Machining process technology and processing equipment

Machining process refers to the process of changing the shape size or performance of the workpiece by processing machinery, and this process requires the help of a variety of processing equipment  

The processing method is classified into cold processing and hot processing  

Cold processing: generally carried out at room temperature, and does not cause chemical or phase changes in the workpiece, cold processing can be divided into Cutting processing and pressure processing according to the difference in processing methods  

Hot processing: It is generally processed at higher or lower than normal temperature, which will cause chemical or phase changes of the workpiece, and common hot processing are heat treatment, forging, casting, and welding.  

It is classified into additive processing and reduced processing by forming method  

Additive processing methods: casting, forging, injection molding, powder molding, 3D printing, etc  

Cutting processing methods: turning, milling, drilling, planing, boring, grinding (surface grinding, cylindrical grinding, internal grinding, centerless grinding), CNC, electron-discharge, wire cutting (slow wire, fast wire), welding (argon arc welding, resistance welding, friction welding), laser processing (cutting, welding, marking), etching, etc.

1.Lathe Machine,generally the lathe is mainly used to cut the rotating workpiece with the turning tool  

Ordinary processing types: end turning, turning round, turning hole, drilling, reaming, turning internal and external threads, tapping internal threads, cutting internal and external grooves, cutting surface grooves, outer diameter knurling , turning cone surface, forming turning, coaxial die turning, copying turning, surface turning.

Machining accuracy:  

The turning accuracy is generally IT8~IT7, and the surface roughness is Ra0.8~1.6um.  

Under the condition of not reducing the cutting speed, large cutting depth and large feed are used to improve the turning efficiency, but the machining accuracy can reach IT11 and the surface roughness is Ra10~20um  

Semi-Precision turning and Precision turning try to use high speed and small feed rate and cutting depth, processing accuracy can reach IT10~IT7, surface roughness is Ra0.16~10um  

High Precision turning using precision grinding diamond turning tool high-speed precision turning of non-ferrous metal parts, can make the processing accuracy reach IT7~IT5, surface roughness get Ra0.01~0.04um, this turning is called "mirror turning".

Processing materials:Carbon steel, brass, stainless steel ,alloy steel, aluminum alloy, zinc alloy, POM, plastic, acrylic, PE-UHWM (ultra-high molecular weight polyethylene) and so on.  

2.CNC is a high-precision, high-efficiency automatic machine tool.  Equipped with multi-station turret or power turret, the machine tool has a wide range of processing technology performance, can process linear cylinder, oblique cylinder, arc and a variety of threads, slots, worm and other complex workpieces, with linear interpolation, arc interpolation of various compensation functions, and in the mass production of complex parts have good economic effects.  CNC using digital signals through programmable automatic control work mode, to achieve the operation of the equipment and its processing process generated by the position, Angle, speed, force and other signals control, that is, according to the pre-prepared processing program, automatic processing of the machined parts.  

Equipment characteristics  

High machining precision and stable machining quality;  

Can carry out multi-coordinate linkage, can process complex shape parts;  

When machining parts change, generally only need to change the numerical control program, can improve the work efficiency: large rigidity, can choose a favorable processing amount, high productivity of the machine itself, high precision machine automation, can reduce labor intensity;  

High performance, low noise  

In terms of processing type, compared with ordinary lathes, in addition to automatic turning processing, CNC can also process multiple threads, variable pitch threads, irregular arcs that ordinary lathes can not complete.  

Machining accuracy  

The highest turning accuracy can reach IT6, and the highest surface roughness can reach Ra1.6um.  

Processing material  

Carbon steel, stainless steel, aluminum alloy, brass, steel, PEEK, ABS, etc. 

3.Ordinary milling machine is mainly a machine tool for machining a variety of surfaces of the workpiece with a milling cutter, usually the main movement of the milling cutter is rotary motion, and the movement of the workpiece and the milling cutter is the feed movement.  Equipment characteristics  

Multi-edge tool processing, blade rotation cutting, tool cooling effect is good, high durability;  High production efficiency, wide processing range;  

High machining precision;  

The processing has to be lower and the processing cost is reduced.  

