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Calculation of machining cost

Mechanical processing cost calculation must understand the process, in order to estimate the processing time, to quote.

The calculation of machining cost can be said to be very simple or complex. The key depends on your company’s situation. For a large company, you should consider various cutting efficiency, tool performance, machinery and equipment performance, etc. if it is a small mechanical processing plant, according to your expenses, including rent, water and electricity, master’s wages, tool wear, equipment loss, etc., how much should you spend a day, plus your own estimated profit.

You’ll have to finish your parts in three hours. If your profit is 5%, your profit on this part is 15 yuan. In this way, it is very simple. In addition, mechanical processing cost calculation must know the process, in order to estimate the processing time, to quote.

Wire cutting processing fee is generally calculated according to the total cutting area, 0.xx yuan / square millimeter

For example, according to the processing area / 1200 * 8 yuan

There are usually two calculation methods

01 yuan / mm2,
Parts that are too small are generally calculated by piece

In most places, it’s 5cm / m2!

The machining cost of ordinary WEDM is generally calculated according to the wire cutting area, and the workpiece height is also high, and the corresponding price will be high

The price of slow wire cutting is about 10 times that of ordinary wire cutting

In Jiangsu and Zhejiang provinces, slow wire processing generally costs 60 yuan per hour (the average cutting efficiency is 40-60mm / min), but the higher precision die cutting costs 80 yuan, because once scrapped, it needs to pay the material cost

Processing time calculation: Processing cross-section area / (1200-1800) = the required time, 1200-1800 is an adjustable parameter, generally taken as 1500, and then multiplied by the hourly processing fee

Fast silk words some can 0.015 yuan mm, also have 0.005 yuan mm

There are also 10 yuan hours

Slow wire cutting tool 0.03mm

Slow wire cutting two cutters 0.038mm

Slow wire cutting with three cutters 0.045mm

Slow wire cutting four cutters 0.055mm

Fast wire is 5 yuan per hour. Generally, each machine can cut 2.5 hours per hour

The cost of WEDM here is basically 10 yuan / hour

WEDM is divided into fast wire and slow wire, and their processing accuracy is different, such as computer gong processing, mechanical parts processing, CNC machine tool processing, Dongguan high-speed computer gong processing

The slow wire can reach 0.001 mm, but the fast wire can’t. I’ve made Sadik’s slow silk. The processing fee is calculated according to the area and also depends on the number of knives. The price of cutting one repair is obviously different from that of cutting a few. If the height of parts processed exceeds one, it will be doubled. If the processed materials are different, their prices are not the same. For example, cutting tungsten steel is twice as much, usually 2-3 times. They can process at least 50 yuan a piece (excluding batch)

Standard charging method: 0.08 yuan / square millimeter

Common wire cutting; sectional area / 1200 * man hour unit price

Standard charging method: batch processing 0.08 yuan / square millimeter, mould 0.12 yuan / square millimeter

The fast one is 8 yuan / hour

Generally, Sodick aq550ls is used to make the first cutting, and the second cutting is about 5 times of the first cutting. The third one is faster!!

Fastwire is about 1200-1800

And then take your own set fee!!

Wire cutting is divided into fast wire and slow wire

Ordinary wire cutting is generally calculated by wire cutting area, and the workpiece height is also high, and the corresponding price will be high

The price of slow wire cutting is about 10 times that of ordinary wire cutting

Processing time calculation: Processing cross-section area / (1200-1800) = the required time, 1200-1800 is an adjustable parameter, generally take 1500, and then multiply the hourly processing fee.

In the case of fast wire, some can be 0.015 yuan mm, and there are 0.005 yuan mm

There are also 10 yuan hours

Slow wire cutting 0.03mm

Two cutting tools 0.038mm

Slow wire cutting three cutters 0.045mm

Professional mechanical processing fee calculation, mechanical processing fee calculation formula, mechanical processing fee calculation method.

The general principle of non-standard parts processing and cutting process arrangement is: the front work must be ready for the later work, lay a good foundation, and do a good service. The working principle of non-standard parts processing can be divided into four aspects

Just like building a house, the foundation determines the height. Only when the foundation is built well can the house be built high. The same is true for precision mechanical parts processing, which always processes the precise datum first, and then processes other surfaces by the precise datum positioning. For example, for box parts, the main hole is generally used as the rough datum to process the plane, and then the plane is used to process the hole system; for the shaft parts, the outer circle is generally used as the rough datum to process the central hole, and then the center hole is used as the fine datum to process the outer circle, end face and other surfaces. If there are several precision datum, the machining of base surface and main surface should be arranged according to the sequence of datum transformation and the principle of gradually improving machining accuracy.

Secondly, the processing sequence of non-standard parts should be determined, and the sequence should be done well. Generally, the main part should be done first

