1高速铣削机床厂现状
我厂有一台5轴联动Rambudi高速铣床，{zd0}刀具直径20毫米夹紧，主轴功率一二千瓦，{zd0}的饲料10m/min，主轴转速1000到15000r/min，菲迪亚系统自动放慢一个很好的机器，当一个曲率急剧变化，自动减速，避免高速时机床的损害，这是一个比较典型的高速机床惯性。
虽然高速铣床速度可以达到1.5万，但它只有在准高速运转，处理速度扁铁件7000至8000转/分，饲料约6000mm/min，每齿0.3饲料0.4（毫米/齿）关于沃尔特SΦ20球刀使用：P3202 - D20的刀具材料：WXK15。沃尔特提供按照“切削参数”，在8000工具的理查德转/分的切削速度已基本达到极限。
2分析工具刃具
由刀具材料的切削材料的切割速度，还有一些切割工具的参数，如：前角，后角，如共同决定，一旦选定工具，切割速度确定的，但我们正在处理的模具表面用球头铣刀，恒定的速度，工具分线速度从零加速尖，刀直径{zd0}，汽车模具不同的往往是复杂的曲面，刀具切削在任何时间点的变化，所以切割速度的变化，这在很大程度上制约了汽车模具高速加工范围非常广泛。
目前，个别企业在高速加工参数已在步骤0.1毫米至3.0万转用，但汽车模具，高速加工仅用于平板适宜加工的，因为更高的速度，工具在范围线速度的变化更大，该工具允许切削速度范围比这个值小。方法来解决这个问题是分片处理，将单独的区域进行隔离处理单位，为了避免零速刀具中心线的缺点，可以适当的角度处理。外板件的，如拉伸模罩，部分温和产品可以进行高速加工，技术，添加有部分高速适宜加工，除了几乎与外压料面板块是不平坦的表面，今天在此间表示该单位表面必须更大，如果补丁也因为太多提许多刀小，刀具路径很短，经常化，但不利于高速加工。即使有部分是外板也过于接近的年数，如前围，事情似乎较为平坦的地区将减少拉丝模出高速冲压加工，可以分区域的不到20％，这20％可提高30％的效率，从而提高了5％以上，如门罩和其他类型的作品整个冲效率更高，可以达到更已超过20％。如果只对部分分离到一个小的高速处理，整体而言，并不一定提gx率。
3高速编程
3.1注意的模具表面质量检验数量
品质数字至高速加工模拟扮演着非常重要的作用，会直接影响刀具路径平滑性，从而影响工作效率和质量。根据以往的经验，在模具表面处理前的数模表面质量分析是必要的。
（1）分析的主要内容：
产品表面平滑，以及裂缝和缺陷，无论是在绘图负面的角度方向，无论是进程的一部分添加圆角等，保证了质量物理处理。
（2）分析：
1）利用截面和索尔兹伯里产品表面平滑一个产品分析高斯曲率半径发现模型表面质量。
2）通过视图操作，偏差分析，模型检查存在的扭曲，重叠，裂缝等缺陷。
3）表面处理模型精度的公差分析中的表面加工质量的生产模式可以预期提前的影响。
4）进入UG的加工环境，加工认证模块数量，不正常的表面（虚线被加工表面的显示框），早期zl，以防止发生在酒吧刀现象。详细分析，特别是较小的过渡面，圆面容易出现问题，重要的是，高速一切等，但加工，出现了错误，这可能导致在很多交通事故。
3.2表面刀切片和原则
访问（1）模具表面处理采用模块进行编程，该单位，并分别在陡峭的一侧，以提高加工技术和提高加工效率。正如图1所示，该程序可以考虑在高速加工利用单位的地区。
（2）采取刀方式
外界面板拉丝模，必须有足够的重视，尽可能沿刀体加工方向，如图2所示。
在刀放回刀（3）反馈的方式刀，并降低了方向前进，后退圆刀切使用。为了不留下痕迹，改善表面光洁度和精度，在此过程中设计的削减，削减了一系列的额外弧段的程序段的位置，以便在初始切削加工点，弧段，同初始切线切割元素，因此这意味着弧切割机切入工件，以确保加工表面粗糙度，如图3所示。
（4）加工的顺逆选择
表面加工切割时正处在一个固定的加工方向，独联体铣削使用。
4。五轴联动功能
我们高速5轴铣床具有联动功能，但我认为赛车是很不适合模具，如果比较大，零件的规则，用五加工轴联动效果好，并作为例如五年叶轮，轴加工部分将不会是很困难的，但汽车模具表面相当复杂，经常会带上部分的方法，是不可能的，因为如果我们这样做也是摆头机严重的，当然与模具型面的干扰，因为工具不能总是使用同一地区的切割，它失去了五轴联动的意义。还有另外一个重要问题，就是如果三个联动中，A与C轴轴机床是由液压系统锁定，如果有5轴机床的A轴和C轴机床上的联系自己的驱动器系统的控制，大大降低了机床，精密五轴保持很差，速度比三五轴插补刚性轴低。
最近，我开始处理这个没收了良好的五种植物轴联动无用的处理材料，是树脂，软物质，以避免五轴联动不利刚性差。检获的中变的角度概述，以及大量的斜孔，以5轴联动程序，大大提高了加工效率，在缺席5轴联动，变刀轴轮廓上球型刀，模仿加工的5轴联动，可以使用刀具的一方边处理，处理效率差别很大。
Car mold how to use high-speed five-axis milling machine linkage
1 high-speed milling machine tool factory the status quo
our plant has a five-axis linkage Rambudi the high-speed milling machine, the largest tool diameter clamping 20mm, spindle power of 12kw, the largest feed 10m/min, Spindle Speed 1000 to 15000r/min, FIDIA systems automatically slow down a very good machine, when a sharp change in curvature, the automatic deceleration and avoid high-speed when the inertia of the machine tool damage, which is a more typical high-speed machine tools.
