Precision Parts Processing Integral Machining One-shot Process Technology

1. Part Structure

　　With The Widespread Application Of CNC Machining Technology, The Complexity Of Part Structures Continues To Increase. In The Processing Of Some CNC Parts , Positioning Clamping Are Very Difficult, They Are Suitable For Multiple Positioning Clamping. The One-Time Forming Technology Of Overall Machining Is To Rotate Flip The Workbench According To The Angle On The Horizontal Vertical-Horizontal Conversion Machining Center Machine Tool, Process All The Faces Holes Of The Parts As A Whole At One Time. After Meeting All The Shape Position Tolerance Requirements Of The Drawing, The Part Connected To The Process Handle Is Milled In Layers To Separate The Process Handle The Workpiece. As Shown In Figure 1, The Part Material Is Aluminum Alloy 2A12-T4 Profile, With An Outer Circle Of Φ32mm, K Base Surface Hole Φ30mm, M Base Surface. The Shape Position Accuracy Requirements Are Relatively High. If Positioning Clamping Are Performed Twice, The Positioning Error Will Be Large Clamping Will Be Difficult. By Adopting The One-Time Forming Technology Without Unloading Parts, The Shape Position Accuracy Of Precision Parts After Processing Is Well Guaranteed.

2. Processing Principle

　　The Machining Plant Fully Utilizesthe Multi-Angle All-Round Processing Advantages Of The CNC Machining Center , Utilizes The High Speed Small Feed Characteristics Of Carbide Milling Cutters To Process Parts With Small Deformation, Utilizes The Residual Shape Of Profile Parts As Positioning Clamping Process Handles, Utilizes The Automatic Programming Function Of UG Software To Ensure The Consistency Of The Overall Processed Parts Good Connection Fit Between Each Surface.

3. Process Plan

　　(1) For Example, The Part Has A Single-Side Allowance Of 0.5mm, Each Surface Hole Are Roughly Processed. The Remaining Part Of The Profile Is Reserved As A Process Installation Handle. A Screw Hole Of 3×Φ6.5mm, A Countersink Of 3×Φ11mm, A Depth Of 6mm, A Boring Hole Of 2×Φ4mm (Locating Pin Hole) Are Drilled At The Process Handle. After The CNC Part Processing Is Stabilized (Internal Stress Is Eliminated), The E Reference Surface Is Ground To Ensure A Flatness Of 0.008mm. Huiwen Zhizao Is A Machining Factory With More Than Ten Years Of CNC Processing Experience . It Has A Full Range Of Equipment, CNC Lathe/Milling/Grinding/Drilling/Processing. Partners With Parts Processing Needs Are Welcome To Call Us For Quotes.

　　(2) For Example, For CNC Parts Processing, Special Bent Plates Are Designed Manufactured. 40Cr Quenched Tempered Steel Is Used. Grinding Ensures The Flatness Of The Installation Surface Is 0.006mm. 3×M6-6H Threads Are Drilled Tapped. 2×Φ3mm Holes Are Drilled Reamed (Locating Pin Holes). 2×Φ13mm Bent Plate Fixing Holes Are Drilled. Flat Holes Are Milled To Make Way (When Processing K Surfaces Φ32mm Holes For Precision Parts , The Rod Milling Tool Can Be Inserted Into The Flat Holes For Processing).

