Taking high speed as the guide
The high speed of CNC machine tools is an important measure to improve its high efficiency and high precision. It can not only improve the cutting ability of the machine tool and shorten the auxiliary time, but also improve the chip forming process, reduce the feed per revolution of the cutter and reduce the cutting force, which helps to improve the machining accuracy. Analyze the development process of high-speed and high-precision of medium-sized machining centers, and it can be concluded that the maximum speed and the maximum feed rate of the main shaft, which characterize the high-speed cutting movement, are roughly continuously increased by a rate that doubles every 10 years. The rapid traverse rate (referred to as ball screw and rotary servo motor drive) and the automatic tool change/table indexing speed of the compressor bed auxiliary time are basically increased at a rate that doubles every 12 to 15 years. After 1993 The new technology of direct drive with a linear motor is gradually promoted, so that the fast moving speed of the machining center is doubled when driven by the ball screw. However, the increase in spindle speed and feed rate will also cause some negative effects, which will increase the tracking error of thermal deformation and position control of the machine structure and measurement system. To this end, the application of information technology development such as thermal error compensation, automatic tracking filtering and suppression of drive system resonance, feed rate forward control, position loop feedforward control and acceleration smooth control, etc., so that under high-speed control conditions It can guarantee the continuous improvement of machining accuracy.
Therefore, the development of high-speed can not simply pursue the improvement of the rotational speed, and must consider improving the various constraints, so as not to do more with less. In addition to the thermal error and control accuracy mentioned above, attention should also be paid to the static and dynamic stiffness, dynamic balance and tool performance of the machine structure.
Develop high-efficiency precision CNC machine tools
At present, the domestically produced CNC machine tools still lack high-efficiency micro-precision grade products, showing the comparison of the satisfaction status of auto parts processing with the domestic machining center, CNC milling machine, turning center and CNC lathe.
Most of the existing CNC machine tools cannot meet the high-efficiency and high-precision requirements of the automobile manufacturing industry as a typical pillar industry for CNC manufacturing equipment.
To this end, it is necessary to develop some high-tech and high-precision CNC manufacturing equipment to meet the needs of manufacturing key parts in the automotive, aerospace, mold and military industries, and their performance is represented by the D area in Figure 1. Since the machining accuracy of these CNC manufacturing equipment is mainly in the micron range, it can be called the level manufacturing equipment and technology research, also known as Micro Precision Machine Tool Engineering.
Representative products in this respect include the M-1250 horizontal high-precision machining center of Germany's Waddrich Zigen, the V56 vertical machining center of Japan's Makino, and the 1000-axis/five-axis vertical of the Beijing Machine Tool Research Institute of China. Machining center. Their positioning accuracy (ISO standard) is 4-6um, and the machine's comprehensive stiffness and metal removal capability are twice as high as those of conventional machines of the same type. Japan's Yuanzhou company's X107 hybrid-drive horizontal machining center is only driven by a linear motor with a long-stroke X-axis. It has a good price/performance ratio and has a MTBF of 5000h. Both are efficient and sophisticated.
Development of composite machining CNC machine tools
Multi-functional composite machining CNC machine tools are referred to as composite machine tools, or multi-function machining or complete machining machines.
The meaning of a compound machine tool is to achieve or complete the entire processing from blank to finished product on one machine. Since the 1970s, there have been machining centers that are mainly used for boring and milling with rotary cutters as the main cutting motion, and turning centers that are mainly used for turning and milling with workpiece rotation as the main motion. The multi-functional CNC machine tool plays an important role in promoting the process concentration of CNC machine tools. However, for more complex parts, their functional range is not enough to complete the entire process from blank to finished product, so the production efficiency under single-piece and small-to-small production conditions cannot be fully improved, and the workpiece is between multiple machine tools. The transfer increases the installation error and is not conducive to the stability of the machining accuracy.
