Suzhou Electric Machining Machine Tool Research Institute (215005) has been widely used in machinery (especially mold manufacturing), aerospace, aviation, electronics, and automobiles because of its many advantages that traditional machining has incomparable. , light industry and other industries to solve the processing problems of difficult materials and complex precision parts. Ultra-large molds and parts ranging from as small as a few tens of micrometers to fine shafts, holes, and slits, up to several meters. Among the advanced manufacturing technologies in the world, special processing technology has become an indispensable key technology and has shown a booming trend. In a wide variety of special processing machines, this article will introduce the current status and development trends of a wide range of machine tools with large areas or rapid technological advances.
Over the years, the numerical control rate of domestic EDM machines has been low.
Through the continuous development of new technologies and new technologies by various production enterprises, the functions of domestic molding machines are becoming more and more abundant. Now it is capable of producing single-axis CNC, three-axis two-link and four-axis three-link machine tools, with C-axis function and AEC function. A relatively complete process database has been established, and artificial intelligence and fuzzy control technology have been adopted to realize numerical control translation (up to 11 kinds of translational modes), with various functions such as automatic positioning, automatic center finding, and automatic conversion of processing conditions. Therefore, this type of machine tool has won the favor of many users. Its representative products are Suzhou DK7140 three-axis CNC, Hanchuan Machine Tool Co., Ltd. Responsible company (referred to as: Hanchuan company) HCD350K three-axis CNC and so on. Among them, Beijing Aqi Xia Mil Industrial Electronics Co., Ltd. (abbreviation: Beijing Aqi) SE2 precision CNC EDM machine is a domestic product with relatively high technical content. It can control X, Y, Z, C4 coordinate axes at the same time, and can realize the processing requirements of the precision precision mold and the automatic precise positioning during the electrode replacement process by automatically exchanging the electrodes. The factory inspection is carried out in accordance with the German VDI standard. The best surface roughness: Ra < 02fxm; the lowest electrode loss < 003%; C axis (optional) repeat positioning accuracy is 18"; AEC device can store the number of electrodes: 5 (optional).
Today, the rapid development of idling washing, the development of EDM machines has been subject to certain constraints. EDM machines should seek development in a long way, avoiding large-area, large-volume high-efficiency machining (this is the advantage of idle milling), to precision, complex, micro-machining, deep cavity machining, deep groove narrow seam machining Development of superhard materials and processing of special parts. Foreign countries have developed earlier in this respect, mainly in the following: in the current large molds, deep grooves and narrow slits with a depth of more than 100 mm have an increasing tendency in the cavity, which usually form the ribs and air-cooled products. Fin. It is almost impossible to machine such deep grooves and slits by idle milling or other conventional methods, and it is extremely difficult to machine with a conventional EDM machine which does not have high speed performance.
Therefore, the high-speed performance of the spindle has important application value in the processing of large molds with deep cavities, deep grooves and narrow slits. The THS1000 machine tool produced by ONA Company of Spain has a working fluid tank size of 4000mmX2000mmX 1250mm and a table size of 3000mmX1500mmX1000mm. However, the maximum electrode weight of the spindle is only 50kg. It has a high-speed jump-free processing function and an expert system. It can be equipped with a C-axis. This machine is suitable for machining after large mold idling. The THS1000 adopts a double spindle head, a double NC system and a pulse power supply. It can be used as two medium-sized machine tools when necessary, which improves the utilization of the machine tool and its sales are very good. This has a certain enlightening effect on China's enterprises preparing to produce large-scale machine tools.
In terms of the high response characteristics of the spindle, the linear motor has the characteristics of high speed and high response due to direct drive, no intermediate transmission link and no backlash. Japan's Sodick's linear motor control has a drive unit of lm. The developed drive controller (SMC) directly controls the motor by detecting the gap state, realizing real-time control without hysteresis with * and 篼 response, and 篼 precision control. Japan's Mitsubishi Electric Corporation's AC motor MSC high-response servo control system with a minimum command value of 0.1/min and a minimum drive value of 0.05. It is equipped with a high-rigidity mechanical structure and a straight weight-free system with no counterweight. Good static and dynamic performance is conducive to the realization of small gap high precision machining and precision micromachining.