Computer gong processing – stainless steel

The application of large-scale iron plate processing stainless steel shows that the mold working in the chemical corrosive environment must have corrosion resistance, and also requires certain hardness, strength and wear resistance. The common martensitic stainless steels are 2Cr13, 3Cr13, 4Cr13, 3cr17mo, 9Cr18, 9Cr18Mo, cr14mo4v, 1Cr17Ni2, etc. According to the requirements of hardness, several kinds of stainless steels are introduced as follows: 1. The application of medium carbon high chromium corrosion-resistant martensitic stainless steel requires a hardness of about 50-55hrc. The typical stainless steel is 4Cr13, which is medium carbon martensitic stainless steel. After heat treatment, it has high hardness and wear resistance, and is resistant to atmospheric and steam corrosion. It can be used to manufacture plastic mold with certain corrosion resistance. The quenching temperature of the steel is generally 1050 ℃, and the steel has good hardenability. For small plastic molds, air cooling can be used to reduce the heat treatment deformation of the mold; while oil quenching can be used for the large-size mold. The quenched mold is generally tempered at 200-300 ℃, and the hardness after tempering is 50-53hrc. Suitable for manufacturing moulds of plastic products under contractor’s load, high wear resistance and corrosive medium. 2. In the application of high carbon and high chromium stainless steel, high carbon and high chromium stainless steel, such as 9Cr18, cr18mov, cr14mo, cr14mov, can be selected for the corrosion-resistant plastic mold with high hardness and high wear resistance. Taking cr14mov as an example, the carbon content of cr14mov is 1.0% – 1.15%. The steel has good hardenability. The quenching temperature is 1100-1120 ℃, the hardness is more than or equal to 58 HRC, the tempering temperature is 500 ℃, the holding time is 2 h, and the tempering time is 4 times. The hardness of cr14mov steel is greater than or equal to 60 HRC. The steel has high hardness, high wear resistance, good corrosion resistance, and high temperature hardness. It is suitable for manufacturing plastic mold with high load and high wear resistance under the action of corrosive medium. 3. Application of low carbon Cr Ni corrosion resistant stainless steel 1Cr17Ni2 steel belongs to martensitic stainless steel, which has good corrosion resistance to oxygen acids (nitric acid at a certain temperature and concentration, most of organic acids) and salt aqueous solutions; the steel has higher strength and appropriate hardness, but its performance is better than 4Cr13 steel. Therefore, some plastic molds with high corrosion resistance are still made of this type of stainless steel. The quenching temperature range of 1Cr17Ni2 steel is 950-1050 ℃. After quenching, the hardness of steel is 38-40hrc after tempering at 200-300 ℃. If the austenite is transformed into martensite, the hardness can be increased to 42-48hrc. The strength, hardness, wear resistance and corrosion resistance of the steel are higher. The tempering temperature is 600-700 ℃, and the basic structure of the steel is tempered sorbite, which has good combination of strength and toughness and high corrosion resistance. This kind of steel can also be nitrided to improve the wear resistance, anti bite ability and the service life of the die.

According to the parts, quantity and accuracy requirements, the charging method is as follows: 1. General materials for drilling and processing; 2.5 times of the diameter; 2.5 times of the diameter; 0.05; 0.12; 0.12; 0.12 For small holes not less than 0.5 yuan), the basic price * depth diameter ratio * 0.4 shall be charged for general materials with the depth diameter ratio greater than 2.5, the base price * 5 shall be charged for the hole diameter accuracy requirement less than 0.1 mm or the center distance requirement less than 0.1 mm; the tapping charge standard shall be charged according to the tap diameter * 0.2 (with cast iron as the standard, and steel parts with an additional * 1.2) shall be charged at the standard base price * 0.2-0.8 during batch processing (according to the batch size and addition) Ease of work) Computer gong processing, mechanical parts processing, CNC machine tool processing, Dongguan high speed computer gong processing lathe, general precision optical axis machining, for small length diameter ratio and 10, it is charged according to the blank size * 0.2 (the minimum is 5 yuan) ﹥ if the length diameter ratio is greater than 10, it will be charged according to the general optical axis base price * length diameter ratio * 0.15, or the precision requirement is within 0.05mm or the taper is required to be charged by the general optical axis base price * 2 The general step shaft (fan shaft, pump shaft, reducer shaft, grinding wheel shaft, motor shaft, spindle, etc.) is charged at the basic price * 2 for general precision smooth shaft processing, or * 3 for the step shaft with taper, inner and outer rib, or for general-purpose screw, it is processed according to the general precision optical axis Base price * 4 charge the general flange parts according to the material diameter * 0.07, and the diameter greater than 430mm is charged according to the material diameter * 0.12. \General round nut parts are charged according to diameter * 0.25 (including materials) generally trapezoidal, triangle nut parts are charged by diameter * 0.3 (excluding materials); (general shaft sleeve parts (diameter less than 100, diameter length ratio less than 2) are charged by material outer diameter * 0.2, and those with diameter length ratio more than 2 are charged according to diameter length ratio * base price * 0.6. Generally repair bearing platform parts with wear loss less than 2mm, diameter less than 40mm and width less than 25m M each 5 yuan, need to be on the central shelf, or the length of more than 1.7 meters of the base price * 2 charge. If the diameter is greater than 40mm, it shall be charged according to the diameter * 0.2. \For milling machine processing, general keyway processing (length width ratio less than 10) keyway width * 0.5 (minimum 5 yuan). If the aspect ratio exceeds 10, it shall be charged according to the aspect ratio * base price * 0.1. If there is strict position requirement, it will be charged according to the base price * 2. Processing of materials with hardness greater than hrc40

Computer gong processing – electrode

A part of an electronic or electrical device or equipment that is processed by a computer gong. It is used as the two terminals of input or output current in a conductive medium (solid, gas, vacuum or electrolyte solution). One pole of input current is called anode or positive pole, and the other pole of discharging current is called cathode or negative pole. There are various types of electrodes, such as cathode, anode, welding electrode, electric furnace electrode, etc.

