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In today's booming modern manufacturing landscape, CNC machine tools have become the mainstay of the field of metal cutting and play an irreplaceable key role. With its high-precision automatic control performance, CNC machine tools can carry out extremely precise cutting of metal materials, and are widely rooted in many cutting-edge industries such as automobile manufacturing, aerospace exploration, and electronic communication innovation, and have become a strong driving force for industrial progress. Next, this article will deeply analyze the underlying working principle of CNC machine tool cutting metal, explain its operation process in detail, and dig deep into its technical advantages.
What is the working principle of CNC machines?
The operating mechanism of a CNC machine is essentially based on a pre-programmed computer program, most commonly the G-code. With the help of this process, the moving parts inside the machine, such as the spindle responsible for high-speed rotation and the feed axis that controls the position accuracy, can be precisely controlled, so that the relative movement between the tool and the workpiece can be accurately and error-free, and the automatic processing of metal materials can be completed. The whole process covers the following key links:
- Program input: First of all, the technician needs to convert the design intent into CNC code that can be recognized by the CNC machine tool according to the part design blueprint through professional programming software. These codes are then entered into the CNC control system of the CNC machine in an orderly manner, which provides a detailed "action guide" for the subsequent operation of the machine.
- Command parsing: When the code enters the control system, the system will quickly analyze it in depth. In this process, the control system accurately calculates and generates a series of crucial machining parameters based on the code content, including the trajectory of the tool, the feed rate during cutting, and the rotation speed of the spindle, which directly determine the quality and efficiency of machining.
- Motion control: After obtaining the machining parameters, the actuator of the machine tool starts to exert force. Through servo motor or stepper motor, the spindle is driven to rotate at a set speed at high speed, and at the same time, the feed shaft is driven to move smoothly in the established direction. In this process, the machine ensures that the tool cuts the workpiece precisely and gradually converts the design on the drawing into a physical object in strict accordance with the predetermined path.
- Feedback adjustment: In order to ensure that the machining accuracy is always maintained at a high standard, the CNC machine is also equipped with various sensors.These sensors monitor the status parameters of the machining process in real time, and if the actual parameters deviate from the preset values, the system reacts quickly, dynamically adjusts the machining parameters, and effectively compensates for the errors, thus ensuring consistent machining accuracy.
What Are the Main Types of CNC Machines?
As a star equipment in the modern manufacturing industry, CNC machine tools achieve ultra-precise control with pre-programmed instructions, and shine in metal processing, machinery manufacturing and other industries.Its main types:
| Types | Description |
| CNC milling machine | The most common, processing planes, curved surfaces and complex shape parts, multi-axis linkage to complete complex processing. |
| CNC lathes | Focus on the processing of rotationally symmetrical parts, such as shafts, discs, and sets, equipped with X and Z axes, and partially add more coordinate axes to expand processing capabilities. |
| CNC plasma cutting machine | Cutting metal with plasma arc, fast speed,low cost,suitable for thick plate metal. |
| CNC water jet cutting machine | Cutting metal with high-pressure water flow or mixed abrasive flow, no heat affected zone, no deformation, environmental protection, suitable for various thickness metal materials. |
| CNC laser cutting machine | Cutting metal with high-energy laser beam, high precision and fast speed, suitable for thin sheet metal. |
How does a CNC machine cut metal?
In modern manufacturing, CNC machine tools are a key process for cutting metal, which is highly automated and precise and controllable. The process of cutting metal by CNC machine tool is as follows:
- Preparation before cutting: select machine tools and tools according to processing needs, consider the type of machine tool and tool adaptability; Stable clamping of the workpiece, precise positioning; CAD/CAM software is used to generate machining programs and import them into the CNC system.
- Planning the toolpath: The toolpath determines the machining quality and efficiency, and the path needs to be carefully designed by considering the workpiece shape, material, tool type and machining parameters.
- Set machining parameters: including cutting speed,feed rate, cutting depth and coolant flow, etc., combined with the workpiece, tool characteristics and machining requirements.
- Cutting: CNC machine tools cut according to the planned path and set parameters, the CNC system monitors and adjusts in real time, and the operator pays attention to the cutting status and adjusts the parameters in time.
- Post-processing: clean up debris, measure the size and shape of the workpiece, compare with the design requirements, find deviations and rework and correct them in time to ensure that the quality is up to standard.
What Physical Principles Enable CNC Metal Cutting?
1.Energy conversion and co-utilization
With the help of the spindle motor, the electrical energy is cleverly converted into the mechanical energy of the high-speed rotation of the tool, providing strong power for metal cutting. In the cutting process, the friction between the tool and the workpiece and the plastic deformation of the material will generate a lot of heat, which will locally soften the metal, reduce the shear strength, and facilitate cutting. At the same time, the cooling system plays a key role in removing heat from the cutting area in a timely manner through heat conduction and heat dissipation mechanisms, strictly controlling the temperature and preventing damage to the tool and workpiece due to overheating.