Processing type  

Milling machine can mill plane (horizontal plane, vertical plane), groove (keyway, T type), gear teeth (gear, spline shaft, sprocket) thread and spline shaft, but also can process more complex profile.  Machining accuracy  

The machining accuracy of milling is generally up to IT7~IT8, and the surface roughness is Ral.6~6.3um.  Rough milling machining accuracy IT11~IT13, surface roughness Ra5~20um;  

The machining accuracy of semi-finishing milling is IT8~IT11, the surface roughness is Ra2.5~10um;  Machining precision IT6-IT8, surface roughness Ra0.63~5um.  

Processing material  

Carbon steel, stainless steel, aluminum alloy, brass, steel, PEEK, POM, Teflon, bakelite, etc

4. CNC milling machine (CNC) is also known as CNC(Computer Numerical Control) milling machine;  That is, the use of digital information to control the mechanical movement and processing process.  Equipment characteristics  

Strong adaptability and flexibility of parts processing, can process the contour shape is particularly complex or difficult to control the size of the parts, such as mold parts, shell parts, etc. : can process ordinary machine tools can not process or difficult to process parts, such as complex curve parts described by mathematical models and three-dimensional space surface parts;  It can process parts that need to be processed by multiple processes after one clamping and positioning;  

High processing precision, stable and reliable processing quality:  

High production efficiency, high degree of production automation, can reduce the labor intensity of the operator, is conducive to the automation of production management.  

Processing type plane parts with plane outline, plane parts with inclined plane, flat parts with upright and inclined rib, variable bevel parts, curved parts, three-dimensional parts, etc.  Machining accuracy  

The milling accuracy in CNC milling is generally up to IT6-IT8, and the surface roughness is Ra0.6-5um.  The positioning accuracy of linear motion coordinates is 0.04, repeated positioning accuracy is 0.025mm, and circle milling accuracy is 0.035mm.  

The current size and position accuracy is 0.01-0.3um, shape and profile accuracy is 0.003~0.1um, surface roughness Ras0.05um for steel and Ras0.01um for copper.  Processing material  

Carbon steel, stainless steel, aluminum alloy, brass, S136, SKD11, steel, PEEK, POM, Teflon, bakelite, etc.

5.Drill machine equipment  

Radial drilling machine: it is a kind of radial arm can be rotated and lifted around the column, usually the spindle box on the radial arm for horizontal movement of the drilling machine, refers to the main drill bit on the workpiece to process the hole machine, usually the main movement of the drill bit rotation, the drill bit axial movement for feed movement.  

Table drilling machine: table drilling machine referred to as table drilling, refers to the small drilling machine that can be placed on the working platform, the main shaft is vertically arranged, the drilling diameter of the table drilling machine is generally below 13mm, generally not more than 25mm.  The spindle speed change is generally achieved by changing the position of the triangle belt on the tower pulley, and the spindle feed is manually operated.  Equipment characteristics  

Drilling machine is a versatile machine tool with a wide range of uses.  

The operation is simple, the workpiece is fixed, the tool does rotating movement, and feeds along the spindle direction, the operation can be manual or maneuvering.  

Bench drilling machine, small horsepower, good rigidity, easy to operate, easy to maintain.  

Processing type  

Drilling, reaming, matching hole, marking hole (countersunk hole), marking plane, tapping thread, etc  

Machining accuracy  

Drilling is a basic method of hole processing, drilling is often carried out on a drilling machine and a lathe, but also on a bed or a milling machine.  The processing accuracy of drilling is low, generally only IT10, the surface roughness is generally 12.5~6.3um, and the semi-finishing and finishing are often carried out by reaming and hole after drilling.  Processing material  

Carbon steel, stainless steel, aluminum alloy, brass, steel, PEEK, POM, bakelite, etc.

6. Grinding machine is a kind of machine tool that uses abrasive tools and rotten materials (such as yard wheel, sandbag, oil stone, abrasive agent, etc.) to process the workpiece surface. It can process various surfaces, such as plane, internal and external cylindrical surface, conical surface and spiral surface.  Through grinding processing, the workpiece shape and surface accuracy, finish to meet the expected requirements, at the same time, it can also be cut processing.  Commonly used grinding machines are hand-operated grinding machine, surface grinding machine (fine grinding), cylindrical bed.  

