5 axis CNC machine secrets you need to know

The 5 axis CNC machineis a high-tech, high-precision CNC machine tool specially used for processing complex curvedsurfaces. And the 5 axis CNC machineincluding 5 axis CNC router and 5 axis machining center. They all have the characteristics of high efficiency and high precision. If equipped with a five-axislinkage high-end CNC system, it can also perform high-precision processing of complex spatial surfaces. Thereforethis 5 axis CNC machine is more suitable for processing modern molds such as auto parts and aircraft structural parts.

1224 5 Axis CNC Machine for Wood Carving

This 5 axis CNC router adopts OSAI control system which supports 5-8 axes linkage and has Diversified control functions. Diversified control can promise the processing speed, idling speed, cutting speed, and greatly improve the quality of processed products and processing efficiency.

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The main difference lies in the diameter of the cutting tool used. The commonly used cutting diameter for CNC milling is 6-40 mm, while the cutting diameter for 5 axis CNC router is 0.2-3 mm.

Before answering this question, let us first understand the concept of the process. The rough machining process requires a large amount of machining, but the finishing machining amount is small. Therefore some people habitually regard rough machining as "heavy cutting" and finishing as "light cutting". In fact, rough machining, semi-finishing, and finishing are process concepts, which represent different processing stages. Therefore, the accurate answer to this question is that the CNC milling machine can be used for heavy cutting or light cutting, while a 5 axis CNC router can only be used for light cutting.

It can not finish it. The main reason is that the design of the 5-axis machining center considers its own cutting range, and the overall structure is not suitable for engraving processing.

Not a substitute. Although the engraving process has narrowed the range of cutter engraving diameters for milling, small molds that could only be machined by EDM can now be realized by engraving. However, the length/diameter ratio of the engraving process is generally around 5:1. When using a small-diameter knife to engrave, only shallow cavities can be machined. In the EDM process, there is almost no cutting force. As long as the electrode can be manufactured, the cavity can be machined.

To judge whether CNC engraving can process a kind of material, it mainly depends on how big a knife can be used. The knife cut used in CNC engraving determines its greater cutting capacity. If the mold shape allows the use of a knife with a diameter of more than 6 mm, it is strongly recommended to use CNC milling first, and then use the engraving method to remove the remaining material.

CNC machining is a relatively complex process. And there are many factors that affect it. It mainly includes machine tool characteristics, cutting tools, control systems, material characteristics, processing technology, auxiliary fixtures, and the surrounding environment.

The 5 axis CNC machining process is firstly milling, so the control system must have the ability to control milling. For small knife engraving, the feed-forward function must be provided at the same time to reduce the speed of the path in advance to reduce the cutting frequency of small knife engraving. At the same time, it is necessary to increase the cutting speed in a relatively smooth path section to improve the efficiency of engraving processing.

The main factors affecting the engraving performance of the material are the material category, hardness, and toughness. The material category includes metallic materials and non-metallic materials. In general, the greater the hardness, the worse the processability, the greater the viscosity, the worse the process The more impurities, the worse the processability, the greater the hardness of the particles inside the material, and the worse the processability.

• 1) Protect the tool setter from excessive oil erosion.
• 2) Pay attention to the control of flying chips, which are very harmful to the machine tool. Flying debris into the electric control cabinet will cause a short circuit, and flying into the guide rail will reduce the life of the lead screw and the guide rail. Therefore, the main part of the machine should be sealed during processing.
• 3) During the machining process, do not observe near the cutting area to avoid flying chips to injure your eyes. When the spindle motor is rotating, no operation is allowed on the work surface.
• 4) When opening and closing the machine door, do not open and close the machine violently. Especially in the finishing process, the shock and vibration during the door opening process will cause the processed surface to have knife marks.
• 5) The spindle speed must be set, and then start processing. Otherwise, because the spindle starts to rotate slowly, it will start processing without reaching the desired speed, causing the motor to suffocate.
• 6) It is prohibited to place any tools or work pieces on the beam of the machine tool.
• 7) It is strictly forbidden to place magnetic tools such as magnetic suction cups and dial indicator holders on the electric control cabinet, otherwise, the display will be damaged.