2.The microscopic mystery of material removal
The tool extrudes the metal under the action of cutting force, causing it to undergo plastic deformation. The metal creates a shear slip along the cutting edge, gradually forming chips and detaching from the workpiece. For brittle materials, such as cast iron, under the impact of cutting force, the internal microcracks of the material expand rapidly, which eventually leads to the fracture and spalling of the material, and the material is removed and processed.
3.Precise control of mechanical action
Cutting force is a key force driving metal deformation and excision, and its magnitude and direction are affected by a variety of factors, such as tool geometry, cutting parameters, and material properties. During machining, the internal stress and strain states of the material precisely control the deformation and fracture behavior of the material. When the stress exceeds the yield strength of the material, the material undergoes plastic deformation; When the stress further exceeds the tensile strength, the material breaks and the machining is completed.
4.A delicate balance of heat and tribology
Efficient heat transfer and heat dissipation systems are key to maintaining a stable temperature in the cutting area and span data-bm="5710">avoing degradation of the tool and workpiece due to overheating. The friction between the tool and the workpiece not only generates heat, but also accelerates tool wear. Therefore, it is necessary to optimize the tool material, coating process and cutting parameters (such as cutting speed and feed) to effectively reduce friction, extend the service life of the tool, improve the machining quality, and achieve the perfect balance between thermal and tribological effects.
How Does Chip Formation Affect Machining Accuracy?
The impact of chip formation on the accuracy of metal processing is multifaceted, mainly reflected in the following points:
Chip morphology interferes with machining
Continuous chips are easy to wrap around the tool or workpiece, causing the tool to vibrate, deflect or even break, destroying the machining accuracy and surface quality. The chips of the chipping are fragmented, and the high-speed impact of the cutting edge of the tool accelerates the wear of the tool and shortens the life of the tool, and the dust generated by the chipping will also pollute the processing environment,affect the operation of the machine tool, and indirectly reduce the machining accuracy.
Chip size affects accuracy
If the chip is too long or too thick, the cutting force will increase,resulting in tool deformation, workpiece vibration, and deviation of the size of the machined product. The chip size is unstable, the cutting force fluctuates, and the machined surface will be uneven, making it difficult to meet the high precision standard.
Accuracy associated with tool wear and breakage
When the chips are discharged, they rub against the tool, accelerate the wear of the tool, change the shape and size of the cutting edge of the tool, and then affect the machining size of the workpiece. Under harsh cutting conditions, chip impact forces can cause tool breakage, interrupt machining, damage the workpiece, and cause economic losses.
The machining environment is affected by chips
Chip accumulation hinders the heat dissipation of the machine tool, increases the temperature of key components, affects the accuracy and stability of the machine tool, and also hinders the operation of moving parts and reduces the accuracy of movement. If the cutting heat carried away by the chips cannot be dissipated in time, the workpiece will be thermally deformed and the subsequent machining accuracy will be affected.
What Hidden Costs Emerge in High-Speed Machining?
In addition to the explicit costs of equipment procurement and raw materials,there are also many hidden costs in high-speed processing:
1.High cost of tool loss
Tool life is significantly reduced at high speeds, e.g. 15 to 30 minutes in titanium machining. Frequent tool changes increase machine downtime, reduce production efficiency, and at the same time, procurement costs also increase significantly, and can also affect the product production cycle.
2.The cost of energy consumption is considerable
High-speed machining requires high-power equipment,such as a 20kW spindle, which consumes a lot of power during operation. The cooling system accounts for up to 35% of the energy consumption of the machine to ensure the temperature of the tool and workpiece, which is an important part of the company's operating costs in the long run.
3.Equipment maintenance costs are rising
The equipment operates at high speeds, and the internal components are subjected to enormous mechanical and thermal stresses, resulting in accelerated wear and tear, especially on delicate components. Repairs and replacement of precision components are costly, and frequent maintenance can also extend downtime and impact production.
4.The cost of efficiency loss exists
Before high-speed machining, it takes a long time to debug equipment parameters and optimize the processing process,which increases the R&D investment and time cost of the enterprise, reduces the production efficiency, and forms a hidden efficiency loss cost.
5.Quality control costs increase
High-speed processing is prone to quality problems due to fast speed and large cutting force. Enterprises need to strengthen quality inspections, invest more manpower and material resources, and rework and repair problems after they are found, and if the scrap rate increases, it will also cause waste of raw materials.
6.Labor costs are rising
High-speed machining requires highly skilled operators and requires a significant investment in training. High work pressure can easily lead to staff turnover, and companies have to pay more costs to retain talent.
7.The cost of safety and environmental protection has increased
There are safety risks in high-speed processing,and enterprises need to install safety protection measures to increase equipment procurement and installation costs. The disposal of waste generated by processing needs to comply with environmental protection standards, which also increases the safety and environmental protection costs of enterprises.
How Do Vibration Patterns Impact Surface Finish?
The influence of vibration mode on surface finish is mainly reflected in the following aspects:
1. Flutter causes surface ripples:
- Flutter mechanism: Flutter in machining is a self-excited vibration caused by the dynamic instability of the tool-workpiece system.
