Milling-instead-grinding machining process for guide rail mounting surface of machine tool part

Abstract

The invention discloses a milling-instead-grinding machining process for a guide rail mounting surface of a machine tool part. The milling-instead-grinding machining process comprises the steps that a tool for roughly milling the guide rail mounting surface is supported and positioned by three points; a finish milling cutter disc is adopted for finish machining of the guide rail installation face, a certain flatness is obtained, the guide rail installation face subjected to finish machining of the finish milling cutter disc serves as a positioning face for machining the four side faces in the next procedure, and a certain number of machining allowance is reserved; three-point supporting and positioning are adopted in finish machining; and a single-blade boring cutter is adopted to replace a finish-milling cutter disc to finish-mill the guide rail mounting surface to the qualified precision. According to the milling-instead-grinding machining process for the guide rail mounting surface of the machine tool part, three-point supporting and positioning are adopted, and it is guaranteed that a workpiece is not subjected to clamping force to generate elastic deformation; a single-blade boring cutter is adopted to replace a facing cutter finish-milling surface to overcome the defect that the diameter cannot be adjusted when a facing cutter is provided with a single blade; and the CBN blade is used for replacing a hard alloy blade to improve the machining efficiency.

Description

Technical Field

[0001] The invention relates to the field of mechanical processing, in particular to a processing technology for replacing grinding with milling for the guide rail mounting surface of a machine tool component. Background Art

[0002] The guide rail mounting surfaces of the columns and saddles, key components of optical machine tools, require high machining precision. These narrow and long guide rail mounting surfaces are 40mm wide with shoulders on both sides, exceeding 1045mm in length. The horizontal distance between the two guide rail mounting surfaces is at least 248mm, with flatness requirements within 0.02mm and surface roughness within Ra 1.6μm.

[0003] Difficulty: Due to production conditions, there is no grinding process for the guide rail mounting surface, and it can only be processed by milling on a machining center. The workpiece is relatively long, with poor structural rigidity and easy deformation during clamping. The guide rail mounting surface is processed with a milling cutter disc with a polishing edge. The milling cutter disc blade is difficult to level, and the axial force during processing is large. At the same time, it will cause elastic deformation of the workpiece due to the axial force. Conventional milling cutters cannot meet the processing accuracy requirements. Moreover, there are no suitable tools for precision milling of the guide rail mounting surface. If a new non-standard precision milling tool is newly purchased, not only will the cost be high, but there will also be no tools for debugging and production during the procurement cycle, affecting product delivery.

[0004] Therefore, it is necessary to develop a processing method that can not only meet the delivery requirements but also does not require the addition of new equipment to solve the problems encountered in existing processing.

[0005] The information disclosed in this background technology section is only intended to enhance understanding of the overall background of the invention and should not be regarded as an admission or any form of suggestion that the information constitutes the prior art already known to a person skilled in the art. Summary of the Invention

[0006] The purpose of the present invention is to provide a process for machining the guide rail mounting surface of a machine tool component by milling instead of grinding. The process adopts three-point support positioning to ensure that the workpiece is not elastically deformed by the clamping force; a single-edge boring tool is used instead of a milling cutter disc for fine milling to solve the disadvantage that the diameter of the milling cutter disc cannot be adjusted by a single-edge; and CBN blades are used instead of carbide blades to improve machining efficiency.

[0007] To achieve the above-mentioned objectives, the present invention provides a process for processing the guide rail mounting surfaces of machine tool parts by milling instead of grinding, including: rough milling of the guide rail mounting surface using a three-point support positioning tool; fine milling of the guide rail mounting surface using a fine milling cutter disc to obtain a certain degree of flatness, and using the guide rail mounting surface finely machined by the fine milling cutter disc as the positioning surface for the next process and for processing the four side surfaces, and reserving a certain amount of processing allowance; fine machining using three-point support positioning; and fine milling of the guide rail mounting surface to a qualified accuracy using a single-edged boring tool instead of a fine milling cutter disc.

[0008] In a preferred embodiment, the tooling for rough milling the guide rail mounting surface adopts three-point support positioning, including: two support columns are arranged on both sides of one end of the workpiece, and one support column is arranged at the far end; side push points are designed and arranged on the four sides of the tooling, and the position of the push points is higher than the side fixed support points; and an integral split-type pressure plate is used at one end close to the two support columns, and the two fork arms are pressed on top of the support columns.

