Five-axis milling and processing of parts allows you to get a product from a solid workpiece, while eliminating the likelihood of local overheating of the workpiece and thermal deformation of the product. The heat released during machining is carried away from the machining zone along with the chips. Also, a product obtained from a solid billet has better strength characteristics in comparison with products made by casting or stamping.
5 - coordinate milling is characterized by the ability to process complex products with a high degree of accuracy without the need for additional technological devices. In addition, the 5-axis milling machine with CNC makes it possible to drill and bore all technological holes in one setup, thereby eliminating the error in basing in the technological device, which is important when the axis is located at an arbitrary angle. Moreover, the absence of reinstallation of the workpiece eliminates the loss of time for this operation, which positively affects cost savings, which in turn is important when setting up serial production parts, as well as the possibility of a human factor, marriage due to the fault of the operator disappears.
With 5-axis machining, it becomes possible to use short cutters, which allow for greater degrees of accuracy and higher cutting speeds, as well as a better surface of the product. This approach combines several technological operations into one due to this, it turns out, to achieve high degree smoothness of the treated surface. This technique It is relevant for cutting polymerized parts from composite materials and parts obtained by vacuum forming.
Machines of our company CNC Modelist:
CNC-2030ASV-5D 5-axis CNC engraving-milling machine with a swivel spindle for metal is designed for 5-axis machining of a wide range of materials of different hardness: non-ferrous and ferrous metals, textolite, carbon, wood, plastics, stone, composite materials, etc. design and high-quality components has a high accuracy of material processing and a long service life. with a working area size of 200x300mm.
CNC-2030ASV -5D is great for working with tall workpieces, specialized tooling, tilt-and-turn mechanisms for full 4/5-axis machining.
It has an increased height along the Z-axis (255 mm), as well as a special spindle mount with "overhang" above the surface of the working table.
To increase the stiffness along the Z axis, the machine is made in the form of a massive cast iron column.
CNC-2030ASV-5D is equipped with a backlash-free spindle rotation mechanism and a workpiece rotation mechanism, allows processing wood, plastic, composite materials with any cutter diameters, as well as non-ferrous metals with cutters up to 8mm in diameter. For precise adjustment of positioning in all axes, this model can be equipped with optical end sensors. Usage swivel spindle greatly expands functionality machine, allowing you to process parts of complex shapes, with negative angles.
Main technical characteristics:
Machine bed material- cast iron
Workspace- 270 * 190 * 255mm (X Y Z)
Maximum workpiece height- 240 mm (in 3-axis version)
Table size- 420 * 180 mm
Guides- profile rail 20mm
Repeatability- 0.02mm.
Maximum travel speed- 3000mm / min
Weight- 160 kg
The warranty period of the machine is 12 months.
Price for a complete set ready to work. The kit includes:
1. Machine
2. Machine control unit.
3. Spindle 1.5 kW (6000 - 24000 rpm), it is possible to install a spindle 2.2 kW (1000 ... 800 rpm)
4. The mechanism of the swivel / swivel-tilt axis. (depending on modification).
5.Optionally, an automatic lubrication system is installed, a system for supplying coolant to the cutting zone
On the basis of CNC-2030ASV, it is possible to build CNC systems for solving individual technological problems. For example, the manufacture of handles for knives and daggers. This video shows the operation of the CNC-2030ASV-5D machine:
Unlike the common method of making knife handle linings on 3-axis machines, this machine is capable of milling the handle of an already finished knife. A custom-made pivoting mechanism with a specially designed blade clamp allows you to hold the knife while leaving the entire knife handle free for processing. Thanks to the swivel mechanism with through fastening of the workpiece, it becomes possible to attach a product of any length to the cartridge, making it possible to mill the dagger handle with a long blade. Using the capabilities of CNC equipment, it is possible to produce high quality handles of unique shapes with individual designs.