- Surface effects: Flutter makes the relative motion between the tool and the workpiece unstable, resulting in ripples or chatter marks on the machined surface, significantly reducing the surface finish.
2. Factors for the formation of surface ripples:
- Feed per tooth: When the feed per tooth is too large, the tool leaves deeper marks on the surface of the workpiece and the surface roughness (e.g., Ra value) increases.
- Radial run-out: The radial run-out of the spindle or tool causes the tool to periodically shift during machining, resulting in visible chatter marks. For example, a radial runout of > 0.005 mm produces visible chatter marks.
3. Vibration frequency and surface morphology:
- High-frequency vibration: This can lead to an increase in surface microscopic unevenness, affecting surface finish and gloss.
- Low-frequency vibration: Usually produces large surface ripples, which seriously affect surface quality and dimensional accuracy.
4.Tool-workpiece interaction:
Vibration will change the contact conditions between the tool and the workpiece, resulting in fluctuations in cutting forces, which in turn will affect the surface topography and finish.
What are the technical advantages of LS cnc machining metal?
In the field of metal cutting, LS has become an industry leader with the following core advantages:
✅ Intelligent processing system:Integrated AI algorithms monitor tool wear and machining status in real time, and automatically adjust parameters to extend tool life.
✅ Multi-axis linkage technology:The five-axis CNC machine can complete complex surface machining, reduce the number of clamping times, and improve efficiency.
✅ Green manufacturing solutions:Minimum quantity lubrication (MQL) and debris recovery systems are used to reduce energy consumption and environmental pollution.
Summary
CNC machine metal cutting is an indispensable technology in modern manufacturing. Through high-precision CNC systems and a variety of cutting tools, CNC machines can achieve precise cutting and efficient processing of metal materials. At the same time, its technical advantages also make CNC machines have a wide range of application prospects in the field of metal processing.
The metal cutting ability of CNC machine tools directly affects product quality and production efficiency. With advanced CNC technology, rich industry experience and perfect after-sales service, LS can provide customers with high-precision, high-efficiency and low-cost metal processing solutions.Whether it is mass production or high-difficulty customized parts, LS can meet your needs with excellent technical strength.
Disclaimer
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LS Team
LS is an industry-leading companyFocus on custom manufacturing solutions. With over 20 years of experience serving more than 5,000 customers, we focus on high precisionCNC machining,Sheet metal fabrication,3D printing,Injection molding,metal stamping,and other one-stop manufacturing services.
Our factory is equipped with more than 100 state-of-the-art 5-axis machining centers and is ISO 9001:2015 certified. We provide fast,efficient and high-quality manufacturing solutions to customers in more than 150 countries around the world. Whether it's low-volume production or mass customization,we can meet your needs with the fastest delivery within 24 hours. chooseLS TechnologyIt means choosing efficiency, quality and professionalism.
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FAQs
1.How does the CNC machine cut?
The CNC machine tool controls the movement trajectory and speed of the tool through a digital program, so that the tool can accurately cut the workpiece according to the predetermined path. This process typically includes program entry, tool selection and installation, workpiece clamping, tool setting and positioning, automatic cutting, and monitoring and adjustment.
2. What is the process of the metal cutting machine?
The process of metal cutting machine involves many links, including material preparation, cutting method selection, parameter setting, cutting operation and post-processing. According to the type of metal material and processing requirements, select the appropriate cutting method (such as flame cutting, plasma cutting, laser cutting, etc.), and set the corresponding cutting parameters, such as cutting speed, gas pressure, etc. Then, the metal material is fixed on the table of the cutting machine and cut according to a predetermined path or shape. Finally, the cut workpiece is subjected to the necessary post-processing, such as deburring, grinding, etc.
3.How does CNC machining work?
CNC machining is a technology that controls machine tools for automated processing through computer programs. First, CAD/CAM software is used to generate machining instructions (such as G-code), which describe the movement trajectory, speed,cutting parameters and so on of the tool during the machining process. The machining instructions are then entered into the CNC machine's controller. The controller drives the movement of the various axes of the machine tool according to the instructions, so that the tool can machine the workpiece according to a predetermined path.During the machining process, the machining status is monitored in real time through sensors and feedback systems, and the movement of the machine tool is automatically adjusted if there is a deviation to ensure machining accuracy.
4. How does metal working work?
Metalworking is a complex process that encompasses multiple steps. First of all, the appropriate metal material is selected according to the processing needs, and the necessary pretreatment (such as cutting, straightening, rust removal, etc.) is carried out. Then, the metal material is processed into the desired shape and size by forging, casting, rolling, extrusion, etc. Next, the metal material is cut using machine tools such as lathes, milling machines, drilling machines, etc., to achieve precise size and shape requirements. In addition, heat treatment (e.g., quenching, tempering, etc.) may be required to improve the mechanical properties and processability of metal materials. Finally, the processed metal surface is subjected to necessary treatment (such as spraying, electroplating, polishing, etc.) to improve its corrosion resistance and aesthetics,and quality inspection is carried out to ensure that the workpiece meets the processing requirements.
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