[0009] In a preferred embodiment, the three-point support positioning is used for finishing, including: three clamping points are arranged directly above the support point to reduce the deformation of the workpiece after being clamped; and after the workpiece is placed on the tooling, a micrometer is used to hit the upper surface of the workpiece, the X and Y axes of the machine tool are moved to observe the changes in the needle, the workpiece is pre-tightened, and then the workpiece is clamped.

[0010] In a preferred embodiment, a fine milling cutter is used to finely machine the guide rail mounting surface to obtain a flatness between 0.06 and 0.12 mm.

[0011] In a preferred embodiment, the guide rail mounting surface finely machined by the fine milling cutter is used as the positioning surface for the next step and the four side surfaces, and the reserved machining allowance is between 0.03 and 0.08 mm.

[0012] In a preferred embodiment, the single-edged boring tool adopts a CBN blade, and the processing linear speed of the CBN blade is between 300 m / min and 400 m / min.

[0013] In a preferred embodiment, when the processing length of the guide rail is 2090 mm, the feed per tooth fz = 0.15 mm, and the tool diameter is φ40 mm, the processing speed of the alloy blade is S = 135×1000÷3.14÷40 = 1075 r / min, and the processing time t = 2090÷(1075×0.15) = 29 min.

[0014] In a preferred embodiment, the wear of the CBN blade during one machining cycle of the guide rail mounting surface is less than 0.005 mm.

[0015] Compared with the prior art, the present invention's milling-instead-of-grinding process for the guide rail mounting surface of machine tool parts has the following beneficial effects: using three-point support positioning, using a micrometer to hit the workpiece guide rail mounting surface, moving the machine tool's X and Y axes to observe the changes in the dial indicator, pre-tightening the workpiece, and then clamping the workpiece to observe whether the dial indicator changes, ensuring that the workpiece is not elastically deformed by the clamping force; using a single-edge boring tool instead of a milling cutter disc for precision milling: solving the shortcoming that the milling cutter disc with a single blade cannot adjust the diameter, and avoiding the problem that a multi-edge face milling cutter disc cannot level the blade. The small number of tool blades can reduce the error caused by axial force and the amount of deformation of the workpiece due to extrusion during machining, ultimately achieving the effect of milling in lieu of grinding; and using CBN blades instead of carbide blades to improve machining efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a process flow diagram of a milling-instead-of-grinding process according to one embodiment of the present invention. DETAILED DESCRIPTION

[0017] The specific embodiments of the present invention are described in detail below with reference to the accompanying drawings, but it should be understood that the protection scope of the present invention is not limited by the specific embodiments.

[0018] Unless expressly stated otherwise, throughout the specification and claims, the term "comprise" or variations such as "include" or "comprising", etc., will be understood to include the stated elements or components but not to exclude other elements or other components.

[0019] like Figure 1 As shown, a milling-instead-of-grinding processing process for the guide rail mounting surface of a machine tool component according to a preferred embodiment of the present invention includes: the tooling for rough milling the guide rail mounting surface adopts three-point support positioning; the guide rail mounting surface is fine-machined by a fine milling cutter disc to obtain a certain flatness, and the guide rail mounting surface fine-machined by the fine milling cutter disc is used as the positioning surface for the next process and the processing of the four side surfaces, and a certain amount of processing allowance is reserved; the fine machining adopts three-point support positioning; and a single-edge boring tool is used instead of the fine milling cutter disc to fine-mill the guide rail mounting surface to a qualified accuracy.

[0020] In some embodiments, the detailed process of the milling-instead-grinding process of the guide rail mounting surface of a machine tool component of the present invention is roughly as follows:

[0021] Process flow: rough milling of guide rail installation surface → rough milling of the back → semi-finishing milling, fine milling of guide rail installation surface and processing holes → semi-finishing milling, fine milling of the back and processing holes → processing of four sides → final fine milling of guide rail installation surface → cleaning, inspection and warehousing.

[0022] Solutions and process methods (1000 words or less, video materials can be attached as supplementary explanations to the written materials):

[0023] Solution: The tooling adopts three-point support positioning and table clamping. The guide rail mounting surface is fine-milled twice. The first time is to use a fine milling cutter, and a processing allowance of 0.03 to 0.08 mm is reserved for final finishing. The second time is to use a single-edge boring tool instead of a milling cutter for fine milling the surface.

