In the actual production process, we will find that different operators of the same CNC lathe operate at different production efficiency within the same working time. The processing capability of many CNC lathes is not fully reflected and their optimal function cannot be achieved. . In the process of use, only fully considering the various factors that affect the production efficiency of CNC lathes, and trying to improve the production efficiency of CNC lathes in order to make full use of the production capacity of CNC lathes.
1. Formulate a reasonable processing route to reduce the auxiliary time of CNC milling In order to improve the production efficiency of CNC lathes, we must first carefully analyze the parts processed by CNC lathes, make clear the parts of the material, structural characteristics and shape tolerance requirements, roughness Technical requirements such as heat treatment. Then on this basis, choose a reasonable milling process and a simple processing route.
The establishment of processing technology: usually a part can have several different processes, parts of the process is different, its production efficiency, processing costs and processing accuracy often have significant differences, so we should guarantee the quality of the parts under the premise of The specific conditions of production, try to increase production efficiency and reduce production costs, and develop a reasonable processing technology.
The determination of the processing route: the correct and simple processing route is the basis for ensuring processing quality and improving efficiency. When selecting the processing route of a part, the principle of determining the processing route must be followed in order to achieve the purpose of improving production efficiency. The principles for determining the processing route are as follows: The requirements for machining precision and surface roughness of the parts should be ensured, and the efficiency is high; the processing route should be minimized as far as possible, which can reduce the program segment and reduce the tool idle travel time. The numerical calculation should be simple and the number of blocks should be small in order to reduce the programming workload. In addition, when determining the processing route, it is also necessary to consider the machining allowance of the workpiece, the rigidity of the lathe, the tool, etc., and determine whether it is one pass or multiple passes to complete the processing. At the same time, it should try to do a clamping, multi-faceted processing, one-time processing. In this way, the number of workpiece installations can be reduced, and the time for handling and settling can be effectively reduced. In this way, it can not only improve the machining efficiency but also ensure the position accuracy of the parts.
2. Choosing the right tool to select the tool The factors such as the machining capability, process content, and workpiece material of the CNC lathe should be considered. The tools selected for CNC lathes not only require high hardness, high wear resistance, sufficient strength and toughness, high heat resistance, and good processability, but also require dimensional stability and easy installation and adjustment. Therefore, a new type of high-quality materials should be used to manufacture CNC machining tools, and the tool parameters should be optimized so that the size of the tool can be adapted to the surface size and shape of the workpiece being machined. So, how to choose the right cutting tool?
(1) Choosing the right tool The role of the metal cutting tool is extremely important in the machining of CNC lathes. The material of the manufacturing tool must have high hardness, wear resistance and heat resistance, sufficient strength and toughness, good thermal conductivity and processability, and have good economics. In the process of selecting tools, under the premise of meeting the requirements of parts processing, try to choose the tool with larger diameter, its strength and toughness are better; in the same process, the number of tools selected should be as few as possible to reduce the number of tool change; It is possible to select a universal standard tool, with no or less special non-standard tools.
(2) Reasonable determination of the tool point The tool point is the starting point of tool movement relative to the workpiece when machining parts on CNC lathes. Also known as "program starting point" or "playing point." The selection of tool points must comply with the following principles: it is easy to use digital processing and simplify programming; it is easy to find on the lathe, processing is easy to check; and the processing error caused is small. The position of the tool point can be selected on the workpiece or outside the workpiece (such as a fixture or lathe), but it must have a certain dimensional relationship with the positioning reference of the part. The tool-cutting point should be selected as far as possible on the design reference or process reference of the part, such as the workpiece with hole location, and the center of the optional hole as the tool-cutting point. The position of the tool is aligned with this hole so that the "location" coincides with the "cutting point." In this way, you can better improve the efficiency of the knife, and ensure the quality of processing.
3. Reasonably install and clamp the workpiece to increase the clamping speed When machining the workpiece on the CNC lathe, the positioning and installation stress of the workpiece shall be designed so that the reference of the design, the process standard and the programming calculation are unified; the number of clamping is minimized, and the positioning is performed as much as possible. After clamping, all the surfaces to be machined are machined; the manual adjustment of machining plans is avoided to take full advantage of the effectiveness of CNC lathes.
When CNC lathes are machined, comprehensive consideration must be given to the positioning of components, clamping design, and the selection and design of furniture. When designing furniture, it is first necessary to ensure that the furniture's coordinate direction is relatively fixed with the lathe's coordinate direction. Second, coordinate the dimensional relationship between the parts and the lathe coordinate system. At the same time, you should also consider:
(1) When the production volume of parts is not large, combination clamps, adjustable clamps, and universal clamps should be used as much as possible to shorten production preparation time and save production costs;
(2) Consider the use of special fixtures in batch production and strive for a simple structure;
(3) The loading and unloading of parts should be quick, convenient and reliable to shorten the downtime of the lathe;
(4) The components on the fixture should not interfere with the lathe's machining of each part surface;
(5) When selecting tooling, it should be beneficial to tool exchange and avoid interference interference;
(6) Multiple fixtures and fixtures can also be used in mass production to increase processing efficiency.
4. Reasonable choice of cutting amount and improved removal efficiency of cutting allowance The cutting amount includes spindle speed, cutting depth and feed speed. When selecting the cutting amount of the CNC milling machine, if it is rough processing, generally it is to increase the productivity, but it is also necessary to consider the economy and the processing cost, and the larger cutting depth and feed rate can be selected; if semi-finishing and finishing , should guarantee the processing quality under the premise, taking into account the efficiency, economical efficiency and the processing cost; When the tool does the empty movement, should set the highest possible feed rate. The specific values should be based on the lathe specification, cutting amount manual, and combined with experience.
5. Implement tool pre-adjustment and automatic measurement of wolf to reduce the time taken to adjust the machine. CNC lathes often use many different tools in the machining process. If the tool cannot be adjusted in advance, the operator is required to install each tool to the spindle. On top, slowly determine their exact length and diameter. Then, manually input through the keys on the CNC control surface. If you use the tool setting tool, it can accurately measure the diameter and length of the tool, reduce the lathe occupation time, improve the first pass rate, and greatly increase the production efficiency of the CNC milling machine.
6. Flexible use of various auxiliary functions of CNC lathes and macro programs CNC lathes have tool radius and length compensation functions. They can compensate for tool size errors by changing tool compensation methods, and use the same machining program to achieve hierarchical milling and rough and fine machining or use. In order to improve the processing accuracy, and can use the same processing program processing fittings.
The biggest feature of using macro programs is that the regular shape or size can be represented by the shortest program, and the lathe is faster and more responsive when executing such programs than the CAD/CAM software. The macro program can use variables, assign values to variables, operate between variables, and run programs to jump. It can form a modular machining program. When the application only needs to input part information, processing parameters, etc., into the corresponding module's call statement. Reduce programming and input time.
CNC lathes also have a fixed cycle function, a subroutine function, a mirror image processing function, and a rotating light function. Using these functions can eliminate the need for long program input and use it properly to try and get a multiplier effect.
