra corrosion resistance or powder coating to add a decorative finish. Additionally, extrusion aluminium offers excellent strength-to-weight ratios and is highly durable, making it an ideal material for products that require high strength and durability.
Another advantage of extrusion aluminium is its cost-effectiveness. The manufacturing process is highly efficient, allowing for the creation of large quantities of products at a reduced cost compared to other materials such as steel or copper.
Although extrusion aluminium has many benefits, it also has some limitations. The material is highly conductive and may require insulation in certain applications. Additionally, extruded aluminum products may have difficulty achieving tight tolerances and precision, making it unsuitable for some specialized applications.
Overall, extrusion aluminium has become an essential material in various industries, providing both strength and versatility at a reasonable cost. As technology continues to advance, even more advanced and innovative applications of extruded aluminum are expected to emerge.
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