In composite machining, the most widely used and challenging process is compound turning and milling. Compound machining is a process that combines turning and milling to perform machining operations. It is typically used in situations where multiple machining operations need to be performed on the same workpiece to improve machining efficiency and accuracy. Compound turning and milling can be performed on the same machine tool, avoiding the need for workpiece repositioning and alignment errors between different machines. This type of machining usually requires the use of multi-axis CNC machine tools with both turning and milling capabilities, such as compound machining centers. In compound turning and milling, turning is used to machine features such as outer contours, apertures, and end faces that are axially symmetrical, while milling is used to machine complex shapes and surfaces. By selecting appropriate tools and setting process parameters, multiple types of machining operations can be performed on the same workpiece, such as turning, drilling, milling, and grooving.
Engine Cylinder Block Machining: The automotive engine is one of the core components of a vehicle, and the machining of the engine cylinder block has a significant impact on engine performance and reliability. Compound turning and milling can be used to machine various special shapes, apertures, and passages of the engine cylinder block, such as turning the cylinder bores and milling the cylinder liner seats.
Suspension System Component Machining: The components in the automotive suspension system need to meet high precision and strength requirements. Compound turning and milling can be used to machine components such as connectors, rocker arms, and shock absorber seats in the suspension system to ensure stability and comfort.
Engine Component Machining: In addition to the cylinder block and crankshaft, compound turning and milling can also be applied to machining other engine components, such as camshafts, valve seats, valve guides, etc., to improve engine performance and reliability, among other factors.
Ensuring accuracy and stability in compound turning and milling is crucial. Here are some commonly used methods and measures:
Process Planning and Preparation: Before machining, thorough process planning and preparation should be conducted. This includes determining appropriate tool selection, machining sequence, cutting parameters, etc. Proper process planning can enhance accuracy and stability in machining.
Machine Tool Precision and Stability: Choose machine tools with high precision and stability. Ensure that the machine tool possesses sufficient rigidity and stability to minimize the impact of vibrations and deformations on the machining results.
Tool Selection and Tool Management: Select suitable tools, including turning tools and milling tools. The quality and wear condition of the tools directly affect the machining results. Regularly inspect and replace tools to maintain their optimal condition.
Control of Machining Parameters: Strictly control machining parameters such as cutting speed, feed rate, cutting depth, etc. Select appropriate machining parameters based on the requirements and material characteristics of the workpiece to guarantee accuracy and stability during the machining process.
Machining Monitoring and Feedback: Monitor the machining process using sensors, measuring instruments, etc. Monitor key parameters such as tool wear, workpiece dimensions, etc., and provide timely feedback and adjustments.
In summary, by implementing proper process planning, utilizing high-quality machine tools, managing tools effectively, controlling machining parameters rigorously, monitoring the machining process, and providing feedback, and ensuring the skills and training of operators, accuracy and stability in compound turning and milling can be ensured.
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