　　(3) For Example, The Principle Of One Side Two Pins Is Adopted To Locate The CNC Parts Processing Special Bending Plate Installed Near The Center Of The Horizontal Machining Center Worktable. The Table Is Used To Verify That The F Surface Is Perpendicular To The Worktable Surface, The Bolts Are Tightened On The Bending Plate. Grind The E Surface 2×Φ4mm Holes According To Figure 2 For Positioning, Fine-Machine The Parts According To Figure 1, Fine-Mill The Outer Circle Φ32mm The K Base Surface, Fine-Mill The M Base Surface The Back Surface, Fine-Boring The Φ30mm Hole, Etc., To Ensure The Size Shape Accuracy. (4) Before The Part Processing Is Completed, The CNC Program Executes The Pause Command (M00), Places A Hard Sponge Pad (Approximately 20mm×300mm×300mm In Appearance) At The Bottom Of The Part Falling, Continues Processing. According To Figure 1, Use A Φ6mm Carbide Milling Cutter To Probe Into The Flat Hole Of The Special Bending Plate Fixture, Mill Each Layer With A Depth Of 0.1mm, Mill The Outer Contour R49mm, 86mm Of The Part The Connection With The Remaining Process Handle In Layers To Separate The Workpiece The Process Handle. The Part Falls On The Pre-Placed Hard Sponge Pad (To Avoid Bumps Deformation Of The Part), The Remaining Flash Around The R49mm Of The Part Is Cleaned Up By The Fitter.

4. Implementation Effect

　　Independent Innovation Adopts The Integral Machining One-Time Forming Process Technology For The Bracket Parts. When The Bracket Parts Shown In The Precision Parts Processing Are Mass-Produced, They Are Tested By Three-Coordinates, The Statistical Data Of Shape Position Accuracy Are As Follows: K Base Surface Flatness ≤0.012mm, M Base Surface Flatness ≤0.01mm, M Back Surface Parallelism ≤0.015mm, Φ30mm To M Base Surface Verticality ≤0.013mm, Φ32mm To K Base Surface Verticality ≤0.015mm, Φ30mm Φ32mm Axis Intersection ≤0.014mm. The Shape Position Accuracy Of Parts Is Stable In Mass Production, Production Efficiency Is Greatly Improved. Huiwen Zhizao Is A Machining Factory With More Than Ten Years Of CNC Machining Experience, With Complete Equipment, CNC Turning/Milling/Grinding/Drilling/Machining. Partners With Parts Processing Needs Are Welcome To Call Us For Quotation.

5. Application Expansion Scope

　　The One-Step Forming Technology Of The Integral Machining Of Parts Can Be Used Only In Horizontal Machining Centers, But Also In Vertical Vertical-Horizontal Conversion Machining Centers. As Shown In Figure 5, The Part Can Be Formed In One Step With A Rectangular Aluminum Alloy Profile On A Five-Axis Machining Center, The Process Handle Can Be Removed By Layered Milling; As Shown In Figure 6, The Part Can Be Formed In One Step With A Rectangular Aluminum Alloy Profile On A Three-Axis Machining Center, The Pressure Plate Can Be Processed. The Left Right Supports Can Be Formed In One Step At The Same Time, The Residual Process Table Can Be Removed By Layered Milling.

6. Conclusion

　　The One-Step Forming Process Technology For Overall Machining Of Precision Parts Is Mainly Used For Parts That Are Difficult To Locate Clamp. It Can Merge Processing Steps, Improve Work Efficiency, Ensure Shape Position Accuracy. It Can Be Used For Paired Nesting Of Symmetrical Structural Parts To Reduce The Number Of Clamping Times Save Tooling Production Costs. It Is Suitable For High-Speed, Small-Feed, Layer-By-Layer Scanning Processing. During Processing, The Cutting Force Is Small, The Cutting Heat Is Small, The Parts Are Easy To Produce Stress Deformation. This Processing Concept Is Being Gradually Promoted In Our Company. The Team Of Shenzhen Huiwen Intelligent Manufacturing Technology Co., Ltd. Was Established In 2010 Is Located On The 1st Floor Of Building F3, Tianyou Maker Industrial Park, Lixinhu, Fuyong, Bao'an District, Shenzhen. It Has Long Been Committed To The Processing Of High-Precision, High-Difficulty, Easy-To-Deform Metal Plastic Parts , Small Medium-Volume Production Manufacturing Of Light Alloy Composite Materials (Such As Aluminum Alloy, Carbon Fiber, Etc.),  Robot Parts Procurement Customization Services. Huiwen Intelligent Manufacturing Can Currently Provide High-Quality, Low-Cost Products With On-Time Delivery In The Following Aspects.