From the continuous innovation process of high-speed machining centers, it can be seen that making full use of the latest achievements in today's technology fields, especially the latest achievements in the use of drive technology and control technology, is the key to continuously improve the high-speed performance, dynamic characteristics and machining accuracy of the machining center. .
Electric spindle
The high-speed electric spindle is the core component of the high-speed machining center. In the processing of free-form surfaces and complex contours of molds, 2 to 12 mm smaller diameter end mills are often used, and in the processing of electrodes for EDM of copper or graphite materials, high cutting speed is required, therefore, electricity The spindle must have a very high speed. At present, the spindle speed of the machining center is mostly 18000~42000r/min. The spindle speed of the XSM400U/XSM600U of the high-speed machining center of Mikro, Switzerland has reached 54000r/min. For micro-milling of the mold (the diameter of the milling cutter is generally 0.1 to 2 mm), a higher rotation speed is required. For example, Germany's KUGler's five-axis high-precision milling machine has a maximum spindle speed of 160,000 r/min (using air bearings). This high speed can achieve 150 m/min when machining a steel mold with a 0.3 mm diameter milling cutter. Cutting speed. At present, the Fraunhofer Institute of Production Technology in Germany is developing a spindle supported by an air bearing with a speed of 300,000 r/min.
When machining molds, high speeds are always used, and the heat generated by high speed and the vibration that may occur during cutting are important factors affecting the precision of mold processing. In order to ensure the stability of the high-speed electric spindle work, sensors for measuring temperature, displacement and vibration are installed on the spindle to monitor the temperature rise, axial displacement and vibration of the motor, bearing and spindle. This provides correction data for the CNC system of the high-speed machining center to modify the spindle speed and feed rate to optimize the machining parameters. When the spindle produces an axial displacement, it can be compensated by zero correction or trajectory correction.
Linear Motor
At present, most of the high-speed machining centers or milling machines used in mold processing use servo motors and ball screws to drive linear axes. However, some machining centers have adopted linear motors, such as the RXP500DS/RXP800DS high-speed milling machine from Germany Rders and Deji. The company's DMC75V linear high-speed machining center (with an axial acceleration of 2g and a fast stroke speed of 90m/min). Since the linear drive eliminates the transmission element that converts the rotary motion into a linear motion, the dynamic performance, the moving speed and the machining accuracy of the shaft can be significantly improved.
Machines driven by linear motors can significantly increase productivity. For example, when processing electrodes for electrical discharge machining, the processing time is reduced by 50% compared to the conventional high-speed milling machine.
Linear motors can significantly improve the dynamic performance of high-speed machine tools. Since most of the molds are three-dimensional surfaces, the tool axes are constantly braking and accelerating while the tool is machining the surface. Only with a high axial acceleration is it possible to ensure that a given contour is tracked with a constant feed per tooth on a shorter path path at very high path speeds. If the radius of curvature of the surface profile is smaller, the higher the feed rate, the higher the required axial acceleration. Therefore, the axial acceleration of the machine tool largely affects the machining accuracy of the mold and the durability of the tool.
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