What precision automatics are used in CNC machining?

Precision automatics in CNC machining refer to equipment or subsystems that achieve high-precision, high-efficiency, and high-stability machining processes through high-precision mechanical structures, sensors, control systems, and automation technologies. These devices are widely used in precision parts machining, mold manufacturing, aerospace, medical devices, semiconductors, and other fields. They can significantly improve machining quality, reduce manual intervention, and achieve automated control of complex processes.

1. Precision automatics 1: Automatic tool setting instrument

(1) Function

The automatic tool setting instrument is an indispensable precision automatic device in CNC machining. It can accurately measure the length, diameter, and wear of the tool before machining. The accurate parameters of the tool are crucial to the accuracy of CNC machining, especially in high-precision machining, where even a small error can lead to a serious decline in machining quality.

The tool setting instrument can ensure that the tool is always in the best condition during the machining process by automatically measuring the various parameters of the tool, reducing manual measurement errors and ensuring the consistency and stability of the tool. As the tool is used for a longer time, wear will cause changes in tool size. The automatic tool setting instrument can update tool information in real time to avoid error accumulation.

(2) Applications

Automatic tool setting instruments are widely used in mass production, especially in production environments that require high precision and high consistency. Typical applications include:

●High-precision mass production of parts: such as electronic parts, precision mechanical components, etc.

●Mold manufacturing: ensuring the stability and accuracy of tools in mold processing.

●Automobile and aviation parts processing: These industries have extremely strict requirements on dimensional tolerances. The application of automatic tool setting instruments has greatly improved production efficiency and part accuracy.

(3) Technology

Automatic tool setting instruments usually use high-precision optical, laser or touch sensors for tool measurement. The latest automatic tool setting system also supports tool wear compensation. By measuring the wear of the tool in real time, it automatically adjusts the cutting parameters in the processing program to ensure processing accuracy.

2. Precision automatics 2: online measurement system

(1) Function

The online measurement system is an important device for real-time monitoring of the workpiece size during the processing process. It can effectively compensate for factors such as tool wear and thermal deformation of the machine tool. Its main function is to ensure that the size of the workpiece being processed always meets the design requirements and avoid scrap caused by processing errors.

This system usually uses contact or non-contact measurement to accurately detect the dimensional changes of the workpiece, and adjusts the processing parameters such as cutting speed and feed rate through real-time data feedback to compensate for errors in the processing process.

(2) Application

● Aircraft engine blades: Due to the complexity and high precision requirements of the blades, the online measurement system can continuously monitor their shape and size during the processing process to ensure that each blade meets strict tolerance requirements.

● Precision mold processing: Mold production requires extremely high dimensional accuracy. The online measurement system can help the factory track the dimensional changes of various parts of the mold in real time to ensure product consistency.

● Automotive parts processing: High-precision parts such as engine cylinder heads and turbochargers require real-time detection through online measurement technology to ensure processing accuracy.

(3) Technology

Online measurement technology usually includes the following forms:

● Contact probe: Obtain the dimensional information of the workpiece by triggering or scanning. Common ones are trigger probes and scanning probes, among which scanning probes have higher accuracy and efficiency.

● Laser measurement: Non-contact measurement method, suitable for workpieces with high precision requirements, can collect the contour data of the workpiece surface in real time for analysis and compensation.

● Visual inspection: Use high-definition cameras combined with image processing technology to quickly obtain workpiece surface shape and size data, especially for parts with complex shapes.

3. Precision automatics 3: automatic tool changing system

(1) Function

The automatic tool changing system (ATC) is an important automation equipment in CNC machine tools, which can automatically change tools during the processing process. As the complexity of the workpiece increases, a variety of different tools are often required for processing. The automatic tool changing system reduces the time of manual tool changing, improves processing efficiency, and also avoids the errors that may be caused by manual tool changing.

(2) Type

● Disc tool magazine: Usually used in small and medium-sized machining centers, it can accommodate 12 to 60 tools and is suitable for simpler machining tasks. It has a short tool changing time and is suitable for fast machining needs.