In the battery, the electrode generally refers to the position where the redox reaction occurs with the electrolyte solution. The electrode can be divided into positive and negative. Generally, the positive electrode is the cathode, which obtains electrons and reacts with reduction. The negative electrode is the anode, which loses electrons and reacts with oxidation. The electrode can be metal or nonmetal. As long as it can exchange electrons with electrolyte solution, it is called electrode. The concept of electrode was put forward by M. Faraday in 1834 after the systematic electrolysis experiment. The original meaning only refers to the metal rod inserted in the electrohydraulic system to form the battery. The component of a battery, which consists of a series of phases in contact with each other. One end of the battery is an electronic conductor metal (including graphite) or a semiconductor, and the other end must be an ionic conductor electrolyte. The electrode with the simplest structure should consist of two phases and a phase interface, i.e., [metal electrohydraulic]. The electrode defined above in machining mechanical parts is also called “half cell”. The naming method is very complicated. Some are named according to the metal part of the electrode, such as copper electrode and platinum electrode; some are named according to the characteristic substances in the redox pair of electrode activity, such as calomel electrode and hydrogen electrode; some are named according to the shape of the metal part of the electrode, such as drop mercury electrode and rotary electrode; some are named according to the shape of the metal part of the electrode The function of the electrode is named. These names, such as reference electrode and sodium ion selective electrode (see ion selective electrode), are conventional. Any metal in contact with electrolyte will produce potential (potential), which is the most important characteristic property of electrode.

electrode

If there is a fast electron exchange of a single redox pair on the electrode interface, that is, there is a single electrode reaction with a large exchange current (see transition overpotential), this kind of electrode can quickly establish an electrochemical equilibrium, which is called reversible electrode. The potential energy of the reversible electrode is stable for a long time, and it has strong anti-interference ability and can be measured accurately. It is a necessary part of the reversible battery and the core part of the potential analysis measuring device. Reversible electrodes have the following types:

① Metal electrodes, such as copper electrodes (Fig. 2), are characterized by the fact that redox pairs can migrate across the phase interface.

② Redox electrodes, such as Pt | Fe, Fe electrode (Fig. 3), Pt | Mn, MnO 嬄 h electrode, etc. Its redox pair can not move across the electrode phase interface. The platinum pt of the electrode only indicates that the electrode metal is inert. It only provides a place for electron exchange. Any inert metal can be used in practical application.

electrode

③ The gas electrode is a component of redox pair, and the redox electrode when it is composed of gas (Fig. 4), such as hydrogen electrode (pt| h2| h), chlorine electrode (pt| Cl2 | CL), etc. In order to accelerate the equilibrium, platinum black is needed to be plated on platinum to increase the surface area and act as electrocatalysis.

electrode

④ One component of redox pair is insoluble salt or other solid phase. Therefore, Dongguan CNC machining center consists of three phases and two interfaces (Fig. 1). There is a single rapid transition process at each phase interface, such as calomel electrode (hg| Hg2Cl2 | CL) and mercury oxide electrode (Hg | HGO | oh). In the calomel electrode, the dissolution equilibrium of calomel and electrolyte is completely controlled by the higher concentration of CL in the electrolyte. The exchange rate of CL on the interface of Hg2Cl2 | is also very fast, so its electrode potential is very stable. It is the most commonly used reference electrode. Some books and periodicals call this kind of electrode the second type.

electrode

Membrane electrode a device for measuring the activity of specific ions in an electrohydraulic system (Fig. 5), such as a glass electrode or an ion selective electrode, using the permeability of the membrane to a single ion or the potential established by the ion exchange equilibrium between the membrane surface and the electrolyte (Fig. 5).

Chemically modified electrodes attach active groups and catalytic substances to the surface of electrode metals (including graphite and semiconductors) by adsorption, coating, polymerization, chemical reaction and other methods to make them have strong characteristic functions. This is a new development of electrode preparation methods since 1970s.

Single electrode and multiple electrode: if there is only one dominant electrode reaction on the metal electro-hydraulic interface of the electrode, it is a single electrode; if there is not only one electrode reaction, it is multi electrode. For example, there may be two kinds of electrode reactions on the zinc electrode (zn| ZnSO4 aqueous solution)

Zn─→Zn+2e ⑴

2H+2e─→H2 ⑵

electrode

However, due to the high Superpotential of hydrogen on the metal zinc, the rate of reaction (2) is too small, and the reaction (1) is dominant. The above zinc electrode is considered as a single electrode and is a typical reversible electrode. When the impure zinc is immersed in sulfuric acid, the reaction rate of (1) and (2) is fast, so [Zn | H2SO4] electrode is a double electrode, and its static potential can be judged according to the polarization curve and polarization law of reaction (1) and (2). Metal corrosion system is often a double electrode. Multiple electrodes cannot be reversible

In practical application, the studied electrode is called working electrode W, which is also called indicator electrode in electrochemical analysis. Its potential can be measured by two electrode measurement battery composed of reference electrode R. When the working electrode needs to be polarized, another auxiliary electrode (or corresponding electrode, represented by C) should be used to form a three electrode measuring battery system (Fig. 6)

Computer gong processing – drilling machine

Drilling and tapping center is a kind of metal cutting equipment. Its style and function are basically similar to the machining center, but it is smaller than the machining center. The general stroke is not more than (x / y) 800 × 400mm. Its main purpose is to process drilling and tapping processes such as nonferrous metals, 3C industry and aluminum substrate. Although boring and milling can be realized, due to the low power of the main motor, ferrous metal can not be used Cutting, but the efficiency and quality of drilling and tapping speed is more than 10 times that of ordinary machining center. It is the most ideal processing equipment for 3C, communication industry and other industrial customers.

At present, the overall market analysis is as follows:

Due to the rise of mobile phone industry, communication industry and tablet computer industry in recent years and the continuous upgrading to please consumers, the following supporting processing industry is also rising, especially the demand for drilling machines is growing.

At present, the common well-known brands include Japan fanco, Japan brother, British jiamite, including Korea Kia and so on.

