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CNC 5 Axis Machine Center in automotive mold manufacturing

Oct 28, 2019

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CNC 3 Axis Machine Center and CNC 5 Axis Machine Center mold comparison CNC vertical machine Center for deep cavity mold processing can only be achieved by lengthening the tool holder and tool, but CNC 5 Axis Machine Center is processing deeper and steeper type In the cavity, the optimum process conditions can be created by the additional rotation and swing of the workpiece or the spindle head, the tool length can be appropriately shortened, and the collision between the tool and the tool holder wall and the cavity wall can be avoided, and the jitter during tool processing can be reduced. The risk of damage to the tool, which increases the surface quality of the mold, the processing efficiency and the life of the tool.

 

When machining the side wall of a mold with CNC 3 Axis Machine Center, the depth of the side wall determines the length of the selected tool. The length of the tool must be greater than the depth of the side wall. If the length of the tool increases, the strength of the tool will be reduced. If the length of the tool exceeds 3 times the diameter will appear to make the knife phenomenon, it is difficult to guarantee the quality of the workpiece. By machining the side wall of the workpiece with a CNC 5 Axis Machine Center, the workpiece or the spindle can be oscillated so that the tool is perpendicular to the side wall of the workpiece, and then the side milling cutter is used to mill the side wall, which can ensure the quality of the workpiece and prolong the tool life.

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When machining a flat surface with the CNC 3 Axis Machine Center, use a ball cutter to finish milling to get a better surface quality, so you should increase the tool path. However, as we all know, the linear velocity of the center of the tool of the ball-end knife is close to zero, so the tool is greatly damaged during the machining, the tool life is shortened, and the surface quality is deteriorated. When machining a flat surface with a CNC 5 Axis Machine Center, in order to increase the relative linear velocity between the ball-end knife and the workpiece, the tool is machined at a certain angle on the workpiece as shown in Fig. 4, so that the ball between the ball-end knife and the workpiece The relative linear velocity increases, which improves the life of the tool and improves the surface quality of the workpiece.

 

In addition, when the CNC 5 Axis Machine Center performs the normal hole machining on the inclined surface, the machining operation in the oscillating machine tool is to position the spindle to the position perpendicular to the inclined surface on the workpiece through the oscillating head, and the hole is processed. At least two linear axis interpolation motions are required to machine the oblique holes, which greatly reduces the accuracy of the holes. When using the pendulum CNC 5 Axis Machine Center for oblique face machining, the action is to place the bevel on the workpiece perpendicular to the main axis through the pendulum table. Only one linear axis movement of the spindle is required for the hole machining, which greatly improves The accuracy of the hole.

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Other advantages of the CNC 5 Axis Machine Center system

Nowadays, the requirements of automotive molds for the surface quality and cutting speed of the mold have become higher and higher. When the five-axis CNC system is used to machine a plane with a three-dimensional curve, the best cutting state can be obtained, and different geometric shapes can be processed by changing the setting angle of the tool axis at any position within the machining area of the machine. The irregular shape of the same shape is usually CNC Vertical Machine Center, the cutting tool direction remains unchanged during the movement along the entire cutting path, and the cutting state of the cutting edge can never be perfected in all parts of the entire surface. However, for deep grooves or curved surfaces that change curvature frequently, it is necessary to use a five-axis CNC system. The direction of the tool or the position of the table can be changed. The cutting tool can always maintain the best cutting state and move along the entire machining path. The tool direction can be optimized during the process, while the tool moves in a straight line so that it is perfect in all parts of the entire surface. If you want to mill a straight line with no direction change, the tool holder will draw a straight line. If the direction changes at the same time, the tool tip draws a curve. If the tool tip can be used to draw the desired line when the direction is changed, the curve must be compensated, which is a crucial point in the 5-axis machining. The tool rotates around the center of the shaft without regard to the tool length. The tip will move out of its position and is not fixed. However, a five-axis control function has been added to the control system. The control system only changes the direction of the tool and the tool nose position remains unchanged. The necessary compensation motion on the X, Y, and Z axes has been automatically calculated to ensure the accuracy of the machining.


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