A typical CNC metal processing center is a multi-axis equipment of complex design, in which control is carried out by two controllers: responsible for the coordinates of the axes and the main one directly executing the PLC program.
Multi-axis capabilities
A CNC metal machining center is capable of simultaneously processing a part from various sides. The production rate is halved, profitability is increased, and accordingly, labor costs are reduced at the same cost of the product for the consumer. Complex machines can perform both turning and milling.
A CNC metal processing center is selected according to the terms of reference, which consists of dozens of employees. It takes into account the ability of the machine to load, unload parts in automatic mode, type of processing, cooling. Also taken into account is the type of workpiece material and rigidity of the machine.
The CNC metal processing center can have interfaces for sending reports to the upper level, the ability to create programs in a single enterprise environment, and also takes into account the method of holding the workpiece. So, for long parts, a counter spindle is installed, and wide products are clamped into special cams.
Do not forget about the supply of parts to the machine. This can be a coordinate robot or a feeder for special rods. Often, versions of equipment with mounting tables on which universal mounting bases are installed are used for multi-purpose turning and milling operations.
Classification
Universal CNC machining centers for metal are divided by level of complexity, by the presence of an anti-spindle assembly. A drive center or an additional axis can also be added for the manufacture of inaccessible recesses, grooves, holes. Multi-axis systems are equipped with complete software for designing parts and creating machine codes.
Turning and milling work is carried out at high intensity, and any, even small oversight of the operator can cause a long downtime of the equipment. Adjusters are required to undergo training before performing simple cutting cycles. All the computing operations are performed by the machine itself, but there are locks that maintenance personnel are entitled to remove during the readjustment.
Tool
CNC machine tools for metal are often equipped with tool magazines. Each cell is calibrated before executing the cutting technology program. Computing centers can independently insert the required tool into the spindle assembly. The shift sequence is set by the installer. Stores may contain 20, 40 or more positions for each type of processing parts.
The tool magazine is equipped with its own controller, which facilitates ways out of emergency situations. For turning, the equipment is equipped with turrets with several positions for cutters. The change of the latter occurs by rotation of the head disk.
Unlike conventional machines
A numerically controlled machine operates in multi-channel mode: several tools, the magazine itself, unloading and loading pallets are simultaneously moving. Such an organization allows you to make the whole process continuous. One center is capable of replacing up to 5 conventional CNC machines due to its performance.
The replaceability of several machines on one powerful machine can be beneficial in terms of saving space in the office space, reducing the number of employees. After all, a complex machine can be serviced by one worker. Turret driven tools come into rotation from a single engine thanks to precise mechanics. This simplifies the design of the machine and helps to carry out a huge number of operations in one zone.
Types of work on machine complexes
The whole chain of operations is replaced by a set of commands from one processing center. On the simplest machines it is sometimes impossible to perform certain types of work with high accuracy. Such work includes milling parts from worm gears. It will also be difficult to undercut the crankshaft.
Gear parts have no less difficulty in processing. Due to several interceptions, complete processing of the part from all sides is carried out. Counter spindles are used when undercutting parts larger than 30 mm, which helps to eliminate the runout of the tool and the appearance of waves on cylindrical surfaces.
Application
One machining center is able to replace all equipment installed in the production chain. The versatility of its use allows us to achieve increased productivity in furniture enterprises, in bending shops, defense industry and automotive industry. Often machining centers are required in case production, when frequent changeovers are needed for small series of parts.
The whole design of the machine is placed on one welded bed, which has a huge weight. Balancing is carried out due to several jacks. Accuracy adjustment is made at the installation stage. At the stage of putting the machine into production, the state of each axis is evaluated. The straightness deviation does not exceed 0.02 microns, which allows the production of parts even for the aviation industry. At all stages of operation, the position of the tool is always monitored by position sensors.