[0024] Process flow: rough milling of guide rail installation surface → rough milling of the back → semi-finishing milling, fine milling of guide rail installation surface and processing holes → semi-finishing milling, fine milling of the back and processing holes → processing of four sides → final fine milling of guide rail installation surface → cleaning, inspection and warehousing.

[0025] Process method:

[0026] 1. The tooling for the rough milling guide rail mounting surface adopts three-point support positioning: two support columns are arranged on both sides of one end of the workpiece, and one support column is arranged at the far end; the four sides of the tooling are designed with side push-on points, which are slightly higher than the side fixed support points; an integral split-type pressure plate is used at the end close to the two support columns, and the two fork arms are pressed as much as possible above the support columns, which ensures stable clamping and convenient disassembly and assembly;

[0027] 2. First, use the fine milling cutter to fine-machine the guide rail installation surface. At this time, the flatness is about 0.06-0.12mm. This surface is used as the positioning surface for the next process and the four sides of the machine. Reserve 0.03-0.08 machining allowance for further finishing: the finishing allowance should not be too large, otherwise it will affect the life of the blade.

[0028] 3. Final finishing uses three-point support positioning: The three clamping points should be located directly above the support points to minimize workpiece deformation during clamping. After placing the workpiece on the fixture, use a dial indicator to strike the workpiece's upper surface. Move the machine tool's X and Y axes to observe the needle movement. Preload the workpiece, then clamp it. Observe the needle movement to ensure the workpiece is not elastically deformed by the clamping force.

[0029] 4. Use single-edge boring cutters instead of milling cutters for fine milling: This solves the problem of single-edge face milling cutters being unable to adjust their diameter, while also avoiding the problem of multi-edge face milling cutters being unable to level the blades. The tool's fewer edges can reduce errors caused by axial forces and minimize deformation of the workpiece due to compression during machining, ultimately achieving the effect of milling instead of grinding.

[0030] 5. Tool Structural Characteristics: Single-edge boring cutters require a counterweight to achieve dynamic balance and reduce spindle vibration. The boring cutter diameter must be adjusted based on the characteristics of the machined surface and the required width. A larger diameter results in greater centrifugal force during rotation, leading to greater vibration at high speeds, which can damage the machine spindle's accuracy. Therefore, when using single-edge boring cutters, a counterweight must be incorporated into the tool design to achieve dynamic balance.

[0031] 6. Single-edge boring tool using CBN inserts can improve processing efficiency and stability:

[0032] In terms of improved processing efficiency: If carbide inserts are used, the linear speed is about 135m / min, which is low in processing efficiency. If CBN inserts are used, the linear speed can reach 300m / min to 400m / min. In actual processing, the middle value of 350m / min is generally taken, which greatly improves efficiency. Taking the processing of a 2090mm long guide rail as an example, the feed per tooth fz = 0.15mm, the tool diameter φ40mm, the processing speed S = 135×1000÷3.14÷40 = 1075r / min with carbide inserts, and the processing time t = 2090÷(1075×0.15) = 29min. The processing speed S = 350×1000÷3.14÷40 = 2786r / min with CBN inserts, and the processing time is t = 2090÷(2786×0.15) = 5.01min, which is about 6 times the efficiency.

[0033] In terms of machining stability: Using carbide inserts, due to the long machining length, the inserts wear from the start of machining to the completion of one guide rail mounting surface machining cycle, and the actual machined flatness exceeds 0.02mm. Using CBN inserts, the insert wear in one guide rail mounting surface machining cycle is less than 0.005mm, indicating good stability.

[0034] 7. Optimize the processing process, tooling, and tool solutions, and use CBN single-edge boring cutters instead of milling cutters + surface grinding to process the guide rail mounting surface, achieving a breakthrough in milling instead of grinding processing technology, meeting the technical requirements of controlling the flatness of the 1200mm machine tool column guide rail within 0.01-0.02mm (the actual detection flatness can reach within 0.01mm). The flatness control accuracy has increased by 5.7 times, significantly improving the high-precision part processing capabilities in complex and subtle fields.