The reason for the laborious processing is that the power and torque of the spindle cannot withstand the current cutting amount. Therefore, a reasonable approach is to remake the path to reduce the depth of the knife, the depth of the groove, and the amount of trimming. If the overall machining time is less than 30 minutes, you can also adjust the cutting speed to improve the cutting state.

Pay attention to cooling oil for metal processing. The role of the cooling system is to take away the cutting heat and flying chips and play a role in lubricating processing. The coolant will remove the cutting heat, reduce the heat transferred to the cutter and the motor, and increase their service life. Take away flying chips to avoid secondary cutting. Lubrication can reduce the cutting force and make processing more stable. In copper processing, the selection of oily cutting fluid can improve the surface quality.

The wear of the knife is divided into three stages: initial wear, normal wear, and sharp wear. In the initial wear stage, the main reason for the wear of the knife is that the temperature of the knife is low, and the better cutting temperature has not been reached.

At this time, the wear of the tool is mainly abrasive wear. Such wear has a greater impact on the cutting of the knife, and it is easy to cause the tool to collapse. This stage is a very dangerous stage. If it is not handled well, it may directly cause the knife to break and fail.

When the knife scale passes the initial wear period, the cutting temperature of the knife cut reaches a certain value. This is the main wear is diffusion wear, and its function is mainly to cause local spalling. Therefore, the wear is smaller and slower. When the wear reaches a certain level, the knife cut fails and enters a period of rapid wear.

We mentioned above that the knife carving is easy to break in the initial wear stage. In order to avoid the phenomenon of knife breaking, we must run-in the knife carving. The cutting temperature of the knife is gradually increased to a reasonable temperature. It is verified by experiments that the same processing parameters are used for comparison. It can be seen that after running-in, the life of the knife has increased by more than 2 times.

The method of running-in is to reduce the feed rate by half while maintaining a reasonable spindle speed, and the processing time is about 5-10 minutes. Use a small value when processing soft materials, and a large value when processing hard metals.

The method to judge the severe wear of the knife cut is:

• 1) When listening to the processed sound, there is a harsh call;
• 2) Listening to the sound of the main shaft, the main shaft is obviously holding back;
• 3) It feels that the vibration increases during processing and the machine tool spindle appears obvious vibration;
• 4) Looking at the processing effect, the knives on the processed bottom surface are sometimes good and sometimes bad (if this is the case at the beginning, it means that the depth of the knife is too deep).

We should change the tool at about 2/3 of the cutting life limit. For example, when the knife is severely worn in 60 minutes, the next time you process, you should start the tool change in 40 minutes, and develop the habit of changing the tool regularly.

After the knife is severely worn, the cutting force can be increased to 3 times the normal. The cutting force has a great influence on the service life of the spindle electrode, and the service life of the spindle motor is inversely proportional to the third power. For example, in the case that the cutting force is increased by 3 times, processing for 10 minutes is equivalent to the spindle using 10*33=270 minutes under normal conditions.

• 1) Stop processing and check the current serial number of processing.
• 2) Check whether there is a broken knife body at the broken knife, and remove it if there is one.
• 3) Analyze the reason for the broken knife. This is more important. Why is the knife cut broken? To analyze, we must analyze the various factors that affect the processing mentioned above.
• But the reason for the broken knife is that the force on the cut suddenly increased. Or the path problem or the jitter of the cutter is too large, or the material has lumps, or the rotation speed of the spindle motor is incorrect.
• 4) After the analysis, replace the cutting tool for processing. If the path is not changed, the original serial number should be advanced one serial number for processing. At this time, you must pay attention to lower the feed rate. One is because the broken knife is hardened severely, and the other is cutting-in.

Note: There is also a limit to adjusting the depth of the knife. If the depth of the knife is too small, there are too many layers, although the theoretical cutting efficiency is high, the actual machining efficiency is affected by other factors, resulting in too low machining efficiency. At this time, you should change to a smaller cutter for processing, but the processing efficiency is higher. Generally speaking, the cutting depth should not be less than 0.1mm.