Exploration of CNC machining technology in mechanical mold manufacturing
Since its introduction in the 1950s, CNC machining technology has developed from simple CNC lathes to multi-axis linkage CNC machine tools.
The traditional method of mold manufacturing has certain limitations in terms of precision and efficiency, and the introduction of CNC technology has made the processing of complex surfaces and high-precision parts a reality.
CNC machining technology reduces human error through automated operation, especially in mold manufacturing, significantly improving overall processing quality and consistency.
Therefore, an in-depth study of the application of CNC machining technology in manufacturing machinery and molds is of great practical significance.
Basic principle of CNC machining technology
CNC machining technology (Computer Numerical Control, also known as CNC) is a computer control program that uses the movement of the machine tool and the machining process to achieve precision control. CNC’s core lies in automation and high-precision characteristics.
Generally speaking, a CNC machining system mainly contains the following parts.
(1) CNC system.
The CNC system consists of a computer, control software, and the corresponding hardware interface, which sends commands through the computer to the various ports. Thus, the CNC system can also be regarded as the brain of the machine tool.
The computer will accept and process the input machining instructions during operation and convert them into operating instructions that can command the movement of the machine tool. The hardware interface is the primary channel for transmitting instructions.
(2) Processing software.
This part is the language of CNC machining technology, usually using CNC code instructions.
(3) Servo system.
The CNC servo system contains servo motors and servo drives. Servo motors drive the machine tool’s various moving parts, such as the spindle, tool, and table.
The servo drive is according to the CNC system’s control instructions, and the servo motor’s speed and position are adjusted to ensure that all parts of the machine tool follow a predetermined trajectory.
The main content of the application of CNC processing technology is the design of CNC programs, which can be divided into artificial programs and computer programming.
CNC programs need to be strictly by the processing design drawings for the design of the program trial run. The program staff also needs to optimize the program to avoid problems that may arise during formal processing.
CNC processing requirements in the manufacture of machinery mold
Determine the processing technology
Manufacturing machinery molds requires a reasonable choice of processing technology to ensure that CNC processing can meet the production accuracy of machinery molds.
At the same time, the process of cutting different metal materials is also different, so it is necessary to combine the basic properties of the material to choose the appropriate tool and cutting process. For example, when the material is strong and rigid, it is necessary to use carbide cutting tools and a high-speed cutting process.
In industrial development, the complexity of machinery molds is also increasing. As a result, mold machining processes are encountering more complex contours and curved surfaces.
More advanced CNC technologies are needed if traditional cutting processes cannot meet the required production accuracy.
One such technology is the five-axis machining process, which can address the complexity of machinery mold processing.
Additionally, depending on the mold’s shape, different machining methods, such as EDM, turning, and milling, should be selected.
Mould processing parameter settings
Machinery molds are processed differently due to the use of different environments and working conditions; a reasonable set of parameters can not only improve the processing accuracy but also avoid material waste.
Therefore, in the processing process, the relevant personnel can use CAD/CAM and other technologies to confirm the three-dimensional model of the machinery mold for the subsequent processing procedures, providing an accurate processing basis.
In setting the mold parameter, staff also need to consider the material’s thermal stability and wear resistance, as far as possible, combined with the material properties of the selection of appropriate processing methods, to enhance the mold’s service life.
Principles for the production of machinery mold
In machinery production, molds are usually produced in a single piece. Each mold has special requirements, which require a strictly determined CNC machining process on the CNC machine program to avoid repeated mold opening.
And in the processing process to reduce processing errors, improve productivity, the staff should be clear on the processing procedures and specific steps, through the depth of cut, feed rate and cutting speed for reasonable control, can effectively avoid the process of processing may occur in the tool wear too fast, cutting too deep and other issues.
At the same time, in the actual processing, staff also want to select the clamping mode, which needs to be determined according to the nature of the material and shape of the machinery mold, to avoid affecting the stability of the workpiece in the processing process.
Different CNC technologies in the processing of machinery and mold applications
CNC EDM technology
CNC EDM technology, which is achieved through the control of spark discharge to process metal materials, is mainly used in some of the more complex mold processing, such as precision parts and the production of machinery and molds.