Fanaco α – T21: FANUC α – T21 mainly produces X-axis stroke 500 with independent system + turret type tool magazine as its main products: fanaco drilling machine is the only machine tool manufactured by fanaco company in Japan, and its market share is in the forefront in Japan. Its core technology is fanuc-31 system, which is matched with the machine tool, and has high performance in spindle acceleration and high-speed displacement. The machine tool is very popular in China, especially in Guangdong electrode market, known as “the king of copper”. The biggest drawback of the machine is that the overall rigidity is insufficient, it can not carry out load cutting, and the use efficiency is not high. In addition, the price of the machine tool is also quite expensive, especially the technical support and accessories price after the warranty period is beyond the ordinary enterprises’ affordability.

Japan brother tc-s2d: Japan’s brother tc-s2d series mainly focuses on X-axis travel of 500 and 700, and has exchange worktable options: brother group was first known as a machinist sewing machine, and later developed printer equipment and machine tool drilling machine equipment. Japan brother drilling and tapping machine is the only one in Japan that can compete with fanco in system calculation. However, brother’s overall workmanship is more rigorous, and the main shaft is different from fanco. The main shaft adopts JIS form and short nose structure, which is stable in high-speed tapping and is not easy to break the tap. In recent years, the sales volume of brother drilling machine in some areas of China has been increased Hold the top position.

Camit t-fm600: jamit is the latest European brand drilling and tapping machine to enter the Chinese market. The most widely used drilling machine in the European market is jamitt drilling machine, with pure European processing technology. The tool change speed and overall mechanical structure of the drilling machine are stronger than those of Japanese machine tools, and the casting of bed body is subject to secondary aging treatment. Its advanced servo tool magazine and optical fiber panel technology is the biggest bright spot advantage of the machine tool. At the same time, it can be combined with BT40 simultaneous action tool library to realize drilling, milling, boring, tapping and other processes, and the price is cheaper than Japanese machine tools, and the comprehensive cost performance ratio is the strongest.

Hyundai Weiya vx380: Hyundai Kia drilling and attack center and Hyundai Weiya belong to Hyundai Group, the largest group in South Korea, and its technology basically comes from Japan. The brand entered the Chinese market late, but its excellent performance price ratio has been favored by enterprises, but after-sales service has always been a short board of the brand, which can not meet the needs of Chinese users. At the beginning of using the drilling and tapping center, the cutting fluid (water-based) was used in the separate cooling water tank, which was used in both stations. However, after a period of time, it was found that the water-based cutting fluid in the drilling and tapping center was not good for drilling and thread tapping. Especially for the tap, it was “astringent” during processing, which was easy to break, and the quality of the finished screw hole was poor. Therefore, we changed the drilling of this drilling center to dry machining. When we arrived at the tapping station, we used kerosene lubrication (kerosene was supplied by the pump separately, and electrical control) the quality of the thread was good, and the tap was rarely broken. Computer gong processing | mechanical parts processing | CNC machine tool processing | Dongguan high-speed computer gong processing drilling and tapping center processing form: manually pushing the material to the conveying position, pressing the “swing up” button will start to enter the automatic cycle, and the two headstock will act at the same time. After the second working feed of the two headstock, they return to the original position.

CNC machine tools are widely used in drilling and tapping center. CNC machine tool is a kind of advanced equipment with excellent performance, wide range of technology, high precision of drilling and tapping center and high production efficiency. It can complete drilling, reaming, boring, groove cutting and plane milling processing at one time. In addition, it can also carry out hole series processing with high precision. CNC machining is heavy machinery, engineering machinery, locomotive and rolling stock, mining equipment, large motor and water turbine , steam turbine, ship, iron and steel, military and other industrial sectors of essential processing equipment. The CNC machine tool has the characteristics of good rigidity, high precision, strong reliability, convenient operation and beautiful appearance. Especially, various accessories can be installed on the end face of the square ram or used with the rotary table, which can further expand the application range of the CNC machine tool. CNC machine tools are mainly used for boring holes of large and medium-sized parts, and can also complete drilling, expanding, reaming, milling plane and other work. The CNC machine tool is equipped with change gear device, which can process metric or British internal thread. The radial tool holder of flat rotating disc can be used to process internal thread

Computer gong processing grinder

The machine bed forward and backward, beam up and down, vertical milling head up and down are equipped with Taiwan ball screw, driven by servo motor.
Unique cross beam lifting safety interlock device, grinder processing to ensure the repeated positioning accuracy of the machine tool.
The side milling head is equipped with V5 type gantry milling head. The computer gong processing is equipped with independent lubrication device. The lifting is driven by ordinary reducer and frequency conversion speed regulation.
The vertical milling head of gantry precision grinder is equipped with tx400 heavy gantry milling head, double rectangular guide rail, strong rigidity; the milling head is equipped with ball screw, pneumatic broach device, driven by servo motor.
The three-axis CNC system of general milling / CNC milling with one key conversion for gantry precision grinder is not only programmable, but also can be operated manually by using the extended panel. It is very practical in the actual machining process.

Do not cut off the connection of protective devices when repairing the electrical equipment of large water mill.

Electrical maintenance personnel shall wear insulating gloves and rubber shoes during maintenance to avoid electric accidents. And do not wear metal jewelry and other conductive articles that may cause electric shock.

Before overhauling electrical equipment, it is necessary to follow the instructions of relevant warning nameplates and use appropriate three-way ammeter to determine that the circuit is in open circuit state.

The main power switch should be cut off and warning signs should be set up to avoid accidental injury caused by reactivating the large water mill without knowing it.

When the motor is activated, sparks may be generated at the contact point of the electrical box. Therefore, the machine can not be used in dust, gas explosion and flammable places.

The electric box of large water mill is designed to provide safe operation of the machine. No one is allowed to modify the structure and circuit design of this electrical box without the authorization of our company.