Equipment characteristics  

It can process materials with high hardness, such as hardened steel, cemented carbide, etc  

Can process brittle materials, such as glass, granite;  

The grinding machine can be used for high precision and small surface roughness grinding, but also for high efficiency grinding, such as strong grinding.  Processing type  

Grinding cylindrical surface, grinding conical outer surface, grinding inner hole, grinding shoulder, grinding end plane, grinding rounded corners, etc.  Machining accuracy  

The grinding accuracy of ordinary grinding machine: steel plate =160x160mm, flatness 0.008mm~0.004mm, roughness Ra0.8um;  Steel plate <250x250mm, flatness 0.025mm~0.01mm, roughness Ra0.8um;  Steel plate 630~1000, flatness 0.08mm~0.05mm, reference tolerance level IT5~IT7, surface roughness Ra0.16~1.25um.  Precision CNC grinding machine grinding accuracy:  

Steel plate 0-500mm, flatness 0.004mm, roughness Ra0.2um.  The grinding tool used in the grinding process of higher precision is the whetstone, but it can only grind off a few microns  

Grinding accuracy of cylindrical grinding machine

Ordinary cylindrical grinding machine, roundness at 3um, roughness Ra0.4um;  High precision cylindrical grinding machine, roundness up to 0.1um, roughness Ra0.01um.  Processing material  

Carbon steel, stainless steel, aluminum alloy, brass, alloy steel, glass, granite, etc.

7.Gear hobbing machine In metal cutting machine tools,the machine which is used to process gear or turbine gear teeth machine called gear hobbing machine.  At present, the more widely used gear hobbing machine is CNC gear hobbing machine, CNC gear hobbing machine is suitable for batch, small batch and single production and processing of cylindrical gear and worm gear, and certain parameters of drum gear can also be splined hob continuous dividing hobbing length less than 300 6 teeth and 6 teeth to short spline shaft.  And the sprocket can be rolled and cut with the sprocket hob.  The full tooth width can be obtained by the method of axial feed (vertical feed).  The method of radial feed is used to process ordinary worm gear in NC gear hobbing machine.  The adjustment and processing method of CNC gear hobbing machine when machining spline shaft and sprocket are the same as that when machining cylindrical spur gear.  

Equipment characteristics  

Wide application, many processing types:  

High machining precision and high efficiency  

Processing type  

Small batch and single production of cylindrical helical gear and worm gear, but also hobbing a certain parameter range of spline shaft adjustment is convenient, with automatic stopping mechanism  

With reliable safety devices and automatic lubrication gear hobbing machine is one of the most widely used gear processing machine, in the gear hobbing machine can cut straight teeth, helical cylindrical gears, but also can process Wuhu wheels, sprockets and so on  

Machining accuracy  

Processing accuracy can reach IT4~IT5.  

Processing material  

Carbon steel, stainless steel, aluminum alloy, brass, alloy steel, etc.  

8. Planer,a machine tool for planing the plane, groove, or formed surface of a workpiece with a planer  

Good versatility, simple structure, can be carried out reciprocating movement.  Processing type  

Horizontal plane, vertical plane, inclined plane, curved surface, groove, dovetail workpiece, etc.  Machining accuracy  

The machining accuracy can reach IT8~IT7, and the surface roughness Ra is 1.6~6.3um.  

Processing materials Carbon steel, stainless steel, aluminum alloy, brass, alloy steel, etc.

9.Electrical Discharge Machining machine, also said as EDM, the full name of Electrical Discharge Machining, mainly used for electrical discharge machining.  It is widely used in the manufacture of various metal molds and mechanical equipment.  

EDM is a special processing method that uses the electrical corrosion generated when the pulse discharge between the poles is immersed in the working fluid to erode the conductive material, also known as discharge machining or electrical corrosion machining, English abbreviation EDM.  

EDM features  

Wide range of applicable materials.  