Although high-speed milling machine speed can reach to 15,000, but it was only in the quasi-high speed operation, the processing speed flat iron parts 7000 to 8000 r / min, feed about 6000mm/min, feed per tooth 0.3-0.4 (mm / tooth) about the use of Walter SΦ20 ball knife: P3202-D20 Tool Material: WXK15. Walter provided in accordance with the Richard of the tool in the 8000 r / min cutting speed has been basically reached the limit.
2 Analysis Tool Cutting Tool
the cutting speed by the tool material, the cutting material, there are the parameters of cutting tools such as: anterior horn, posterior horn, such as jointly decided, once the selected tools, cutting speed on the identified, but we are processing mold surface using a ball cutter, constant speed, the tool points the linear velocity is different from zero tip speed, knife diameter the largest, automotive molds often are complex surfaces, cutting tool cutting point change at any time, so a very wide range of cutting speed changes, which to a large extent restricted the car mold high speed machining.
At present, individual enterprises in high-speed machining parameters have been used in step 0.1mm to 30,000 rpm, but the car dies, the high-speed processing is only suitable for flat plate processing, because the higher the speed, tool the linear velocity changes in the scope of the greater, and the tool allows the cutting speed range is much smaller than this value. Ways to solve this problem is the sub-chip processing, will be flat out separate regional isolation processing, in order to avoid zero speed cutter centerline disadvantage can be the appropriate angle processing. Outer plate of pieces such as the hood of the Drawing Die, part gentle Products can be carried out high-speed processing, technology to add part of it is suitable for high-speed processing, with the plates apart from almost outside the binder surface is no flat surface, said here today that the flat surface must be larger, if the patch is too small because of too many to mention many knives, tool path is very short and frequent turning but is not conducive to high-speed machining. Even if some parts are outside the board is also too close to the number of years, such as pre-Wai, things appeared less flat areas will be less Drawing Die punch out high-speed processing can be sub-regional less than 20%, and this 20% can improve efficiency of 30%, then improve the efficiency of the whole punch in more than 5%, such as doors and other pieces of the hood is even higher can be achieved more have more than 20%. If a separation of parts only to a small high-speed processing, on the whole does not necessarily improve efficiency.
3 high-speed programming
3.1 Note the number of mold surface quality inspection
quality digital-to-analog for high-speed machining plays a very important role, will directly affect the Tool Path Smoothing sex, thereby affecting the efficiency and quality. Based on our past experience, in the mold surface before processing for digital-analog surface quality analysis is necessary.
(1) analysis of the main contents:
Products Surface Smoothing, and the cracks and defects, whether in the direction of drawing negative angle, whether it was part of process to add rounded corners, etc. guarantee the quality of the physical processing.
(2) Analysis:
1) using cross-section and the Gaussian radius of curvature of Salisburys Products Surface Smoothing analysis of a product is found to model the surface quality.
2) through the view operation, deviation analysis, model checking the existence of twist, overlap, cracks and other defects.
3) processing model precision surface analysis model of tolerance during production of the surface machining quality can be expected to impact in advance.
4) to enter the UG-processing environment, the number of processing module for authentication, to have abnormal surface (dotted line to be machined surface shows that the box), early treatment to prevent the occurrence of bar-knife phenomenon. To analyze in detail, especially the smaller the transition surface, rounded surface prone to problems, it is important, high-speed processing of one-cut, etc. However, there have been errors, which may result in a lot of accidents.
3.2 Surface knife slicing and access principles
(1) mold surface processing using block programming, the flat and steep side separately in order to improve the processing technology and improve processing efficiency. As shown in Figure 1, the flat region of the procedure one can consider the use of high-speed machining.
(2) take the knife way
for the outside panel drawing die, there must be sufficient attention, as far as possible along the direction of knife body processing, as shown in Figure 2.
(3) Feed back the way knife
in the knife back into the knife and cut the use of circular knife cut out the way to advance and retreat. In order to not leave marks, improve surface finish and accuracy, in the process design, in the cut and cut out a section of the location of the additional arc program segment so that the arc segment in the processing of initial cutting point, with the initial cutting element tangent, so that means arc cutter to cut into the workpiece, to ensure processing of the surface roughness, as shown in Figure 3.
(4) milling the choice of good or bad times
surface machining when cutting is at a fixed direction of processing, the use of cis milling.
4. five-axis linkage function
our high-speed five-axis milling machine has the function of linkage, but I think the car is not very suitable for mold, if the processing of relatively large and the rules of spare parts, used five-axis linkage good effect, and as the impeller, such as five-axes machining parts will not be very difficult, but the car mold surface is rather complicated, it is impossible to always along the parts method, because if we do摆头machine too serious, certainly with the mold-type surface interference, since the tool can not always use the same area to the cutting, it lost its five-axis linkage significance. There is another important issue, that is, if three linkage, the A-axis machine tool with the C axis are locked by hydraulic system, and if linked with five-axis machine of the A axis and C-axis machine tools are on their own drive systems control, which greatly reduces the rigidity of machine tools, precision five-axis to maintain a very poor and five-axis interpolation faster than three-axis low.
Recently, I started processing plant seized with this for a good five-axis linkage useless, with the materials seized are resin, soft material to avoid a five-axis linkage disadvantage poor rigidity. Seized with the outline of the perspective of the medium variant, as well as a lot of slant-hole, the use of five-axis linkage procedures greatly enhance the processing efficiency, in the absence of five-axis linkage, variable knife-axis contours are on the ball-type knife to imitation processed, with five-axis linkage can use the cutter to the side edge processing, processing efficiency varies greatly. (07-12-10)
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