[0035] In summary, the milling-instead-of-grinding process for the guide rail mounting surface of machine tool parts of the present invention has the following beneficial effects: adopting three-point support positioning, using a micrometer to hit the guide rail mounting surface of the workpiece, moving the X and Y axes of the machine tool to observe the changes in the indicator needle, pre-tightening the workpiece, and then clamping the workpiece to observe whether the indicator needle changes, ensuring that the workpiece is not elastically deformed by the clamping force; using a single-edge boring tool instead of a milling cutter disc for fine milling: solving the disadvantage that the diameter of the milling cutter disc cannot be adjusted when equipped with a single blade, and avoiding the problem that the multi-edge face milling cutter disc cannot level the blade. The small number of tool blades can reduce the error caused by axial force and reduce the deformation of the workpiece due to extrusion force during machining, ultimately achieving the effect of milling in lieu of grinding; and using CBN blades instead of carbide blades to improve machining efficiency.

[0036] The foregoing descriptions of specific exemplary embodiments of the present invention are for purposes of illustration and description. These descriptions are not intended to limit the invention to the precise forms disclosed, and it is apparent that many variations and modifications are possible in light of the foregoing teachings. The exemplary embodiments have been selected and described for the purpose of explaining the specific principles of the invention and their practical application, thereby enabling those skilled in the art to realize and utilize a variety of exemplary embodiments of the invention and various options and modifications. The scope of the invention is intended to be defined by the claims and their equivalents.

Claims

1. A process for milling instead of grinding the guide rail mounting surface of a machine tool component, characterized in that: include: The tooling for rough milling the guide rail mounting surface adopts three-point support positioning; Use a fine milling cutter to finely machine the guide rail mounting surface and obtain a certain flatness. Use the fine milling cutter to finely machine the guide rail mounting surface as the positioning surface for the next process and the four side surfaces, and reserve a certain amount of machining allowance. Three-point support positioning is used for finishing; and A single-edged boring tool is used instead of the fine milling cutter disc to fine mill the guide rail mounting surface to a qualified accuracy.

2. The process for machining the guide rail mounting surface of a machine tool component by milling instead of grinding according to claim 1, characterized in that: The tooling for rough milling the guide rail mounting surface adopts three-point support positioning, including: Two support columns are arranged on both sides of one end of the workpiece, and one support column is arranged at the far end; Side push points are designed and arranged on the four sides of the tooling, and the positions of the push points are higher than the side fixed support points; and An integral split-type pressing plate is used at one end close to the two supporting columns, and two fork arms are pressed above the supporting columns.

3. The process for machining the guide rail mounting surface of a machine tool component by milling instead of grinding according to claim 1, characterized in that: The three-point support positioning used in the finishing includes: The three clamping points are arranged directly above the support points to reduce the deformation of the workpiece after being clamped; and After the workpiece is placed on the fixture, use a micrometer to hit the upper surface of the workpiece, move the X and Y axes of the machine tool to observe the changes in the needle, pre-tighten the workpiece, and then clamp the workpiece.

4. The process for machining the guide rail mounting surface of a machine tool component by milling instead of grinding according to claim 1, wherein: The guide rail mounting surface is finely processed by the fine milling cutter to obtain a flatness between 0.06 and 0.12 mm.

5. The process for machining the guide rail mounting surface of a machine tool component by milling instead of grinding according to claim 1, characterized in that: The guide rail mounting surface finely machined by the fine milling cutter disc is used as the positioning surface for the next process and the four side surfaces, and the reserved machining allowance is between 0.03 and 0.08 mm.

6. The process for machining the guide rail mounting surface of a machine tool component by milling instead of grinding according to claim 1, wherein: The single-edged boring tool adopts a CBN blade, and the processing linear speed of the CBN blade is between 300m / min and 400m / min.

7. The process for machining the guide rail mounting surface of a machine tool component by milling instead of grinding according to claim 6, characterized in that: When the processing length of the guide rail is 2090mm, the feed per tooth fz = 0.15mm, and the tool diameter is φ40mm, the processing speed of the alloy blade is S = 135×1000÷3.14÷40 = 1075r / min, and the processing time t = 2090÷(1075×0.15) = 29min.

8. The process for machining the guide rail mounting surface of a machine tool component by milling instead of grinding according to claim 6, wherein: When the CBN blade is used to process one guide rail mounting surface during a machining cycle, the wear of the blade is less than 0.005 mm.

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