Suitable for processing special and complex shape parts;  

Continuous rough, semi-finishing and finishing can be performed on the same machine:  

Direct use of electric energy for processing, easy to realize automation;  

Only metal conductive materials can be processed:  

The processing speed is slow and the processing cost is high  

Machining accuracy  

The machining method of EDM perforation is based on the principle of electrocorrosion. It can process the workpiece with complex shape and hard material.  The surface roughness value can be controlled in 0.63~2.5um by the method of perforating forming.  For different processing materials, the material selected for the electrode is also different, in the processing process, the electrode will consume part of the energy, which will lead to the loss of the electrode.  In the actual EDM process, there are many factors to be controlled, such as the magnetic field energy around the electrode, heat energy, etc., due to the existence of these interfering factors, directly lead to the machining accuracy requirements of the workpiece, in general, the minimum discharge spacing is 0.50mm, and the corner can reach R0.05-R0.07mm.  Discharge depth (30 ±0.02) mm Discharge accuracy is usually ±0.01mm, surface roughness Ra0.8um.  

Processing material  

Tungsten carbide, hardened steel, graphite, aluminum alloy, titanium alloy, diamond, structural steel, electrodes and other conductive materials, but there are technologies to process ceramic materials

10.Wire cutting is a kind of electrical processing machine tool, molybdenum wire through electrical corrosion to cut metal (especially hard material shape complex parts) Wire cutting machine working principle is the use of continuous moving fine metal wire (called electrode wire, generally molybdenum wire 0.03 ~ 0.1mm or copper wire 0.1 ~ 0.3mm,  Common specifications 0.12, 0.14, 0.16, 0.18, 0.20) as the electrode, pulse spark discharge cutting molding of the workpiece.  (The instantaneous temperature of the pulse spark discharge can reach 7000℃ or higher, and the high temperature vaporizes the metal to be cut instantly, generates metal oxides, and melts into the cutting fluid)  

Wire cutting processing characteristics  

The workpiece must be a conductive material  

The removal of materials is achieved by the action of electrical energy during discharge  

High hardness materials can be selected for processing  

The processing object is mainly the plane shape, when the machine tool is added to make the electrode wire to make the corresponding tilt of the function, the cone can also be processed.  However, blind holes cannot be processed  

High degree of automation, easy to operate, easy to automate  

There is no need to manufacture a formed electrode  

Processing type  

Plane parts, step parts, surface parts, axis parts, etc  

Wire cutting with brass as the cutting wire precision of ±0.02mm, processing speed of 5m/min.  Corner cut  

Cutting radius R Angle (if it is discharge, the corner radius is about R0.1~RO.2mm).  Commonly used copper or silver wire has many specifications, among which  

Medium 0.20mm wire diameter: normal processing, the minimum groove width can be processed 0.25mm, the minimum inner corner radius in R0.11-R0.13mm.  

Medium 0.15mm line diameter: normal processing, the minimum groove width can be processed 0.20mm, the minimum inner corner radius is R0.08-R0.1mm.  

Medium diameter 0.10mm: normal processing, the minimum can be processed slot width 0.15mm, the maximum thickness of the workpiece 25m.  The minimum inner corner radius is R0.06~R0.08mm  

The smaller the wire diameter, the easier it is to break during processing, and the lower the efficiency, the time consuming of 0.1mm wire diameter is about four times that of 0.2mm wire diameter, and twice that of 0.15mm wire diameter.  The thicker the workpiece, the larger the inner corner of the processing, the smaller the inner corner of the oil processing (insulation medium classification: pure water and kerosene), about 0.02mm, for the processing of die punching or 0.10mm copper wire occasions.  

The wire cutting Angle is up to 45°, the thickness is up to 80mm, and the accuracy is up to ±0.002mm.  If the water medium, the oxide layer will be attached to the surface of the workpiece, with a unilateral thickness of 3um, and the mold parts will cause dimensional changes after the oxide layer falls off during use, resulting in an error of about 0.05mm.  Oil processing precision is high, the quality is good, can process all conductive materials, but the cost is also high.  Processing material  

It can process tungsten carbide, hardened steel, graphite, aluminum alloy, ferroalloy, diamond, structural steel, electrodes and other conductive materials  

After the anodized surface treatment, the surface anodized layer of aluminum alloy is aluminum trigasification, which is not conductive, so it can not be wire cut for precious metal cutting.  Wire cutting processing electrode wire size is much smaller than the cutting tool size (fine electrode wire can reach 0.006mm), using it to cut metal, can save a lot of slit consumption.

11. Engraving machine from the processing principle is a combination of drilling and milling processing  

According to different engraving methods can be divided into laser engraving and mechanical engraving.  