To this end, speed up the development of composite CNC machine tools, improve the concentration of the process, and make the process chain intensive, which can improve the efficiency of multi-variety single-piece and medium-to-small batch processing. The compound CNC machine tool can reduce the waiting time and the multiple loading and unloading time caused by the process conversion between different CNC machine tools. Usually these times account for 40%-60% of the entire production cycle of the part, even in the case of better information management, it will still account for about 20%. Therefore, the composite CNC machine tool has obvious technical effects.
According to its structural characteristics, composite CNC machine tools can be divided into the following two categories:
* Composite CNC machining tools across the processing category: This type of machine tool is mainly composed of multiple types of functions such as tool rotary machining, workpiece rotary machining or special machining. Therefore, the requirements of different machining methods should be reflected in the machine structure. At present, there are common milling and milling centers, milling centers and milling-laser processing machines;
* Multi-faceted multi-axis linkage machining of composite CNC machine tools. Developing a Rapid Restructuring Manufacturing System With the support of Reconfigurable Manufacturing technology, it is a noteworthy development direction to build a flexible manufacturing system that is suitable for high-volume and efficient production.
Development of networked manufacturing units
Driven by the rapid development of information technology, the manufacturing industry is facing the era of digitalization of the whole enterprise with the goal of improving competitiveness. CNC machine tools and their manufacturing systems, which are the main manufacturing equipments, will also actively move toward digital manufacturing, which will become a manufacturing unit for information integration and rapid implementation. Its main features can be attributed to 3F (flexibility, alliance and novelty). ), 3I (integration, information and intelligence) and 3S (systematization, software and personalization).
At present, some domestic and foreign machine tool and CNC system manufacturing companies are researching compatible manufacturing units from the perspective of networked alliance manufacturing. It will be able to integrate information with enterprise ERP, PDM and CAD/CAPP/CAM, and then through customer relationship. The relationship between management (CRM) and supply chain management (SCM) makes intelligent decisions, implements concurrent engineering, visual monitoring, etc. to improve machine tool utilization and achieve efficient and flexible production.
The high speed of CNC machine tools is an important measure to improve its high efficiency and high precision. It can not only improve the cutting ability of the machine tool and shorten the auxiliary time, but also improve the chip forming process, reduce the feed per revolution of the cutter and reduce the cutting force, which helps to improve the machining accuracy. Analyze the development process of high-speed and high-precision of medium-sized machining centers, and it can be concluded that the maximum speed and the maximum feed rate of the main shaft, which characterize the high-speed cutting movement, are roughly continuously increased by a rate that doubles every 10 years. The rapid traverse rate (referred to as ball screw and rotary servo motor drive) and the automatic tool change/table indexing speed of the compressor bed auxiliary time are basically increased at a rate that doubles every 12 to 15 years. After 1993 The new technology of direct drive with a linear motor is gradually promoted, so that the fast moving speed of the machining center is doubled when driven by the ball screw. However, the increase in spindle speed and feed rate will also cause some negative effects, which will increase the tracking error of thermal deformation and position control of the machine structure and measurement system. To this end, the application of information technology development such as thermal error compensation, automatic tracking filtering and suppression of drive system resonance, feed rate forward control, position loop feedforward control and acceleration smooth control, etc., so that under high-speed control conditions It can guarantee the continuous improvement of machining accuracy.
Therefore, the development of high-speed can not simply pursue the improvement of the rotational speed, and must consider improving the various constraints, so as not to do more with less. In addition to the thermal error and control accuracy mentioned above, attention should also be paid to the static and dynamic stiffness, dynamic balance and tool performance of the machine structure.
Develop high-efficiency precision CNC machine tools
At present, the domestically produced CNC machine tools still lack high-efficiency micro-precision grade products, showing the comparison of the satisfaction status of auto parts processing with the domestic machining center, CNC milling machine, turning center and CNC lathe.
Most of the existing CNC machine tools cannot meet the high-efficiency and high-precision requirements of the automobile manufacturing industry as a typical pillar industry for CNC manufacturing equipment.