The operator must be familiar with the position of emergency stop switch and main power activation switch of large water mill. In case of emergency, the machine can be stopped and the power supply can be cut off as soon as possible. Process specification is one of the process documents that stipulate the machining process and operation method of parts. Under specific production conditions, the more reasonable technological process and operation method are written into the process in accordance with the prescribed form; the large-scale CNC machining center for gongs processing is a kind of tool library with automatic tool change, and the workpiece can be in a certain degree CNC machine tools for various processing operations within the scope.

Because the machining center can finish many kinds of working procedures in a centralized and automatic way, it can avoid the artificial operation error, reduce the time of workpiece clamping, measuring and machine tool adjustment, as well as the time of workpiece turnover, handling and storage, and greatly improve the processing efficiency and accuracy, so it has good economic benefits. Machining center can be divided into vertical machining center and horizontal machining center according to the position of spindle in space.

Large computer gong machining centers are usually classified into horizontal, vertical and multi axis linkage machining centers according to the relative position of the spindle and the worktable.

A horizontal machining center: it refers to the machining center with the spindle axis parallel to the worktable, which is mainly suitable for processing box type parts.

B vertical machining center: it refers to the machining center with the spindle axis perpendicular to the worktable. It is mainly used for processing complex parts such as plates, plates, molds and small shells. C multi axis linkage machining center, also known as universal machining center, refers to the machining center which can control the linkage change through the angle between the spindle axis and the rotary axis of the worktable to complete the machining of complex spatial curved surface. It is suitable for machining impeller rotor, mould, cutting tool and other workpieces with complex space curved surface.

After the workpiece is clamped once, the CNC system can control the machine tool to automatically select and change the tool according to different working procedures; it can automatically change the spindle speed, feed rate of Dongguan CNC machining center, the motion path of the cutter relative to the workpiece and other auxiliary functions, and automatically carry out multiple processes such as drilling, countersinking, reaming, boring, tapping, milling and so on Processing.

Because the early milling machine numerical control system does not have the function operation function, the processing program of function equation curve cannot be compiled directly by G code, (the lower version) CAD / CAM software usually does not have the function of directly inputting graph from equation, so it is very difficult to process function equation curve contour.

The programming method of machining center: the contour composed of simple contour line and arc is directly programmed with G code of NC system. The complex profile of 3D surface is drawn by CAD / CAM in the computer, and the corresponding parameters are set according to the surface type, and the NC machining program is generated automatically. The above two programming methods can basically meet the requirements of NC machining.

The process of large-scale mechanical parts processing plant is to change the shape, size, relative position and nature of the production object to make it into finished or semi-finished products on the basis of the process. It is the detailed description of each step and process. For example, as mentioned above, rough machining may include blank manufacturing, grinding, etc. mechanical precision parts processing may be divided into turning, fitter, milling machine, And so on, as much as the tolerance of each step has to be achieved.

What are the technical requirements for large-scale machining?

Only by complying with these technical requirements can the finished products of large-scale machining be more standardized and reasonable. In large-scale machining, what are the technical requirements to be observed?

The specific technical requirements are as follows:

(1) Remove oxide scale from parts.

(2) Undeclared shape tolerance shall conform to GB118

报错笔记双语对照
排序
重点词汇
重点词汇
伺服电机【计】servo motor
连锁装置 interlock ; interlocking device
润滑装置 lubricating arrangement

Computer gong processing – bakelite

The chemical name of bakelite is phenolic plastic, which is the first variety of plastics put into industrial production. It has high mechanical strength, good insulation, heat resistance, corrosion resistance, so it is commonly used in the manufacture of electrical materials, such as switches, lamp caps, earphones, telephone case, instrument case, etc. “bakelite” is named from this. Its appearance is of great significance to industrial development. Phenolic resin can be prepared by polycondensation of phenols and aldehydes in the presence of acidic or alkaline catalysts. Bakelite powder was obtained by mixing phenolic resin with sawdust, talcum powder, urotropine, stearic acid and pigment in mixer. Bakelite powder is heated and pressed in the mold to obtain thermosetting phenolic plastic products. The disadvantages of phenolic resin are poor mechanical properties, oil resistance and chemical corrosion resistance. In order to overcome the above defects, people have modified phenolic resin. Adding different fillers into phenolic resin can obtain modified phenolic plastics with different functions. For example, adding asbestos and mica in the ingredients can increase the mechanical properties of phenolic resin With its acid, alkali and wear resistance, it can be used as the material of chemical equipment and the accessories of motor and automobile; the hardness can be increased by adding glass fiber, which can be used as machine parts; the oil resistance and impact strength of the modified NBR are greatly improved; the mechanical strength and acid resistance can be improved after the modification with PVC.

Bakelite is non absorbent, non conductive, high temperature resistant and high strength. It is mostly used in electrical appliances. Like wood, it has high insulation and good plasticity, so it is called “bakelite”. Bakelite is a kind of powdered phenolic resin mixed with sawdust, asbestos or clay. It is extruded with a mold at high temperature. Phenolic resin is the first synthetic resin in the world.

Phenolic plastic (bakelite): the surface is hard, brittle and fragile, and there is a sound of board knocking. It is mostly opaque and dark (brown or black). It is not soft in hot water. It is an insulator. Its main component is phenolic resin.

When formaldehyde / phenol (molar ratio) is less than 1, thermoplastic products can be obtained, which is called thermoplastic phenolic resin, namely linear phenolic resin. It does not contain further condensation groups, and can be cured by adding curing agent and heating. Such as hexamethylene tetramine as curing agent, curing temperature 150 ℃, mixed with fillers made of molding powder, commonly known as bakelite powder. When the molar ratio of formaldehyde to phenol is greater than 1, the first step resin, namely thermosetting phenolic resin, is obtained under the catalysis of alkali. It can be dissolved in organic solvents. The first stage resin contains hydroxymethyl which can be further polycondensated, so it can be cured without adding curing agent. The second stage resin, also known as semi soluble phenolic resin, is insoluble and insoluble, but can be swelling and softening. Then, the insoluble phase C resin, also known as insoluble phenolic resin, was obtained by further reaction. Phase a resin can also self cure after long-term storage.