High-precision pulsed power supply has a problem of "accuracy". It is reflected in the discreteness of electrical components, the stability of voltage, the dispersion of surface roughness, the flatness of processing, and the processing index under the same processing conditions. Repeatability and other aspects. For example, the newly developed PS finishing power supply from PF Power Supply of Mitsubishi Electric Corporation of Japan has a processing area of ​​100~1000mm2. The surface after processing has no ripples and dents. It is especially prominent in large-area processing and rib processing. The best surface The roughness can reach Ra0.16Mm. Some special pulse power sources have been developed abroad, such as sharp-angle small-area processing power supply, which regulates the electrode loss, which is of great significance for improving the cavity precision of small-area multi-cavity processing.
Low-speed wire-cut wire EDM machine Low-speed wire EDM wire cutting machine has a very wide application market, and its application range in mold manufacturing and parts processing is expanding.
Compared with foreign countries, China's research and development of low-speed wire cutting machines started late. After 20 years, especially the introduction, digestion and joint venture production in the past 10 years, there are already several companies in China, and the products are both economical and medium-to-high-end. Machine tool specifications, control functions and structural performance have made great progress, initially showing the good development of low-speed wire cutting machine Yu Jing. Its representative products are: Beijing Aqi's Xenon-type machine tools are at the leading level in China.
The machine tool retains the same principle and superior performance as the original model CC100. It adopts a new wire-receiving technology and uses compressed air to collect the wire. The software platform adopts the Windows operating system, which is rich in functions and friendly in interface.
The positioning accuracy is ±0.005mm; the maximum cutting taper: ±20° (120mm thick); the best surface roughness: Ra<0.5/rni; the processing precision can reach 0005mm DK7632 type machine tool of Suzhou Special Company, belonging to the economy Low-speed wire cutting machine is more suitable for the domestic market. Its numerical control system uses industrial computer, CRT color display, ISO code and 3B code compatible. The NC software adds a cornering strategy, and the dimensional accuracy of the sharp-edged workpieces is greatly improved. It has numerical control functions such as pitch compensation, short circuit retraction and graphic tracking.
Suzhou Shadike Sanguang Electromechanical Co., Ltd. (abbreviation: Su Sanguang) DK7632A and DK7663 machine tools, CNC system uses imported industrial computer as the host, using multi-CPU control technology, high current discharge and high-speed sampling control technology, with medium, Japanese and English menus are convenient for different users. Equipped with RS232 communication port, easy to achieve online operation. In addition, the unique "immersion" processing keeps the working fluid temperature constant during processing, achieving wire cutting processing with idle speed, stability, high precision and low coarse sugar content. The maximum cutting speed is >210mm2/min; the surface roughness is: Ra<0.8fmi (standard), Ra<0.Vn (optional); the machining accuracy is ±0.005mm. The HCX320A machine tool of Hanchuan Company adopts the vertical bed. Structure, fully enclosed protection, linear guide, imported ball screw pair and AC servo motor drive. Machining accuracy: 0.005mm; processing efficiency > 100mm2 / min; processing surface coarse sugar: Ralfxm. Some industrial countries started earlier on the development of low-speed wire cutting machine. At present, such machine tools have been developed more maturely, and the technical and economic indicators are also in a leading position. It is still the catch-up target of domestic low-speed wire cutting machines. Mainly reflected in: pulse power supply is the core of low-speed wire cutting machine. In recent years, the basic feature is to continue to maintain high peak and narrow pulse width characteristics. The ROBOFIL240CC wire cutter from Swiss Charmilles is equipped with a pulse power supply (CC power supply) called CleanCut. The maximum peak current is 1200A, the maximum voltage is 250V, and the pulse front reaches 6008/, and the maximum peak current can be reached. . The extremely short rising edge indicates a high power and lays the foundation for fast cutting. The CC power supply belongs to the whole