Laser engraving: mainly used in the machinery industry, basically is the use of numerical control technology, laser as the processing medium, processing materials in the laser engraving irradiation instant melting and gasification of physical degeneration, can make laser engraving to achieve the purpose of processing.  

Mechanical engraving: also known as CNC engraving machine, mainly used in woodworking, advertising, craft gifts and other equipment characteristics  

Laser engraving machine  

No contact with the surface of the material, not affected by mechanical movement  

Processing is not affected by the elasticity and flexibility of the material,  

High processing precision, fast speed, wide range of applications  

Mechanical engraving machine  

High machining precision  

Smooth operation, not affected by the shape of the material  

Machining accuracy  

Laser engraving machine: the processing accuracy is 0.05mm.  

Mechanical engraving machine: the processing accuracy is 0.05mm.  

Processing material  

Two-color board, Plexiglass, acrylic, rubber board, plastic, cardboard, leather, cloth, marble, tile and other brittle materials.

12.laser cutting equipment is the laser emitted from the laser, through the optical path system, focusing into a high power density laser beam.  The laser beam shines on the surface of the workpiece, so that the workpiece reaches the melting point or boiling point, while the high-pressure gas coaxial with the beam blows away the melted or vaporized metal.  With the movement of the relative position of the beam and the workpiece, the material is finally formed into a slit, so as to achieve the purpose of cutting.  Equipment characteristics  

High precision, fast cutting,  

Not limited to cutting pattern restrictions, automatic typesetting saves material  

Smooth incision, low processing cost:  

It will not cause scratches to the work surface during work,  

Laser cutting speed is fast, the incision is smooth and smooth.  

Processing type  

Plane class seasonal parts, curved parts, round class carved parts, special type carved parts, etc  

Machining accuracy  

The best cutting accuracy is ±0.02mm, the incision roughness Ra<6.5um.

Processing material:carbon steel, stainless steel, alloy steel, copper, aluminum, galvanized sheet and other materials.

13.Engraving machine (CNC engraving and milling machine) it is a kind of CNC machine tools, can accurately achieve a variety of processing methods.  

Equipment characteristics  

Adopting full closed-loop control technology,  

With 0.1u feed and 1u cutting capacity, low tool wear:  

The software is used to simulate the machining process, optimize the process elements, improve the safety of the process, and the accuracy of the processing size is high  

Strong cutting ability, with milling, grinding, drilling, boring, tapping, polishing and other composite processing capabilities  

The high light processing effect is like a mirror, and the processing speed is fast  

Processing type  

Curved parts, plane parts, cylindrical parts, special-shaped parts, complex cavity and so on  

Machining accuracy  

Machining accuracy is 0.002mm, surface roughness Ra<0.015um.  

Processing material  

Plexiglass, resin, wood, copper, aluminum, iron alloy, electrode, hardened steel, hard alloy steel, ceramics, etc

14.Bending machine is a machine that can bend thin plates, and the structure mainly includes a bracket, a workbench and a clamping plate  

Equipment characteristics  

All steel welded structure, high strength and rigidity  

Hydraulic drive, the equipment runs smoothly  

Mechanical block structure, stable and reliable  

Slide stroke maneuvering fast adjustment, manual fine tuning, counter display  

Oblique wedge deflection compensation mechanism to ensure high bending accuracy.  

Processing type  

Bending rice gold parts, electric control cabinet box parts, etc  

Machining accuracy  

The bending accuracy is 0.3mm, the maximum parallelism is 0.04mm, and the maximum perpendicularity is 0.2mm  

Processing material  

Steel, copper, stainless steel, aluminum alloy, etc.  

15.Sawing machine for sawing a variety of metal materials.  There are three common sawing machines: circular sawing machine, band sawing machine, hacksaw machine  

Equipment characteristics  

Fast and efficient  

High geometric accuracy of the workpiece  

Easy operation and maintenance  

Reliable performance, energy saving, material saving.  

Processing type  

Cylindrical parts, plane parts, step parts, curved parts, etc.  

Machining accuracy  

Sawing without burrs, perpendicularity up to 0.1mm, surface roughness Ra3.2~1.6um  

Processing material  

It can complete the cutting process of steel, aluminum, graphite, electrode, plastic and other materials.