Other videos can be viewed by selecting the "VIDEO WORKS" tab, as well as by the link on our channel Youtube
Briefly about the machine and the elements:
Stanina
The basis of the machine is a column-shaped bed made of cast iron elements, with subsequent machining. The use of cast iron makes it possible to obtain an almost "monolithic" bed, not subject to deformation, which has a positive effect when working with especially strong materials. All elements of the bed have high-quality milling for mating with each other and installing structural elements such as a profile rail, fastening elements for ball screws and stepper motors. The quality of milling in this case determines the accuracy of the installation of all elements of the machine, their alignment and parallelism.
Table
The table is a massive plate cast from high quality cast iron. The surface of the table is sanded and processed to a "mirror" state. With "bad" casting, it is practically impossible to obtain such a quality of subsequent processing, due to the presence of cavities, air chambers, etc. The table has additionally milled slots for fixing workpieces, vices, tilt-and-turn mechanisms and other working equipment (T-slot).
Mechanics
The mechanics of the CNC machine deserve special attention. It all starts with a 20mm profile rail. Profile rail today is the best choice to build the foundations of the mechanics of a high-quality CNC machine tool. Profile rails are installed in specially milled grooves on the bed, which ensures their absolute parallelism to each other along each of the axes, as well as the absence of a height difference during installation. The rails are fastened with a large number of screws and are additionally pressed to the frame with special hardened cylindrical "crackers". Such a rail fastening design is difficult to implement on machines of the budget segment due to its high cost and increased requirements for material processing.
Each of the axes is equipped with 4 linear bearings. To increase the rigidity of the moving elements, the bearings themselves are fixed at some distance from each other. On the one hand, this somewhat increases the dimensions of the machine. On the other hand, it gives increased rigidity and no backlash in all planes.
All moving parts of the CNC machine are driven by the 1605 ball screws, optionally with an additional nut and a "pre-tensioning system". This system provides full compensation for ball screw backlash in the longitudinal plane, and also has a better load distribution during movement, since the entire load is actually distributed over two independent nuts. Ball screws are attached to the bed using special support blocks. The entire machine is driven by NEMA 23 100mm stepper motors.
Control electronics
Stepper motor control is implemented on discrete Leadshine DM556 drivers. These drivers have their own built-in DSP processor that controls the operation of the entire driver (current tracking, step splitting, anti-resonance algorithm). Leadshine is one of the leading manufacturers of stepper motor drivers today. By default, the electronic unit is controlled by a computer via LPT. It is also possible to control the machine via USB or Ethernet.
Spindle
This machine is equipped with a high quality 1.5 kW liquid cooled spindle. The control is carried out by a frequency converter, which makes it possible to adjust the revolutions of the cutting tool in the range of 6-24 thousand revolutions per minute.
Additional options (available on request):
Spindle installation 2.2 kW
Tool sensor. Helps with high precision to adjust the position of the cutting tool in height, relative to the work surface.
Installation of servo stepper motors. The servo-stepper drive differs from the classic one by the presence of a chain feedback with an encoder and flexible current control of the motor operating modes. The use of servo stepper motors can improve machine productivity during intensive work by reducing the number of failures due to skipped steps. Also, the use of servo stepper motors allows you to work with higher speeds and accelerations, compared to conventional stepper motors, which has a positive effect on the processing speed.
Lubrication system. The machine can be equipped with a semi-automatic lubrication system. Oil is supplied to each linear bearing and ball screw nuts. Adjustment of the supply and the amount of supplied lubricant is regulated by a special dosing and distribution unit. The use of a lubrication system can significantly increase the working life of the moving elements of the machine and improve performance.
Computer. Finding a stable CNC PC is not an easy task. The computer offered by us is tested and configured to work with the machine, it has on board all the programs necessary for the operation.
Five-axis machining centers from the best manufacturers in Germany and Taiwan, demonstrated by the company " Modern technologies Metalworking ", combine the best practices of famous brands. To create machines, the manufacturer was able to combine the advantages turning equipment and milling and drilling centers. Thanks to the modern 5-coordinate center, the production capabilities of high-quality parts processing increase several times. In the process of equipping workplaces, the urgent need for irrational filling of the working space disappears. Due to the versatility, versatility and progressive constructive assembly of the centers, there is no need for additional equipment and the purchase of unnecessary equipment. The center allows you to carry out work missions as quickly and accurately as possible, reducing the complexity of manufacturing parts. An important feature: high productivity and amazing flexibility during changeover will be appreciated by professionals who are accustomed to fast and accurate work.
