The machining of complex curved surface parts requires precise programming. Through computer-aided design (CAD) and computer-aided manufacturing (CAM) technology, accurate tool paths are generated according to the three-dimensional model of the part. Programmers need to consider the geometric features of the surface such as curvature and slope, as well as the radius and length of the tool to ensure that the tool can accurately machine along the contour of the surface.
At the same time, the generated tool path is simulated by machining simulation software to find possible interference, collision and other problems in advance, and make timely adjustments to avoid errors in actual machining, thereby ensuring the dimensional accuracy of the parts.
Selecting the right tool is the key to ensuring the machining quality of complex curved surface parts. For turning and milling composite machining, high-precision carbide tools or diamond tools are usually used. These tools have good wear resistance, rigidity and cutting performance, can maintain a stable cutting edge under high-speed cutting conditions, reduce tool wear and deformation, thereby ensuring machining dimensional accuracy and surface quality.
In addition, the geometry and structure of the tool also need to be optimized according to the characteristics of the surface. For example, when using a ball-end milling cutter to machine a curved surface, the ball radius of the tool needs to match the curvature of the curved surface to ensure that the contact point between the tool and the curved surface is always in the best cutting position and reduce surface roughness.
The accuracy of the turning and milling composite machining machine tool itself directly affects the machining quality of the parts. The machine tool needs to have a highly rigid structure that can withstand the large cutting forces and vibrations generated during high-speed cutting and multi-axis linkage machining, thereby ensuring the stability of the machining process.
At the same time, each coordinate axis of the machine tool needs to have high-precision positioning accuracy and repeat positioning accuracy. By adopting high-precision ball screws, linear guides, encoders and other precision transmission and detection components, as well as advanced servo control systems, the precise movement and positioning of each coordinate axis can be achieved to ensure that the tool can accurately machine the shape of the complex curved surface according to the programming requirements and ensure the dimensional accuracy of the parts.
Reasonable selection of machining process parameters is crucial to ensuring the dimensional accuracy and surface quality of complex curved surface parts. Cutting speed, feed rate and cutting depth are three key process parameters. During the machining process, these parameters need to be optimized based on factors such as the material of the part, the performance of the tool and the complexity of the surface.
Generally speaking, for materials with higher hardness, lower cutting speed and larger feed rate should be used; for materials with lower hardness, the cutting speed can be appropriately increased. At the same time, the cutting depth also needs to be reasonably adjusted according to the rigidity of the tool and the power of the machine tool to avoid excessive cutting depth causing tool overload and part deformation, affecting dimensional accuracy and surface quality.
In the process of turning and milling composite machining, the online detection technology can be used to monitor the processing status and dimensional accuracy of the parts in real time. By installing laser measuring instruments, contact probes and other detection equipment on the machine tool, the parts in processing are measured in real time, and the measurement results are compared with the design dimensions.
If dimensional deviation is found, the system can automatically make compensation adjustments, such as adjusting the position of the tool or modifying the processing parameters to correct the deviation in time and ensure the dimensional accuracy of the parts. This online detection and compensation technology can effectively reduce machining errors and improve machining quality.
The wear of the tool during the machining process is inevitable, and the tool wear will directly affect the dimensional accuracy and surface quality of the parts. Therefore, the turning and milling composite machining system usually has tool wear monitoring and compensation functions.
By monitoring the cutting force, vibration and other signals of the tool, or using optical, electronic and other detection methods, the wear of the tool can be monitored in real time. When the tool wear reaches a certain degree, the system will automatically compensate for the length, radius and other parameters of the tool to ensure that the tool can always be processed with the correct size and position, thereby ensuring the dimensional accuracy and surface quality of the parts.
In addition to the above technical measures, strict quality control and management are also important links to ensure the processing quality of complex curved surface parts. Establish a complete quality management system, from the inspection of raw materials, the selection of tools, the formulation of processing technology to the inspection of finished products, each link is strictly controlled.
Carry out comprehensive inspection of the processed parts, including the inspection of dimensional accuracy, shape error, surface roughness and other indicators, to ensure that the parts meet the design requirements. At the same time, record and analyze the data during the processing process to timely discover potential quality problems, and take corresponding improvement measures to continuously improve the processing quality.