The curing forms of thermosetting phenolic resin can be divided into room temperature curing and thermal curing.

Non toxic curing agent NL, benzenesulfonyl chloride or petroleum sulfonic acid can be used for room temperature curing, but the latter two materials are toxic and irritant.

The main purpose of modification of phenolic resin is to improve its brittleness or other physical properties, improve its adhesion to fiber reinforced materials and improve the molding process conditions of composite materials. Modification is generally carried out through the following ways:

① Blocking phenolic hydroxyl groups. Phenolic hydroxyl group of phenolic resin does not participate in chemical reaction in resin manufacturing process. The phenolic hydroxyl left in the molecular chain of the resin is easy to absorb water, which makes the electrical properties, alkali resistance and mechanical properties of the cured products decrease. At the same time, phenolic hydroxyl groups are easy to form quinone or other structures under the action of heat or ultraviolet light, resulting in uneven color changes.

② Other components were introduced. In order to change the curing rate and reduce the water absorption of phenolic resin, the components which react with phenolic resin or have good compatibility with it are introduced to separate or surround hydroxyl groups. The advantages of the two polymer materials can be obtained by introducing other polymer components.

Polyvinyl acetal modified phenolic resin is widely used in industry. It can improve the adhesive force of the resin to glass fiber, improve the brittleness of the phenolic resin, increase the mechanical strength of the composite, reduce the curing rate, so as to reduce the molding pressure. Phenolic resin used for modification is usually phenol formaldehyde resin synthesized with ammonia or magnesium oxide as catalyst. The modified polyvinyl acetal is a polymer with different proportions of hydroxyl, acetal and acetyl side chains. Its properties depend on: 1) the molecular weight of polyvinyl acetal; 2) the relative content of hydroxyl, acetyl and acetal groups in the molecular chain of polyvinyl acetal; 3) the chemical structure of the aldehyde used. Due to the addition of polyvinyl acetal, the concentration of phenolic resin in the resin mixture is reduced correspondingly, which slows down the curing rate of the resin and makes it possible to form under low pressure, but the heat resistance of the products is reduced.
Polyamide modified phenolic resin the impact toughness and adhesiveness of the phenolic resin are improved, and the fluidity of the resin is improved, and the advantages of the phenolic resin are still maintained. Polyamide used for modification is a kind of hydroxymethyl polyamide, which is modified by the reaction of hydroxymethyl or active hydrogen to form chemical bond in the process of resin synthesis or resin curing.
Epoxy modified phenolic resin composites made of 40% first-order thermosetting phenolic resin and 60% bisphenol propane type epoxy resin can have two kinds of composite materials

The machining center does not grasp the knife

Vertical machining center: it is called computer gong in Hong Kong, Taiwan and Guangdong. It is a highly automatic multi-functional CNC machine tool with tool magazine and automatic tool changing device. The first machining center appeared in the United States in 1958. It can realize the centralized processing of milling, drilling, boring, reaming, tapping and other processes after the workpiece is clamped at one time, with special emphasis on “milling”.

Engraving machine: its spindle speed is high, suitable for small cutting tools processing, torque is relatively small, focusing on the “carving” function, such as wood (wood carving machine for special processing of wood), dual color board, acrylic plate and other plates with low hardness, which are not suitable for large workpieces with strong cutting. At present, most of the products on the market with the banner of engraving machine are mainly for processing handicrafts with low cost. Due to the low precision, they are not suitable for mold development. However, there are also exceptions, such as wafer engraving machine.

Engraving and milling machine: it can be carved or milled. On the basis of engraving machine, the power of spindle and servo motor is increased, and the bearing force of lathe bed is maintained. At the same time, the high speed of spindle is maintained. More importantly, the precision is very high. Engraving and milling machine also to high-speed development, commonly known as high-speed machine, cutting ability is stronger, processing accuracy is very high, but also can directly process hardness above HRC60 materials, one-time molding. Vertical machining center refers to the machining center with the spindle axis perpendicular to the worktable. It is mainly used to process complex parts such as plates, plates, molds and small shells. Vertical machining center can complete milling, boring, drilling, tapping and thread cutting. Vertical machining center is at least three axis and two linkage, generally can achieve three axis and three linkage. Some can be controlled by five or six axes.

The disadvantage of vertical machining center is to reduce the height of vertical machining center. However, the vertical machining center is convenient for workpiece clamping and positioning; the movement track of the cutting tool is easy to observe, the debugging program is convenient to check and measure, problems can be found in time, and the machine can be stopped or modified; the cooling conditions are easy to establish, and the cutting fluid can directly reach the cutting tool and the machining surface; the three coordinate axes are consistent with the Cartesian coordinate system, which makes it intuitive and consistent with the drawing perspective, and the chip is easy to be removed and dropped, Avoid scratching the machined surface. Compared with the corresponding horizontal machining center, the structure is simple, the floor area is small and the price is low.

Vertical machining center is a highly automatic multi-functional CNC machine tool with tool magazine and automatic tool changing device, which is based on CNC control unit. It communicates with the servo system to control the operation of servo motors of several shafts, so as to achieve the cutting movement of each axis. The machine tool is composed of bed, slide plate, worktable, column, electrical cabinet, tool magazine, oil mist lubrication unit of spindle, chip conveyor, etc.