● Chain tool magazine: Suitable for large five-axis machine tools, it can accommodate 60 to 300+ tools and is suitable for the processing of complex parts. Due to its large tool storage space, it is suitable for long-term and efficient mass production.

(3) Applications

● Mass production: In an efficient production environment that requires frequent tool changes, the automatic tool changing system greatly shortens the production cycle and improves processing efficiency.

● Complex parts processing: For parts processing that require multiple tools, such as aerospace, precision mold processing, etc., the automatic tool changing system is a key equipment to ensure high precision and high efficiency.

(4) Technology

Modern automatic tool changing systems use high-speed tool changing technology and can complete tool changes within a few seconds. Through close cooperation with the CNC system, the automatic tool changing system can realize automatic identification, storage and switching of tools, avoiding the inconsistency of manual operation.

4. Precision automatics 4: workpiece automatic clamping system

(1) Function

The workpiece automatic clamping system can automatically position and clamp the workpiece during processing, reduce the instability of manual clamping, and improve processing accuracy. Through hydraulic, pneumatic or electric clamps, the system can complete the clamping and positioning of complex workpieces within a few seconds, ensuring the stability of processing accuracy.

(2) Technology

● Zero point positioning system: The system can ensure that the positioning of the workpiece remains consistent after multiple clamping.

●Robot loading and unloading: The automated robot system can deliver the workpiece into the processing area and automatically clamp and unload the fixture, reducing manual intervention.

(3) Application

●Automotive parts processing: Such as engines and body parts, the size of each workpiece in mass production is required to be consistent. The automatic clamping system can greatly improve production efficiency.

●Medical implant production: The medical industry has extremely high requirements for the size and quality of parts. The automatic clamping system can ensure the precise processing of each part and meet strict quality standards.

5. Precision automatics 5: Adaptive control system

(1) Function

The adaptive control system can automatically adjust the feed speed and spindle speed during the processing process based on real-time monitoring data such as cutting force, vibration, and temperature. This system enables the machine tool to optimize and adjust in real time according to different processing conditions and material properties to ensure efficient cutting and processing quality during the processing.

(2) Technology

●AI optimizes cutting parameters: Through artificial intelligence technology to analyze cutting data, automatically optimize cutting parameters, improve cutting efficiency and processing quality.

●Vibration suppression algorithm: Use high-frequency vibration suppression technology to reduce vibration generated during processing and improve processing accuracy.

(3) Application

● Titanium alloy processing: Titanium alloy is a high-strength and difficult-to-process material. The adaptive control system can effectively improve its processing efficiency.

● High-temperature alloy cutting: The adaptive control system can automatically adjust the processing parameters according to the changes in cutting force and temperature, thereby avoiding overheating and tool wear and ensuring processing stability.

6. Precision automatics 6: high-precision turntable

(1) Function

The high-precision turntable is a precision automatic device used for multi-faceted processing, usually used in four-axis or five-axis linkage processing systems. Through the precise rotation function, the high-precision turntable can realize multi-faceted processing of complex parts, improving processing efficiency and accuracy.

(2) Accuracy

Modern high-precision turntables usually have extremely high repeatability and positioning accuracy, and the general accuracy can reach ≤±2 arc seconds.

(3) Application

● Impeller processing: The complex geometry and high precision requirements of the impeller make it a typical application field of high-precision turntables. The turntable can realize multi-faceted operations during the processing process, reducing processing time and improving accuracy.

● Spiral bevel gear processing: Spiral bevel gears have very high precision requirements. The use of high-precision turntables can effectively improve the stability and precision of processing.

7. Summary

The application of these precision automatics in CNC processing has greatly improved the accuracy, efficiency and consistency of processing, and is widely used in high-end manufacturing fields such as aerospace, automobiles, medical treatment, and precision molds. With the continuous development of automation technology, these devices will become more intelligent and efficient in the future, bringing more innovations and breakthroughs to the field of precision processing.