The economical machining center is an automated machine tool that is relatively inexpensive and can perform various processes such as drilling, boring, milling, and reaming. The machining center is a high-tech modern equipment with a wide range of processes, high degree of automation and high processing precision. It can complete multi-process processing after clamping the workpiece at one time, so it is an efficient processing equipment for medium and small batch production. Since the machining center is a high-tech equipment that integrates the functions of machine, electricity, liquid, and instrumentation, the price of the processing center at home and abroad is currently very high. For our company, we hope that the machining center not only has the characteristics of wide processing range, high flexibility and high degree of automation, but also does not pursue excessive processing precision and meets the processing precision requirements of general parts to reduce the price. The overall design of the economical machining center we have undertaken has been completed. The four axes of the tool rotation of the machining center, the up and down movement of the tool, and the two-way movement of the table realize digital control, and the up and down movement of the tool and the two-way movement of the table realize three-axis linkage.
The numerical control transformation of ordinary machine tools and its application to the combined machine tool production line is undoubtedly one of the effective ways to improve its flexibility and reduce costs. Our company successfully applied the CNC to the production line after the CNC was modified. The CNC transformation of the C620-1 ordinary lathe adopts the two-coordinate linkage economical numerical control system with single chip as the core, stepping motor, open-loop control, and can carry out inner and outer cylindrical surface, conical surface, cylindrical thread, conical thread, etc. Processing. The start, stop, and shift of the machine tool spindle, the stroke and speed of the longitudinal and lateral feed motion, and the replacement of the tool can be automatically controlled. After the transformation, the machine tool is used to process the tractor-type steering cylinder integral piston rod, which can automatically control the radial and axial dimensions of the parts, and the production efficiency can be increased several times.
We also modified the original Hungarian VF-222 milling machine for the joint surface of the Fiat wheel tractor cone support parts and the four boss planes. Because the joint surface of the cone support is an octagonal plane and is limited by the structure of the part, it is impossible to cover the entire plane for milling with a large milling cutter. Therefore, a small milling cutter is used to perform peripheral milling along the polygon. Because the VF-222 machine can't realize the simultaneous movement of the table x and y in both directions, the worker needs to manually operate the bevel cutting, so that the processing of one cone bearing part can be up to 48 minutes, making the process a cone bearing. Bottlenecks on the production line. And because of the manual operation of the workers, the processing quality is difficult to guarantee. In order to shorten the processing time of the process, improve the machining accuracy of the parts, and create a good positioning base for the next process of the part to enter the machining center, we have carried out numerical control transformation on the VF-222 milling machine. The project uses AC servo motor and semi-closed loop control. According to the speed and displacement commands sent by the numerical control device, the feed speed, direction and displacement of the components in the three directions of x, y and z are controlled. The feed rate of each coordinate can be adjusted within a certain range, and the operator can program the part machining process to complete the three-axis machining of the part.
The machine tool after transformation has high machining precision, and the positioning accuracy of the worktable can reach 0.01mm. Practice has shown that it is a good way to meet the national conditions of China by using the ordinary machine tool after the NC transformation to use the combined machine tool production line to improve its flexibility.
(Finish)
"Gravity Die Casting. A permanent mould casting process, where the molten metal is poured from a vessle of ladle into the mould, and cavity fills with no force other than gravity, in a similar manner to the production of sand castings, although filling cn be controlled by tilting the die."
Gravity Die Casting
Sometimes referred to as Permanent Mould, GDC is a repeatable casting process used for non-ferrous alloy parts, typically aluminium, Zinc and Copper Base alloys.
The process differs from HPDC in that Gravity- rather than high pressure- is used to fill the mould with the liquid alloy.
GDC is suited to medium to high volumes products and typically parts are of a heavier sections than HPDC, but thinner sections than sand casting.
There are three key stages in the process.
- The heated mould [Die or Tool] is coated with a die release agent. The release agent spray also has a secondary function in that it aids cooling of the mould face after the previous part has been removed from the die.
- Molten metal is poured into channels in the tool to allow the material to fill all the extremities of the mould cavity. The metal is either hand poured using steel ladles or dosed using mechanical methods. Typically, there is a mould [down sprue" that allows the alloy to enter the mould cavity from the lower part of the die, reducing the formation of turbulence and subsequent porosity and inclusions in the finished part.
- Once the part has cooled sufficiently, the die is opened, either manually or utilising mechanical methods.
Advantages
- Good dimensional accuracy
- Smoother cast surface finish than sand casting
- Improved mechanical properties compared to sand casting
- Thinner walls can be cast compared to sand casting
- Reverse draft internal pockets and forms can be cast in using preformed sand core inserts
- Steel pins and inserts can be cast in to the part
- Faster production times compared to other processes.
- Once the tolling is proven, the product quality is very repeatable.
- Outsourced Tooling setup costs can be lower than sand casting.
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