There are two kinds of tool changing methods in vertical machining center: manipulator tool changing mode and direct tool changing mode. Many reasons can cause the tool magazine can not grasp or change the tool correctly, summed up as follows 7 points.

Caused by electromagnetic valve or magnetic induction switch of tool magazine

Vmc750 vertical machining center adopts direct tool changing mode, and the action of tool magazine includes swing and rotation. A three position five way solenoid valve is used to control the cylinder to drive the magazine to swing, and a single-phase magazine motor is used to realize the rotation of the magazine. There is a progressive switch in the magazine for counting. When changing the tool, the tool magazine should first be placed at the spindle position, and the original tool should be put back into the tool sleeve, and then the tool magazine should be rotated to find the next tool and grasp it again. The position and position of the main shaft of the tool magazine are judged by two magnetic switches on the cylinder of the tool magazine. When the solenoid valve and magnetic switch fail and alarm [39-12], the tool magazine is not set to the spindle position within the specified time; when [39-15], the tool magazine is not put to the original position within the specified time. At this time, it is necessary to check whether the solenoid valve acts. If the swing tool magazine can not hear the action sound of the solenoid valve, it is necessary to manually check the quality of the valve (at this time, it is better to disconnect the output end of the valve), and if it is broken, replace it.

Three switch values in the headstock are incorrect

Whether the spindle state is correct or not is judged by the three progressive switches in the spindle box (sq7 clamping switch, SQ8 release switch, sq9 knife free switch). The three switches are distributed in a triangle and sense the different parts of the loose broach cylinder. The correct position switch value should be as follows: (1) normal no knife: sq9 and sq7 lights are on; (2) normal knife is on: only sq7 light is on; (3) press release button: only SQ8 light is on. Generally, the three switches are not in correct state. The alarm code is [39-4]: pull rod failure; [39-13]: pull rod loosening fault; [39-14]: pull rod clamping fault; [39-34]: the tool is not clamped. These alarms are related to the three progressive switches. It is necessary to check whether the switch is good or not, and adjust it to the appropriate position to make the switch value indication correct.

Caused by damage of photohazard board

If the valve is correct, check the status of I / O switch value: whether the signal of spindle position slidrum spdl000:00 / 15 or original position slidrum park000:00 / 16 has been given. Check whether the corresponding 24 V level signal on the optical hazard board, the fuse on the board and the 110V voltage of the signal coming from the optical hazard board are sent to the solenoid valve. The fault point can be found out by checking the signal voltage all the way. Vertical CNC machine tools are usually more likely to damage the safety tube and optical tube. It is good to buy the same glass fuse or optical tube to replace it.

Mechanical jamming

If the handle is stuck, press the release button to hear the cylinder pressing down, but the knife will not come off. This is due to the fact that the handle is rusty due to no attention to maintenance

Computer gong machining spiral bevel gear

The development of China’s precision manufacturing industry is still relatively fast, but there is still a distance between China and developed countries. Manufacturing enterprises like spiral bevel gear are mainly small enterprises, without brand, it is difficult to compete with developed countries.

At present, China’s spiral bevel gear industry is still dominated by the expansion of quantity, which has formed excessive competition in the international market at the unified level. To change this development mode, we should adhere to the concept of innovation, innovate in the development and technical transformation of spiral bevel gear, and actively cooperate with scientific research institutions and colleges and universities to jointly develop new spiral bevel gear projects and strive to develop them In order to improve the status of spiral bevel gear wholesale in the global industrial division of labor, improve the anti risk ability and self bargaining ability, and enhance the sustainable development competitiveness of spiral bevel gear industry. China’s market has been eroded by the world spiral bevel gear industry. In order to have a long-term development of spiral bevel gear industry in China, it is necessary to adjust and optimize the industrial structure. We should not only inherit and give full play to the advantages of traditional spiral bevel gear industry, but also make great efforts to develop knowledge and technology intensive industries and emerging industries to promote the development of spiral bevel gear industry.

If China’s spiral bevel gear industry wants to improve its competitiveness and gain a place in the international competition, it is necessary to reasonably analyze the current situation and take measures to deal with the problems. We should not lose the traditional development advantages, but also combine the new knowledge and skills to improve the innovation ability, so as to promote the spiral bevel gear industry to enter a new stage, with a breakthrough development.

Although the gear industry is developing rapidly and there are more and more types, such as reducer spiral bevel gear, spiral bevel gear and so on, there are not many manufacturers specializing in gear mold, most of which are made by gear factory themselves, especially plastic gear in gear industry.

In terms of plastic gears, generally speaking, plastic gears and their molds are mainly distributed in two regions: Ningbo, Zhejiang Province, where there are more than 340 plastic gear factories, which is also the largest plastic gear mold production base in China; the other is Shenzhen Bao’an, which is dominated by Hong Kong funded enterprises with high product precision, which is mainly used for export. Among them, the demand for plastic gear mold is relatively large.

Throughout the current situation of gear mould in China, it can be said that there are mixed feelings. Fortunately, gear mold production has a certain foundation, and the development trend of plastic gear will bring more market space for gear mold; The worry is that there is still a gap between the level of domestic gear mould production and that of the world’s predecessors. Moreover, with the development trend of the gear industry, especially the plastic gear industry, the domestic response to market changes is not sharp enough, and the supporting research is difficult to keep up with the market demand. At present, medium and low-grade gear molds can be produced at home, and high-grade gear molds are mostly imported. The application scope of domestic gear mold can be roughly divided into three aspects: plastic gear mold, powder metallurgy gear mold and precision forging bevel gear mold.

It can be seen that there is still a large space for the development of China’s gear industry. Our company specializes in the production of spiral bevel gears and other products. The advanced equipment and technology ensure the quality of the products, which has been recognized by customers.