Professional equipment from a company with an impeccable reputation
The STM group of companies has been pleasing the domestic consumer with products from the world's leading manufacturers for a long time. On the basis of the trading platform, the most complete range of metalworking machines has been formed. The company's specialists work throughout Russia, providing not only a trade profile service, but also a full range of services to support production locations. STM masters develop engineering projects, analyze the work at the enterprise, develop technical specifications, postprocessors and programs for ultra-modern equipment, creating the most favorable basis for the launch of advanced equipment. And the most important thing: they will help you to choose a five-axis machining center, the price of which will be acceptable for a potential buyer, and a functional one which meets the strictest quality criteria and the client's needs as much as possible.
Unconditional advantages of the five-axis center
The five-axis CNC-controlled center is operated at various enterprises, due to its wide functionality and the ability to work with the vast majority of materials. One center is capable of performing a cycle of the most complex operations that require high skill and precision in work. The operator sets computer program, allowing filigree processing of parts and forming their edge lining, which usually requires additional skill. The machine allows you to quickly and efficiently carry out complex machining of parts of a high level of complexity: shafts, sleeves, engine blades, dies, molds, etc. The centers allow you to operate different kinds cutters, drills and countersinks, spending a minimum of time and effort on reformatting the process. Threading, boring of titanium, cast iron and steel parts is dynamic and precise thanks to the powerful milling head and rigid construction
To accelerate the productivity of modern factories, a 5-axis machine has been developed, this unit operates on the basis of a spindle head, unique in its design.
Workpieces can be machined in 5 different planes, eliminating the need for separate equipment for such tasks.
general information
The main characteristic of the functionality of the master's coordinate installation is the increased number of degrees of freedom up to five.
Processing of parts in the following planes is allowed:
- the movement of the cutter is capable of being carried out along the vertical axis;
- movement in a horizontal plane is allowed;
- the movement of the cutter at a set angle to the workpiece - 5th plane.
The CNC coordinate milling machine is practically similar in design features to its previous versions (four-plane and three-coordinate), but in terms of functionality, the addition of a fifth plane made it possible to significantly outstrip them. An innovation for an innovative machine tool stands out by equipping it with a servo drive, which ensures maximum precision.
The main difference is that the fixing of the working tool is carried out by means of a unique swivel mechanism. This feature is responsible for tilting the working tool during milling.
Advantages of 5-axis installation
For many outdated models, it was required to select blanks that would correspond to a certain template shape; working with complex parts required significant preliminary preparation.
The coordinate milling machine is capable of working with the most complex blanks, which makes it a versatile machine.
In addition to extended versatility, the machine with software algorithms of operation is characterized by the following advantages:
- Processing of products with non-removable complex elements is allowed: fillets, built-in stiffeners, various lugs.
- The machine allows you to drill any number of holes located in different planes.
- The operating time on the machine is significantly reduced due to the absence of stops, changes in the position of the workpiece, and additional fixations.
- Working with numerical algorithms eliminates the human factor of interference.
- Additionally, there is no need to manually place the cutter in the "zero" position after the end of the work.
This type of machine is actively used when machining even large parts of complex shape. The model is necessarily present in the staff of advertising organizations, car repair shops, it is used in the architectural direction, in the manufacture of household appliances and in other areas.
Features of 5-axis technology
Carrying out work on the 5-axis milling installation begins with the creation of the main control algorithm. Thanks to the presence of CNC, this process is carried out in automatic mode. The software for complex parts is created with the obligatory presence of a specialist.
After creation software the main stage begins - the embodiment of mechanical work directly on the machine. The programming cycle of the five coordinate system is as follows:
- A 3D model of the workpiece is created.
- Often a pre-designed template is used, or the programming of the plant is done from scratch.
