Over the past decade, mechanical processing has undergone significant advancements, driven by innovations in technology, materials, and techniques. As a seasoned mechanical processing master with extensive experience in the field, I have witnessed and actively contributed to these developments. In this blog post, I will share my insights, expertise, and authority gained over the years, providing a comprehensive summary of the machining process.
The Evolution of Machining Technology
a) Introduction of CNC Machining
Over the past decade, computer numerical control (CNC) machining has become the backbone of mechanical processing. CNC machines offer unparalleled precision, repeatability, and efficiency in producing complex parts. The integration of advanced software and automation has further enhanced the capabilities of CNC machining, making it an indispensable tool in various industries.
b) Emergence of 5-Axis Machining
5-axis machining has revolutionized mechanical processing by allowing simultaneous machining in multiple directions. This technology has expanded the design freedom and reduced the number of setups required, resulting in faster production and superior surface finishes. As a mechanical processing master, I have extensively utilized 5-axis machining to achieve intricate geometries with utmost accuracy.
Materials in Machining
a) Advancements in Cutting Tool Materials
The past decade has witnessed remarkable progress in cutting tool materials, leading to longer tool life, improved wear resistance, and higher cutting speeds. Harder and more durable tool coatings, such as diamond-like carbon (DLC) and titanium nitride (TiN), have significantly extended tool life and reduced machining costs.
b) Introduction of High-Performance Alloys
With the rise of aerospace and automotive industries, the demand for high-performance alloys has grown exponentially. These materials, such as titanium alloys and Inconel, pose unique challenges in machining due to their high strength and low thermal conductivity. As a seasoned mechanical processing master, I have developed specialized techniques to overcome these challenges and achieve optimal results.
Machining Processes and Techniques
a) Precision Turning
Precision turning remains a fundamental machining process, especially for cylindrical and rotational parts. Over the years, advancements in CNC lathes and tooling have enabled high-speed, high-precision turning, catering to a wide range of industries.
b) Milling and 5-Axis Machining
Milling has evolved from conventional 3-axis machining to sophisticated 5-axis machining, allowing for complex contours and multi-directional operations. As a mechanical processing master, I have harnessed the power of 5-axis machining to create intricate parts with exceptional precision.
Optimization and Efficiency
a) Simulation and Virtual Machining
In recent years, the adoption of simulation and virtual machining has become prevalent in mechanical processing. These tools allow us to visualize the machining process, identify potential issues, and optimize toolpaths before physical machining. This approach saves time, minimizes material waste, and ensures smooth production runs.
b) Tool Path Optimization
Tool path optimization plays a critical role in achieving efficient machining and optimal surface finish. As a mechanical processing master, I have honed my skills in selecting the right tool paths for different materials and geometries, resulting in reduced machining time and improved part quality.
The past 10 years have been transformative for mechanical processing, and the future holds even greater potential. With the emergence of Industry 4.0 and the Internet of Things (IoT), I foresee increased integration of data-driven manufacturing, artificial intelligence, and automation in the machining process. As a seasoned expert, I am excited to be at the forefront of these advancements and continue pushing the boundaries of what is possible in mechanical processing.
In conclusion, my journey as a mechanical processing master over the past 10 years has been both fulfilling and enlightening. I have witnessed the evolution of machining technology, materials, and techniques, and have continually strived to stay at the cutting edge of innovation. Through my expertise, experience, and authority, I am confident that the next decade will bring even more groundbreaking advancements in the field of mechanical processing. As we embrace the future with enthusiasm, I look forward to contributing to the ongoing progress and making a lasting impact in the world of machining.
The mechanical processing process is the step of workpiece or parts manufacturing processing, using the method of mechanical processing, directly change the shape, size and surface quality of the blank, so that it becomes a part of the process called mechanical processing process.
For example, the processing process of a common part is rough machining – finishing – assembly – inspection – packaging, is a general process of processing.
Machining process is on the basis of process, change the shape, size and the relative position of production object and nature, etc., making it a finished product or semi-finished products, is each step, a detailed description of each process, for example, it says, roughing may include blank manufacturing, polishing, etc., finish machining may be divided into the car, fitter, milling machine, etc.,
Each step will have detailed data, such as roughness to achieve how many, how much tolerance to achieve.
Technical personnel according to the product quantity, equipment condition and the quality of workers, etc., determine the process of using, as the content of the related process files, this file is called process planning.
This is more targeted. Every factory may be different, because the actual situation is different.
In general, the process is a platform, the processing technology is the detailed parameters of each step and process planning is a factory specific processing technology according to the actual situation.
Mechanical processing process
Machining process planning/machining process are specified parts machining process one of the files on the technology and operation method, it is under the condition of concrete production, the reasonable technological process and operation method, according to the regulations in the form of a written into process file, used to direct production after approval.
Mechanical processing procedures generally include the following contents: workpiece machining process route and the specific content of each process and the equipment and process equipment, test items and test method of artifacts, cutting dosage, the time quota, etc.
- Calculate the annual production program and determine the production type.
- Analyze parts drawing and product assembly drawing, and conduct process analysis of parts.
- Select the blank.
- Draw up the process route.
- Determine the processing allowance of each process, calculate the process size and tolerance.
- Determine the equipment and tools, fixtures, measuring tools and auxiliary tools used in each process.
- Determine the cutting dosage and working hour quota.
- Determine the technical requirements and inspection methods of each main process.
- Fill in the process documents.
In the process of formulating technological rules, it is often necessary to adjust the content that has been preliminarily determined before to improve economic benefits. In the process of implementing the process rules, there may be unexpected circumstances, such as the change of production conditions, the introduction of new technology and new technology, the application of new materials and advanced equipment, which require the timely revision and improvement of the process rules.