process of anti-electrolysis power supply, which is called zero defect processing. After rough machining, the metamorphic layer produced on the surface of the workpiece is below 1 (Vm, after 4 times of finishing, the metamorphic layer is l~1.5fmi, the cemented carbide is crack-free and has no electrolysis. No surface oxidation occurs when cutting titanium. With copper, zinc anti-adhesion, cutting polycrystalline diamond and carbide tools, the best surface roughness can reach Ra0.2; im, can get a smooth and sharp edge. CC power supply when cutting 6080mm thick workpiece, Using 0.33mm alloy wire, the cutting speed is 400rW/min. It cuts a piece of material K10712 steel, the height is 60mm, the circumference is 433mm, and all the round-shaped connected leaf-shaped holes are used. The newly developed ¢0.33mm is used. Zinc-plated copper wire SW33XOC, processing time is lh, its speed is 30% faster than the old model machine tool is the eternal theme of developing low-speed wire cutting technology, high-precision machine tools directly show the level of production enterprises. Swiss Archie Company's new AGIECUTVERTEX type wire cutting machine with a machining accuracy of ±1Mm and a surface roughness of Ra0.05/zm. The Japanese Makino UPH-2 machine tool is configured by horizontal wire-cutting method and Japanese Mitsubishi PA05 ultra-high-precision machine tool. Precision The machining accuracy is also ± lf / m, the best surface roughness is Ra 0.06f / m. Japan's Sodick EXC100 machine is also a super high-precision wire cutting machine, using SuperPIKA ultra-fine power supply, in oil When processing cemented carbide, the best surface roughness is RaO.05m. High-speed wire-cut EDM wire cutting machine is a unique original product in China. Its design ability, manufacturing process and machine quality are all. It has been improved year by year and constantly improved. Whether it is CNC system, pulse power supply, machine tool structure and its basic parts, accessories, etc., the CNC system has been developed from discrete components and MOS components to PC control, conversational Or drawing size direct input programming; high frequency power supply generally uses grouping pulse, new high power FET, pulse width, voltage, current size can be arbitrarily combined to improve productivity and processing stability; Nozzle mechanism, taper cutting device, molybdenum The wire tensioning mechanism has undergone numerous improvements, which can meet the processing precision requirements of upper and lower profile cutting and large taper and variable taper. The maximum cutting thickness is up to lmm. Representative products are: Su Sanguang's DK7750, Beijing Achi's FW2, etc. Among them, Suzhou Jinma Machinery Electronics Co., Ltd. DK77100, DK7763 machine tools have a maximum cutting taper of 90 °; Suzhou New Spark Machine Co., Ltd. DK7740D machine tool can meet 6\12° and 6 (T taper processing, and can cut unequal taper workpieces; DK77100 machine tool of Nanchang Jiangnan Electronic Instrument Factory adopts novel and unique gantry type wire frame structure, with wire frame stiffness High precision, reliable and reliable processing range.
Third, the speed-sparking small hole processing machine 20 years ago is still a blank EDM small hole processing technology, developed rapidly in recent years, has now formed a small branch, the indicators are equivalent to the international advanced level, but the price is It is much lower than similar foreign products. High-speed EDM small hole processing machines are widely used not only in the mold industry but also in parts manufacturing. For example, in the aerospace field, due to the particularity of the shape, material, processing location and size of the workpiece, especially for small holes, inclined holes and non-linear axes, round holes, special-shaped holes, deep narrow grooves, slits, etc. It is quite difficult to carry out the cutting process, which provides a broad space for the application of the idle electric spark hole machining technology. These products mainly include: DK703 three-axis CNC electric spark small hole processing machine of Suzhou Special Company. The whole machine adopts electromechanical integration design, compact structure, small floor space and convenient operation. The secondary stroke of the spindle head (W-axis) adopts a linear rolling guide, which is easy and flexible to manually move up and down. The control system adopts 586 industrial computer, X, Y, Z three-axis point control, with automatic conversion processing parameters, electrode automatic trimming function and power failure memory, pitch and backlash compensation.