In bevel gear, according to the tooth length direction of the tooth, there are spur gear and curve gear. The straight bevel gear is formed by the intersection line of tooth length profile and pitch cone surface. If it is a curve, it is called curve gear.

At present, spiral bevel gear should be synonymous with curved bevel gear. According to the different curves, there are three kinds of spiral bevel gears, which belong to different companies. The hypoid gears (including circular arc bevel gears) designed by Gleason company of the United States, extended epicycloid gears of olicon company of Switzerland and quasi involute gears of Klingenberg of Germany.

In short, the Japanese and American car series are equipped with Gleason gears such as Buick and Toyota. European car lines such as Benz, BMW and Audi use orikon gear.

Spiral bevel gear is a kind of transmission parts with stable transmission ratio and low noise. It has different names in different areas, and is also called spiral bevel gear, spiral bevel gear, spiral bevel gear, circular arc bevel gear, spiral bevel gear, etc. Spiral bevel gear has high transmission efficiency, stable transmission ratio, large arc overlap coefficient, high bearing capacity, smooth transmission, reliable operation, compact structure, energy saving and material saving, space saving, wear resistance, long service life and low noise. Among all kinds of mechanical transmission, the transmission efficiency of spiral bevel gear is the highest, which has great economic benefits for all kinds of transmission, especially for high-power transmission; The transmission ratio of spiral bevel gear is always stable, which is often the basic requirement of transmission performance in the transmission of various mechanical equipment; the spiral bevel gear works reliably and has long service life.

Several tooth systems, characteristics and application fields of bevel gears

Bevel gear and hypoid gear are the type of gear transmission with intersecting shaft and staggered shaft respectively. But according to the characteristics of the tooth length curve, the form of the tooth height and the processing method, there are various classifications. Because the tooth length curve has a great influence on the transmission performance and special processing method is used, it is generally classified according to the tooth length curve.

Straight bevel gear: the tooth length direction of the tooth is straight line, and its extension line intersects the apex of the cone and the retraction tooth

Processing high strength steel with computer gong

When the material is formed by stamping, it hardens. The hardening degree of different steels is different. Generally, the increase of 3 Ksi of high strength low alloy steel is less than 10%. Note: the yield strength of dual phase steel increases by more than 40% by 20ksi! During the forming process, the metal will become completely different, completely unlike before the stamping process begins. The yield strength of these steels increases a lot after being stressed. The higher yield stress and work hardening of the materials processed by CNC lathe are equal to the great increase of flow stress. —-This results in the need for more tonnage to make parts – it increases the deformation temperature of the metal (which may burn or destroy improper lubricants), hard spots increase die wear – and the coating may not help or last as long as expected. To sum up, the high pressure requirements of high strength steel forming, the increase of springback, the increase of processing hardness and the operation under high forming temperature pose challenges to the die and lubrication.

In the past, in the production of deep drawing or re punching parts, everyone thought that pressure resistant (EP) lubricating oil was the best choice to protect the mold. Sulfur and chlorine EP additives have been mixed into pure oil to improve mold life for a long time. However, with the emergence of new metal high strength steel and strict environmental protection requirements, the value of EP oil-based lubricating oil has decreased or even lost its market.

What are the characteristics and functions of CNC lathe precision machining? It is an automatic machine tool controlled by program. The control system can logically process the program with control code or other symbol instructions, and decode it by computer, so that the machine tool can perform the prescribed action, and the blank can be processed into semi-finished products by cutting tool.

Traditional mechanical lathe processing is manual operation of ordinary machine tools. When lathe processing, the machine tool is shaken by hand to cut metal, and caliper and other tools are used to measure the accuracy of products. Modern industry has long been using computer digital control machine tools for operation, and any products and parts can be processed directly according to the program prepared by technicians in advance.

The information is stored on the information carrier (such as magnetic disk, perforated paper tape, magnetic tape, etc.) in a certain format, and then read in by the CNC system on the machine tool (or input directly through the keyboard of the CNC system, or through the communication mode). By decoding the information, the lathe can process the action and parts, and the modern CNC machine tool can process parts It is a typical product of mechatronics and the technical foundation of new generation production technology and computer integrated manufacturing system.

The development trend of modern CNC lathe precision machining is high speed, high precision, high reliability, multi-function, compound, intelligent and open structure. The main development trend is to research and develop intelligent full-function universal CNC device with open structure in both software and hardware. CNC technology is the foundation of machining automation and the core technology of CNC machine tools. Its level is related to the national strategic position and the level of national comprehensive strength. It develops with the development of information technology, microelectronics technology, automation technology and detection technology. CNC lathe precision machining is a kind of CNC machine tool with tool library and automatic tool change, which can carry out a variety of processing operations on the workpiece in a certain range.

CNC lathe precision machining is the use of CNC technology to control machining machine tools, or equipped with CNC system. Computer gong processing uses CNC machine tools to process mechanical parts, known as CNC processing. NC machining is different from ordinary machine tools. CNC machining needs control information, such as tool feeding, the sequence of various actions, and various auxiliary functions (such as soil shaft speed, speed, tool change, coolant switch, etc.), etc. the program is stored in the control in digital form, and the automatic machining machine tool is realized through digital control device.

CNC lathe precision machining is an efficient automation tool. Dongguan CNC machining center is a typical electromechanical product, which can realize high-speed machining, high precision and high degree of automation. Mechanical parts processing is an important difference from other types of automatic machine tools: CNC machine tools use flexible automation technology, that is, when the processing object changes, in addition to clamping parts and replacement tools, only need to change the processing program can automatically find out new parts, without changing other hardware equipment.