What is 5-axis milling? Application of 5-axis milling.
There are many manufacturing tasks for which 3 + 2 positioning axis milling is sufficient and even has advantages. But at the latest when it comes to free-form surfaces, there is no way around 5-axis simultaneous milling.
There are many reasons for the deformation of machined aluminum parts, which are related to the aluminum material, the shape of the part, and the CNC machinery and equipment. There are mainly the following aspects: blank internal stress, cutting force, deformation caused by cutting heat, and deformation caused by clamping force.
For CNC machining of aluminum parts with a large margin (large, thin-walled, aluminum cavity parts), in order to have better heat dissipation conditions during the machining process and avoid heat concentration, symmetric machining should be used during machining. If there is a 90mm thick aluminum sheet that needs to be machined to 60mm, if one side is milled, the other side should be milled immediately, and the flatness can only reach 5mm after processing to the final size at a time;
Turning and milling thin parts (aluminum, aluminum alloy, pure titanium, copper, magnesium alloy) are always prone to deformation during machining. Oval or “waist shape” with a small middle and large ends, which makes it difficult to ensure the quality of parts. Its clamping design is often the most discussed point. Let’s take a look at two design examples of thin-walled fixtures on turning and milling parts, and how they solve the deformation problem.
In milling, an important characteristic of titanium alloys is extremely poor thermal conductivity. Due to the high strength and low thermal conductivity of titanium alloy materials, extremely high cutting heat (up to 1200°C if not controlled) is generated during processing. The heat is not discharged with the chips or absorbed by the workpiece, but is concentrated on the CNC cutting edge. Such high heat will greatly shorten tool life.
When titanium alloy is milled at low speed in an inert gas medium, the milling deformation coefficient is greater than 1.0; But in the atmosphere, when the milling speed Vc=30 m/min, the chip deformation coefficient is less than 1.0. This is because titanium alloys have a great affinity for oxygen and nitrogen in the atmosphere during high-temperature milling.
High diffuse reflection laser cavity is mainly used for the production of pump cavity for solid and liquid laser devices. The structure adopts a tightly packed form, and uses a high-reflectivity diffuse reflection material as the reflector of the pump light source. Due to the design and structural characteristics of the highly diffuse reflection laser cavity, the energy of the pump light source is evenly distributed in the pump cavity, so that the laser material can absorb energy in a balanced manner.
Common surface treatment of processed prototypes: grinding, polishing, electroplating, oxidation, passivation, blackening, phosphating, etc.
In the entire process of prototype processing, after selecting the appropriate processing method (CNC processing or 3D printing), most of the prototypes require surface treatment. The purpose of surface treatment is to meet the product’s corrosion resistance, wear resistance, decoration or other special functional requirements. There are dozens of surface treatment processes for prototype processing. Next, we will introduce the common surface treatment processes for prototype processing.
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