5-axis machining turbocharger impeller
The high-precision turbocharger impeller is the most stringent key component. Through advanced 5-axis machining, hundreds of turbocharger impellers can be manufactured every day. Using solid aluminum milling, compared with the old-fashioned cast supercharger, not only has the price advantage but also higher tolerance accuracy.
Impeller refers to a wheel disc equipped with moving blades. Common materials for impellers include cast iron, bronze, stainless steel, manganese bronze, Monel, INCONEL, and non-metallic materials such as PPS plastic, phenolic resin and so on. .
Machining requirements for impeller:
Ordinary CNC milling machines also have a CNC operating system (such as FANUC, Siemens, China Huazhong or Guangshu, etc.), as well as three feed axes and a rotating spindle. Their processing mode geometry is exactly the same, and basically the same processing capabilities can be achieved.
Virtual reality, as a new high-tech technology, has been widely used in many fields such as aviation, aerospace, and manufacturing. An important application of this technology is the simulation of some phenomena in the manufacturing industry. The most typical is the simulation of CNC machining process. At present, simulation technology based on surface modeling and solid modeling has been widely used in CNC simulation, and there are also good algorithms for single-sided machining simulation of three-axis CNC milling machines.
Before the 5-axis milling tool path design, the system accuracy of the CAD 3D model should be set as high as possible. Especially when model conversion between different CAD systems, CATIA (*.model) format and Parasolid (*.x_t) format are preferred for data conversion. Secondly, use IGES format for data conversion. When using the IGES format, the system accuracy should generally not be less than 0.01mm. Especially when performing five-axis high-speed cutting of precision parts, the accuracy of the model and the accuracy of tool interpolation have an important impact on the output of the tool path.
With the increase of complex surface design of parts in modern industry, 5-axis machining will account for an increasing proportion of CNC machining. As 5-axis CNC machining adds two degrees of freedom of rotation, it increases the difficulty of CNC machining motion simulation calculation and tool interference check, especially when machining parts with extremely complex shapes.
Path simulation of 5-axis high-speed milling
Because the tool path is more complicated during five-axis high-speed milling, and the tool axis vector changes frequently during the machining process. Especially in high-speed cutting, the tool movement speed is very fast, so it is very necessary to carry out the verification and review of the CNC program before the actual product cnc processing.
Milling can obtain a good curved approximate surface. When using a ball-end tool for three-axis milling, the linear feed motion in the x, y, and z directions can ensure that the tool cuts to any coordinate point on the workpiece, but the direction of the tool axis cannot be changed. The actual cutting speed of the point on the tool axis is zero, and the chip space in the center of the tool is also very small. If these points are involved in cutting, the unfavorable cutting conditions will cause the quality of the machined surface to decrease, the blade wear will increase, and the machining time will be prolonged. So that high-grade tool materials are not fully utilized.
In order to overcome the shortcomings of 3+2 axis machining, five-axis simultaneous machining may be a better choice, not to mention that some five-axis machine tools also have some functions specially designed for the mold industry. Five-axis linkage machining can coordinate three linear axes and two rotary axes to make them move at the same time, which solves all the problems of 3-axis and 3+2 axis machining. The tool can be very short, there is no overlapping of views, the possibility of missing the processing area is less, and the processing can be performed continuously without additional import and export (see Figure 3).
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