In the actual processing of the technology, staff can realize the precision processing of hard materials through the electric spark discharge current, discharge voltage, pulse width, and spacing, and electrode control, which can be etched on the material, and ultimately achieve the processing requirements.
For example, in auto engine mold production, the staff can mold cavities and shape holes for processing with the help of CNC EDM technology.
The use of this technology can help staff meet the complex mold structure and facilitate the later processing of mechanical parts, assembly, and other operations.
At the same time, the current auto parts production process often needs concave and convex surfaces, holes, and other conditions of the parts.
Traditional processing technology has limitations in this regard, and the application of CNC EDM technology can make mechanical molds more precise.
Application of CNC milling processing technology
The traditional processing method realizes the milling processing through CNC machining technology for cutting.
It can be applied to various metal materials and processed into a variety of complex machinery mold shapes. Because of its flexibility, high efficiency, and high precision, it is widely used in producing machinery molds.
For example, in the field of automobile manufacturing, the staff, with the help of CNC milling processing technology, can control the path of the tool, in strict accordance with the needs of automobile mold processing on the plane of the mold parts, such as cavity cutting, and then improve the processing accuracy.
Turning processing technology
When applied in turning processing, CNC machining technology refers to the use of CNC machine tools for cutting and shaping. This technology’s most significant advantage is its ability to perform multiple operations simultaneously.
These include machining the outer circle of mechanical parts (including tapers), boring (also with tapers), and cutting internal and external threads. It offers high efficiency, strong stability, and excellent precision.
Because of these advantages, CNC turning technology is widely used in mechanical mold manufacturing.
Its applications extend across industries such as automotive manufacturing, aerospace, and other advanced technologies.
For example, in the production of aviation engines, the staff can determine the cutting parameters and carry out internal and external round machining of engine parts.
It can carry out thread processing simultaneously during the machining process, improving the overall machining efficiency.
At the same time, components such as bearings, gears, bearing housings, and other transmission system parts are required to be precisely matched in aerospace processing.
Turning processing technology applied to mechanical parts can meet these high-precision requirements. This technology enables high-precision machining, ensuring that mechanical molds and components achieve high accuracy.
As a result, it guarantees excellent matching performance between parts used in aerospace systems.
Electrolysis technology
Electrolysis technology in CNC machining uses electrochemical principles of processing technology. In the actual application of the process, electrolysis technology can clean up the surface of the metal material impurities, oxidized layer, and oil, enhancing the overall accuracy of the technology.
At the same time, additional surface treatment methods are often required to improve the surface quality of metal materials during processing.
These methods include brushing, electro-etching, and electroplating. Electrolytic technology can also be used for these processes.
In this process, the operator adds specific substances to the electrolyte solution. When the system is energized, a cathodic and anodic reaction occurs between the material and the electrolyte.
This reaction helps remove surface contaminants from the metal, improving overall processing accuracy.
At the same time, in the electroplating process, CNC machining technology can form special anti-corrosion materials on the surface of metal materials by guiding the electric current and carry out precision processing of technical materials so that they can form specific patterns.
Ultrasonic technology
This technology uses ultrasonic vibration to process and treat material. This technology is usually used in the mechanical mold-making to dust and clean the tool to enhance processing efficiency.
In the actual application process, the staff will be processed into the tool ultrasonic wave bath, and through the wave bath of high-frequency vibration, the use of small bubbles burst on the surface of the metal tool to clean it, enhancing the service life of the tool.
The staff can also use ultrasonic technology for metal welding in the automotive machinery mold production process.
Staff can pass through the metal surface for high-frequency vibration, promoting the collision between the metal and then realizing the cold welding. Automotive mold assembly and repair have a wide range of applications.
At the same time, the automotive machinery mold production process also needs to be used in a plastic welding situation.
Through ultrasonic vibration, friction, and heat, brazing material and metal or plastic material between the micro-touch can achieve high efficiency and a high-quality brazing and plastic welding effect.
CNC machining technology in the production of machinery mold application points
Establishment of the processing database
The CNC machining processing database’s improvement can effectively improve the processing efficiency.
Staff in each mechanical mold processing should be used in the tool selection records.
The tool type, model, cutting conditions, and other summary parameters can clarify the same material processing tool selection, enhancing the efficiency of the application of CNC machining technology.