Beijing Aqi's SDI three-axis CNC EDM small hole processing machine adopts mechatronic design on the structure, and the electrical part is placed under the bed, which is waterproof and dustproof; adopts overall structural design and modular design, and the functions of each circuit board Clear, easy to insert, easy to repair; automatically compensate for electrode wire consumption according to processing conditions; rotate the R axis to make deep hole processing easier. The product has recently been widely introduced in the domestic market and the price is much lower than that of imported machines.
The expert appraisal of the special fund project of the Ministry of Science and Technology undertaken by Suzhou Zhongte Company. The appraisal committee unanimously agreed that the 6-axis CNC high-efficiency EDM small hole processing technology and equipment have reached the technical and economic indicators stipulated by the special fund project of the Ministry of Science and Technology. The equipment developed has filled the domestic gap and reached the international advanced level. The main technical performance indicators have been reached. International leading level. The 6-axis CNC high-efficiency EDM small hole processing technology and the road for R&D and edge conversion of the equipment have solved the technical problems of medium and deep hole processing in aviation, aerospace and military enterprises. At present, there are more than 50 such devices in operation, which is the state. Save more than 30 million US dollars in foreign exchange and earn more than 60 million US dollars.
4. Rapid Prototyping Technology Rapid prototyping technology is a new technology that has appeared in manufacturing since 1987. It uses discrete/stacking principles to create parts that can be used to create three-dimensional solids of any complex shape without the need for special molds, tools, and a high degree of flexibility. In order to promote the global development of rapid prototyping technology, the Global Rapid Prototyping Society (GARPA) was established in 1998, and China is a member of its sponsors. At present, the world's strongest rapid prototyping technology is still in the United States (3DSystems and Stratasys are ranked first and second in the world respectively). In 2001, the rapid prototyping equipment produced in the United States accounted for 80.7% of the world market. Since 1998, relevant industry organizations have held two national rapid prototyping and rapid manufacturing conferences. In March 2004, the third national conference was held in Kunming. With the joint efforts of scientific research, production and application units, domestic rapid prototyping technology has achieved good development. Sales of major producers have grown steadily, and in addition to occupying a growing domestic market share, exports have begun. China's rapid prototyping machine accounts for less than 1% of the world market in 1999 (incomplete statistics), and increased to about 3% in 2000, and more than 4.7% in 2001. Major manufacturers have introduced light-based curing. Equipment, and the quality tends to be stable; the application field is expanding, such as the application of bio-manufacturing in Tsinghua University and Xi'an Jiaotong University in Beijing is a bright spot. Also, Xi'an Jiaotong University uses rapid prototyping technology in the water-saving irrigation system. The performance of the emitter directly affects the effect of drip irrigation, while the structure of the emitter is very fine (minimum 0.5) and the precision is high (0.02mm). The traditional development route requires the production of molds, which are produced by rapid curing with light curing. The integrated emitter can directly conduct flow test and develop new emitters, which greatly shortens the development cycle of New Products and reduces costs. Representative products of rapid prototyping machines are: AURO-350 of Tsinghua University Enterprise Group Beijing Yinhua Laser Rapid Forming System Co., Ltd., ASF-450 of Beijing Longyuan Automatic Forming System Co., Ltd., SPS of Shaanxi Hengtong Intelligent Machine Co., Ltd. -600 type, etc.