To this end, it is necessary to develop some high-tech and high-precision CNC manufacturing equipment to meet the needs of manufacturing key parts in the automotive, aerospace, mold and military industries, and their performance is represented by the D area in Figure 1. Since the machining accuracy of these CNC manufacturing equipment is mainly in the micron range, it can be called the level manufacturing equipment and technology research, also known as Micro Precision Machine Tool Engineering.
Representative products in this respect include the M-1250 horizontal high-precision machining center of Germany's Waddrich Zigen, the V56 vertical machining center of Japan's Makino, and the 1000-axis/five-axis vertical of the Beijing Machine Tool Research Institute of China. Machining center. Their positioning accuracy (ISO standard) is 4-6um, and the machine's comprehensive stiffness and metal removal capability are twice as high as those of conventional machines of the same type. Japan's Yuanzhou company's X107 hybrid-drive horizontal machining center is only driven by a linear motor with a long-stroke X-axis. It has a good price/performance ratio and has a MTBF of 5000h. Both are efficient and sophisticated.
Development of composite machining CNC machine tools
Multi-functional composite machining CNC machine tools are referred to as composite machine tools, or multi-function machining or complete machining machines.
The meaning of a compound machine tool is to achieve or complete the entire processing from blank to finished product on one machine. Since the 1970s, there have been machining centers that are mainly used for boring and milling with rotary cutters as the main cutting motion, and turning centers that are mainly used for turning and milling with workpiece rotation as the main motion. The multi-functional CNC machine tool plays an important role in promoting the process concentration of CNC machine tools. However, for more complex parts, their functional range is not enough to complete the entire process from blank to finished product, so the production efficiency under single-piece and small-to-small production conditions cannot be fully improved, and the workpiece is between multiple machine tools. The transfer increases the installation error and is not conducive to the stability of the machining accuracy.
To this end, speed up the development of composite CNC machine tools, improve the concentration of the process, and make the process chain intensive, which can improve the efficiency of multi-variety single-piece and medium-to-small batch processing. The compound CNC machine tool can reduce the waiting time and the multiple loading and unloading time caused by the process conversion between different CNC machine tools. Usually these times account for 40%-60% of the entire production cycle of the part, even in the case of better information management, it will still account for about 20%. Therefore, the composite CNC machine tool has obvious technical effects.
According to its structural characteristics, composite CNC machine tools can be divided into the following two categories:
* Composite CNC machining tools across the processing category: This type of machine tool is mainly composed of multiple types of functions such as tool rotary machining, workpiece rotary machining or special machining. Therefore, the requirements of different machining methods should be reflected in the machine structure. At present, there are common milling and milling centers, milling centers and milling-laser processing machines;
* Multi-faceted multi-axis linkage machining of composite CNC machine tools. Developing a Rapid Restructuring Manufacturing System With the support of Reconfigurable Manufacturing technology, it is a noteworthy development direction to build a flexible manufacturing system that is suitable for high-volume and efficient production.
Development of networked manufacturing units
Driven by the rapid development of information technology, the manufacturing industry is facing the era of digitalization of the whole enterprise with the goal of improving competitiveness. CNC machine tools and their manufacturing systems, which are the main manufacturing equipments, will also actively move toward digital manufacturing, which will become a manufacturing unit for information integration and rapid implementation. Its main features can be attributed to 3F (flexibility, alliance and novelty). ), 3I (integration, information and intelligence) and 3S (systematization, software and personalization).
At present, some domestic and foreign machine tool and CNC system manufacturing companies are researching compatible manufacturing units from the perspective of networked alliance manufacturing. It will be able to integrate information with enterprise ERP, PDM and CAD/CAPP/CAM, and then through customer relationship. The relationship between management (CRM) and supply chain management (SCM) makes intelligent decisions, implements concurrent engineering, visual monitoring, etc. to improve machine tool utilization and achieve efficient and flexible production.
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