At the same time, after summarizing the time of each CNC machining process, the staff can effectively clarify the problems that may occur in the machining process and then look for solutions.
Finally, the processing database contains a record of each CNC machining operation, and the final solution, by summarizing and analyzing these data, can help staff avoid the same problem in subsequent processing.
Control of geometric errors
The production of machinery molds requires complex precision work. Even a small error in the actual processing can have a more serious impact on the final processing results.
Therefore, the processor needs to have reasonable control of geometric errors.
First, in the processing process, staff use advanced CNC machine tools and measurement technology, geometric error for comprehensive monitoring and control, to ensure that the geometric error meets the processing needs.
In the actual measurement process, staff need to use precision measuring instruments, such as three-coordinate measuring machines, to accurately measure the coordinates of the mold to ensure that the geometric parameters and shape of the mold are accurate.
At the same time, the deviation found in the strategy process needs to be determined in time for the processing parameters.
Secondly, to reduce the error in tool movement, you can also use compensation technology, the running trajectory of the tool for continuous fine-tuning, and then realize the automatic correction of geometric errors.
It is important to pay attention to the adjustment mechanism and the implementation of the feedback mechanism during program writing.
By reasonably controlling the accuracy of the machining process, potential errors can be identified and corrected in time. This ensures that the mold can be accurately processed throughout the machining operation.
Compensation technology in the process of program preparation for reasonable application can ensure that in the processing of complex molds to avoid machine movement, tool wear errors.
Finally, simulation technology is necessary to avoid uncorrectable errors during actual machining. This involves simulating the actual machining process before production begins.
Potential risks can be identified in advance by using a simulation environment to replicate the real processing scenario.
This allows staff to make necessary corrections before actual machining, improving overall processing efficiency.
Acquisition of mold information
Mechanical mold processing as a precision processing technology, in the actual operation process needs to pay attention to the acquisition of mold information.
First, the staff needs to collect temperature data from the mechanical mold. Temperature sensors can be installed on the machine tool to do this.
These sensors are used to monitor the friction temperature of the tool in real time during the machining process.
Real-time detection helps prevent abnormal rises in temperature during cutting. This is important because excessive heat can deform the workpiece.
To enhance the success rate of mold processing, based on a comprehensive collection of temperature data, it is also necessary to adjust the cutting speed and cooling system parameters in real time through the software according to the rising temperature trend to achieve effective temperature control.
Secondly, during the machining process, abnormal vibration of the equipment can affect the accuracy of mold processing. If such vibrations occur, the mold may fail to meet the required precision.
Therefore, vibration data must be collected during the machining process. This helps prevent excessive tool vibration, which can cause processing errors.
In addition, comprehensive vibration data collection allows staff to analyze abnormal equipment failures.
This analysis helps avoid sudden equipment breakdowns during processing, which could otherwise decrease machining accuracy.
Determination of the tool route
The most important aspect of CNC machining technology is controlling the tool route. The staff needs to accurately specify the tool’s trajectory in the programming process, including idling, retreating, cutting, and other actions.
For reasonable planning, the tool’s process should be combined with the processing of the actual shape of the mold and the tool characteristics of the tool movement path.
In the calculation process, the staff can use artificial intelligence learning technology, through the simulation of different processing situations, and continuous learning to help staff find the best tool path and then realize the efficient processing of mechanical molds.
At the same time, in the construction process, the staff can use computer simulation software to simulate the tool path of the equipment and, by judging the possible problems of the tool in the machining process, achieve the optimization of the tool path.
Finally, when determining the tool path, the staff must also consider the fixture’s shape and structure. This becomes especially important if the mechanical mold has a more complex shape.
Select fixtures that provide enough fixed points to avoid interference with the tool path. These fixed points help to hold the mold securely during machining.
This prevents any unwanted movement of the mold, which could affect the accuracy of the tool path.
Conclusion
In summary, CNC machining technology has broad application prospects in machinery mold processing. This paper analyzes using different CNC machining technologies in mold processing applications.
It also outlines the key points related to the application of CNC machining technology. The study shows that the reasonable application of CNC machining can significantly enhance the precision of machinery mold processing.
In addition, it can help reduce processing costs and improve overall machining efficiency.