In recent years, there have been three major advances in the field of rapid prototyping technology research, and it should also be the main direction of discipline development: from rapid prototyping to rapid manufacturing development, mainly the manufacture of direct gold parts. The direct application of metal parts with rapid principle has important application value in space engineering and aircraft industry, and thus has received extensive attention, but it is still in the stage of research and semi-commercialization. For example, the University of Loughborough in the United Kingdom has a large-scale rapid prototyping research center. Direct manufacturing of metal type is an important research content of the center. One example is their use of EOSINTM equipment to do research on direct metal laser sintering systems and to obtain direct gold injection molds. Singapore Nanyang Technological University also conducted research on the direct manufacture of metal molds using the SLS2500 system from 3D Systems of the United States. The University of South Australia in Australia combines a robotic system with a multi-axis rapid prototyping system for the direct manufacture of metal parts. There is also a lot of research work in this area in China. For example, Huazhong University of Science and Technology uses a dieless digital press forming process to produce sheet metal parts with complex curved shapes; Beijing University of Technology based on a 6-axis robotic system, using a tantalum beam YAG laser to fabricate three-dimensional metal parts by laser coating.
Rapid prototyping is the development of rapid manufacturing molds to form a rapid mold manufacturing system based on rapid prototyping. At present, the market demand for rapid prototyping systems is more and more extensive. Combining rapid prototyping technology with rapid mold manufacturing technology can reduce the manufacturing time of molds by 1/3, cost by 20% to 30%, and can be solved well. Mold production cannot keep up with the contradiction of product development needs. Rapid tooling based on rapid prototyping has both direct manufacturing and indirect manufacturing. Direct manufacturing is highly regarded because it does not require process conversion and has great application potential in terms of manufacturing cycle. At present, research focuses on how to obtain metal types directly from existing rapid prototyping processes and to develop new processes suitable for direct metal forming. Indirect manufacturing processes are more widely used, and can be summarized as precision casting, metal spray forming, electroforming, and powder sintering. Through these methods, rapid manufacture of metal parts can be achieved. The United States, the United Kingdom, France, and China have carried out research in this area. At present, the main research is the electro-spray deposition of medium- and low-melting alloys, and the metal-spray deposition manufacturing molds on rapid prototyping prototypes or natural material prototypes (such as skin texture).
Rapid prototyping technology has been involved in the frontiers of biomanufacturing and its biomedical applications are compelling. The University of Drexel in the United States has the ability to reconstruct organ and tissue CAD models (software systems) based on organ anatomy data (from CT data or CTX light), which they have (down to page 10). 13. Actively introducing technology and foreign capital With the industrial countries shifting manufacturing industries to China, China's mold industry is facing unprecedented opportunities for development. On November 6, 2003, the Austrian Gruber Group, the second largest mold manufacturer in Europe, signed a contract with the Chinese side to form Shandong Gruber Technology Co., Ltd. to produce high-grade molds. The Chinese company that cooperates with it is Shandong Huasu Building Materials Co., Ltd., which is currently ranked third in the field of plastic profiles in China. The newly established joint venture company has an initial registered capital of 21 million yuan. The joint venture project is implemented in two phases with a total investment of about 51 million yuan. It is expected to produce 600 sets of molds.
Since the mold industry is a relatively intensive technology, capital and labor force, China's average labor cost is only 1/40~1/30 of the US. With the rapid development of China's economy, the level of China's technical talents is gradually improved. However, the trend of shrinking mold development in industrial countries has also accelerated the transfer of their mold industries to countries or regions with certain industrial and technological bases. At present, the surrounding areas of Shenzhen and the Pearl River Delta have become the most developed areas in China's mold industry and the areas with relatively high technological content. In the next few years, as the global manufacturing industry shifts its focus to China, this region is likely to develop into a world mold production center within 10 years. In addition, the private mould industry in Yuyao, Ninghai, Huangyan and Wenzhou in eastern Zhejiang Province is also developing very fast, with more than 100,000 employees and an annual output value of 7 billion yuan.
