Non-standard automated parts processing methods
If the wrong equipment is selected when processing non-standard parts, the scrap rate of a set of boxes can be as high as 30%. Only by first clarifying the classification and related processes before placing the order can we save a lot of money that would otherwise be wasted.
How to divide machine tool parts
Among Okoli's non-standard automation parts, the box, base, spindle, flange and sheet metal are the core components of machine tools. The box bears the heavy responsibility of the overall structure, the base responsible for stability plays a role in it, the spindle determines the rotation speed and positioning accuracy, and the flange connects the transmission system. Each of them is responsible for one area and does not interfere with each other.
Different parts have very different requirements for material hardness and dimensional tolerances. The flange is a non-standard automated equipment part that needs to withstand pressure and prevent torsion. For sheet metal, it needs to be easy to fold and suitable for welding. Therefore, the two aspects of material selection and processing technology are completely different. One set of parameters cannot be applied to all situations.
What processes does the processing equipment correspond to?
Ordinary lathes are the basis, and CNC milling machines are also the basis. The planer is responsible for removing the excess. The grinder performs fine surface modification and processing of non-standard automation equipment parts , and the accuracy can reach micron level. Wire cutting machines are capable of processing special-shaped contours. Electric drills are specifically used to open holes. Heat treatment furnaces are used to adjust the hardness of materials. These devices all do their own thing.
The five-axis four-link machine tool is a special tool for special scenes. For example, large propeller processing in the military industry. Ordinary three-axis machine tools simply cannot reach the curved surface. It must rely on multi-axis linkage to clamp and form at one time. If you change the outfit midway, it will all be scrapped.
The boundary between cold working and hot working
Cutting, bending and stamping operations under normal temperature environments are called cold working. This method does not cause changes in the crystal structure of the metal. Although the external dimensions and shape of the workpiece have changed, its internal microstructure has not changed. Therefore, the machining accuracy must completely rely on the tool and fixture for mandatory control.
When the temperature exceeds the critical point, operations such as forging, annealing or quenching are performed at this time, which is the stage of hot processing. Due to the phase change, the material will change, from softening to hardness, or from hardness to softening. In this case, cold working is completely impossible to achieve this effect.
The difference between cutting and pressure processing
The essence of so-called cutting is to remove material. Such as lathe processing, milling machine processing, planer processing and grinder processing, these are all considered as cutting categories. The material is peeled off bit by bit in the form of chips. In this process, the workpiece will become smaller and smaller, and it is more suitable for processing large parts such as boxes and spindles.
Pressure processing is a non-standard automated equipment parts processing method. To put it bluntly, it uses extrusion to process materials. Forging, stamping and drawing, these three processes fall into this category. During this process, the overall amount of material remains constant, only its shape changes. Therefore, very little waste is produced, but the corresponding mold cost will be relatively high. Therefore, this method is more suitable for mass production of flange parts and sheet metal products.
Heat treatment furnaces are not just for burning
Quenching, tempering and carburizing, these three processes only have a few dozen degrees of difference in temperature range, which will bring about hugely different effects. The spindle is usually carburized and quenched, mainly to further improve its wear resistance. The base is generally just normalized, which can effectively remove the internal stress generated during the casting process. .
In Okoli's production line, sufficient cooling time must be reserved before and after the heat treatment process. If you are eager to catch up with the progress of the project and forcefully omit steps to save time. This will cause residual stress inside the part. In this case. Wait until the installed components are put into operation and run for three months. Quality problems such as box deformation and cracking will occur.
Look at three hard indicators when choosing equipment
The first step is to find out what the maximum diameter of the workpiece is and how long the processing stroke is. The second step is to clearly see how many axes are required for linkage operation. The third step depends on the surface roughness requirements reaching a level of several microns. If these parameters are not matched, then no matter how expensive the machine tool is, the non-standard automated parts processing method will be in vain.
When you need to find a manufacturer that specializes in non-standard automation equipment parts processing , it is recommended that you take out the design drawings first and ask a few core questions very clearly, such as what kind of equipment should be used for processing, how many different process steps are required in the entire process, and what is the precise temperature value when heat treating the parts.
If the answer given by the other party is vague or they just copy ready-made clichés, then such a supplier can be eliminated directly.
In the production environment of your factory, the component that gives you the most headaches and is difficult to handle is the box or the spindle. Please chat about related topics in the comment area. Through likes and sharing, more peers can see what you have to say.
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