- For each stage of the machining process, the trajectory of the cutter is built, and both the rough version and the final finishing are designed immediately.
- Loading the developed algorithm into a specific milling machine.
The technological features of the workpiece machining process include milling the contour of the part. To maintain efficiency, this function should be performed both with standard template blanks and when working with complex parts.
Maximum precision is ensured by pre-calculated trajectories of the working cutter, as well as absolute fixation of the workpiece.
Subtleties of technological milling
Due to the single clamping of the workpiece, it is not necessary to stop the machine, the position of the working tool at each point of the path is controlled under the control of the chip. Only 5- and 4-axis machines are characterized by such an accurate calculation. In the process of milling, these machines independently remove excess chips and remove them from the workspace.
Control of the angle of inclination of the cutter, the current position of the spindle - these parameters are controlled every second by the CNC, which is the basis for the most accurate processing of parts.
On the machine, it is easy to mill the part relative to the horizontal plane, cut holes vertically, and cut at any angle of the cutter. In addition, internal processing of any elements and parts of the workpiece is allowed.
The extended functionality of this innovative model is used everywhere today. In any area, this installation allows you to significantly save time on work, financial resources while the quality of the final result only increases.
It has the ability to process workpieces along three independent coordinate axes. In 3-axis settings, the cutter makes a longitudinal and transverse movement in a horizontal plane, parallel to the working table and the workpiece fixed on it. This corresponds to the X and Y axes. In a 3-axis machine, these movements are performed by moving the table with the workpiece.
Vertical movement along the Z axis in 3-axis machines can be carried out both by moving the table and the spindle assembly. In the case of moving the table with the workpiece, it is carried out using a hydraulic console. This method has significant disadvantages, since it requires the movement of massive parts. Therefore, this method is used only in light and medium horizontal and universal milling machines. Due to low accuracy, this method is limitedly used in coordinate milling machines. In 3-axis machines, vertical movement is mainly performed by the spindle with the tool.
4-axis milling machine is equipped with rotary device, which allows you to rotate the cutter about one of the axes. Most often, rotation about the Y axis is provided. This expands the technological capabilities of the milling machine in comparison with 3-axis installations. On a 4-axis machine, it is possible to simultaneously process a number of workpiece surfaces without changing its position.
With an increase in the degrees of freedom of movement of the tool to 5, the capabilities of the machine also increase. An additional work axis for a 5-axis milling machine appears either by rotating the work table or by the spindle. This leads to the complication of the design of the milling machine and an increase in its price, however, it is compensated by a significant expansion of technological capabilities. There are also metal milling machines that have the ability to rotate the desktop along two axes. This greatly limits the size and weight of the available workpiece, but at the same time allows the production of extremely complex parts. 5-axis milling machines have one of the broadest functionalities among all equipment for metal processing, for which it is worth buying.
Features of multi-axis milling machines
Advantages of coordinate milling machines:
- The ability to manufacture the most complex parts. These include products with a curved and shaped surface. In modern technology, these parts are used quite often, they are many gears, impellers, rotors, etc. In some cases, the part can only be produced on a 4-axis or even a 5-axis milling machine.
- The ability to manufacture parts in a small number of operations. Even parts of ordinary complexity, especially body parts, contain a large number of structural elements. These include stiffeners, fillets, bosses, holes, etc. The implementation of such elements on a 5-axis CNC milling machine is quite simple.
- Ample opportunities. The convenience of a 3-axis milling machine and machines with a large number of working axes is that they allow you to perform many operations without rearranging the workpiece. Using these CNC machines, it is possible to carry out a significant part of the processing in automatic mode.
Multi-axis CNC metal milling machines are widely used due to their efficiency.
The jig has significantly greater rigidity, but complex design requirements lead to restrictions on the weight and dimensions of the workpiece. Therefore, their scope of use is limited, they are used for small and medium-sized parts of complex shapes. In some cases, for the production of simple parts, it is more profitable to buy simple machines - with less functionality, but also at a lower price. Therefore, before you buy a machine, you should carefully analyze the options technological process and choose the best solution for the price.