Promoting the standardization of molds At present, precision molds have generally achieved an accuracy of 2~3fxm.
Although the production of nano-scale molds is difficult to achieve in China in the short term, it is an inevitable trend to achieve a mold with a precision of lMm. Superfinishing with machining tolerances below lfxm is also inevitable.
Mold standardization is the foundation of modern mold design and manufacturing. Promoting mold standardization is a necessary condition for rationalized production of molds. The United States and Germany have been working on mold standardization for 100 years. However, due to the lack of standardization of molds in China, the types and specifications of standard parts are not uniform, and the quality is not good enough to meet the interchangeability requirements. To this end, we should take corresponding measures to organize the industry's strengths in terms of mold production characteristics, and organize mold production enterprises to carry out standardized production in a timely and timely manner so as to fully implement mold standardization work.
Promoting design and manufacturing informationization Because of the close relationship between mold and manufacturing, it can be said that manufacturing is a continuation of design. However, the artificial design method is relatively slow, and it is impossible to realize the integration of mold design and manufacturing, and it is impossible to achieve the requirements of optimized design. Practice has proved that mold CAD/CAM technology is the most reasonable mold production method in the contemporary. Computer control and management of the mold production process is the guarantee and condition for rational production. In order to make the whole process of mold design, production preparation, processing and assembly, and test mode always in control and management, the promotion of mold production process control and management is conducive to improving the precision and quality of mold manufacturing, shortening production cycle and reducing production. cost. Although some domestic manufacturers also use computer-aided design and computer-aided manufacturing technology, they still stay in the stage of introduction, digestion and absorption, and it is difficult to form a mature theoretical guidance and design system. Therefore, it is imperative to standardize the development of mold design software systems.
Promote the automation of processing automation With the continuous promotion and deepening of the traditional mold processing mode with new technology and advanced applicable technology, digital processing has become the development direction of mold processing. Mold processing equipment using digital technology has become the first choice for mold companies to improve their equipment level. At the same time, multi-functional composite processing can effectively improve the efficiency of mold processing, so it also has great development prospects.
The finishing of the mold surface is one of the difficult problems in the mold processing in China. The surface quality of the mold has a great influence on the service life of the mold and the appearance quality of the workpiece. China is still mainly based on manual grinding and polishing, which is not only inefficient (about 1.% of the entire mold manufacturing cycle), but also labor intensive. The quality is unstable, which restricts the development of China's mold processing to the level. Therefore, research on the automation and intelligence of polishing is an important development trend. Japan has developed a numerically controlled grinding machine that can automate the grinding and polishing of 3D curved molds. In addition, due to the complex shape of the mold cavity, any grinding and polishing method has certain limitations. Attention should be paid to the development of special grinding and polishing methods, such as extrusion grinding, electrochemical polishing, ultrasonic polishing and composite polishing processes and equipment to improve the surface quality of the mold. (Author's contact number) (Continued from page 13 for bone tissue engineering stent manufacturing, surgery and prosthesis repair, dental, jaw and skull repair, structural design of various blood vessels, etc. Beijing Hua The University has conducted extensive research in biomanufacturing. They offer software systems for biomedical applications, using a variety of rapid prototyping processes (SSM, MEM and SL) for various prostheses: for surgical assisted planning and Diagnosed rapid prototyping model of skull, maxillofacial bone, lower bone, etc.; completed the first artificial bionic pelvic repair operation in China, and completed the manufacture of the true proportional pelvic three-dimensional model according to the patient's pelvic CT data provided by the hospital; The three-dimensional model of the ear is used, and the injection molding of the ear repair bracket is completed by using the Medform machine.
In short, with the continuous advancement of science and technology, in order to meet the ever-changing needs of the manufacturing industries such as mold industry, aerospace industry and automobile industry, special processing machine tools are developing in the direction of precision, automation and networking. People are expecting the emergence of special processing machines with more varieties and higher levels. (
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