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The key factors that determine economics:
The first part that achieves high precision machine tool accuracy is the most important part of the temperature is the feed drive. The high speed and large acceleration cause the ball Screw to heat up and the screw to expand. Without the corresponding position measurement technique, the positioning error can reach 100 μm in a few minutes. Therefore, workpieces with tight tolerances can only be machined on machine tools with good thermal properties, even if the machining process is very different.
Position measurement of the feed drive In principle, the position of the linear NC axis can be measured with the pitch of the feed screw and the rotary encoder or linear encoder mounted on the lead screw.
In the case of a rotary encoder on the feed screw, the ball screw has two functions: as a drive system, it must transmit a large driving force; but in order to achieve high-precision positioning, it also requires a precise pitch and good repeatability. . However, the position control loop only has a rotary encoder measuring device that provides screw rotation speed and subdivision information per revolution. In this case, the positional changes caused by the wear and temperature of the drive mechanism are not included in the measured values.
The drive system has unavoidable positioning errors and seriously affects the quality of the workpiece. If the carriage position is measured with a linear scale, the position control loop includes all feed mechanisms. At this time, the axial clearance and error of the machine motion transmission element cannot affect the position measurement accuracy. The measurement accuracy depends only on the linear scale accuracy and mounting position.
Example of integral component processing Typical monolithic components use high-speed feed and high-speed machining on high-performance high-speed cutting (HSC) machines. Different roughing and finishing feed rates make the ball screw expansion coefficient very different. If the feed drive does not use a linear encoder, the size of each machined part will vary when producing in small batches and short lead times. Therefore, thermal expansion may make machining tolerances unsatisfactory. When the end face is milled at a feed rate of 10 m/min, the ball screw heats up. The left side is the workbench and the right side is the servo motor. The temperature log shows a temperature of 25 ° C (dark blue) to 40 ° C (yellow).
Low-volume and single-piece production of linear encoders from HEIDENHAIN improves machining accuracy, speed measurement and position measurement. If linear encoders are used, these errors can be avoided and the thermal expansion effects of the ball screws can be fully compensated.
The test results shown in the figure clearly show the error caused by the heat generated when the linear encoder is not processed. The aircraft's aluminum links are machined from 10 mm deep with aluminum blanks. After 20 empty knife cycles above the workpiece, the lower end of the link is milled. The influence of the temperature change of the feed axis can be clearly seen from the edge of the workpiece. The workpiece processed using the linear encoder in the test does not have this edge. Therefore, it is possible to ensure high precision with the first piece.
The influence of mold processing The mold processing requires high shape accuracy. At the same time, high-speed feed must be used to reduce machining time. The time that the first and last paths must match to avoid high-speed feed savings will be offset by a large amount of repair work. The shape of the test piece is the shape of the Watzmann peak. In order to visually understand the difference between the use of a linear scale and the processing of the mold without a linear scale, the machining is intentionally started from the middle of the workpiece. The first and last paths are adjacent, and the visible edges clearly reflect the effects of temperature changes. For machines using linear encoders, the Watzmann peak shape does not have this edge.
Position measurement method of the feed axis, the Vazman peak of the free-form surface: the case of no linear scale on the left side and the use of a linear scale on the right. Conclusion: If the machine has high thermal stability, the production order can be completed very successfully. . The feed axis must have the required accuracy over the entire stroke, including when the speed and cutting force vary greatly. These requirements can be met by machines using linear encoders.
Linking, machining twice with no linear encoder with the same blank (left): Linear encoder with sharp temperature changes (right): no edge due to temperature and temperature changes
The first part that achieves high precision machine tool accuracy is the most important part of the temperature is the feed drive. The high speed and large acceleration cause the ball Screw to heat up and the screw to expand. Without the corresponding position measurement technique, the positioning error can reach 100 μm in a few minutes. Therefore, workpieces with tight tolerances can only be machined on machine tools with good thermal properties, even if the machining process is very different.
Position measurement of the feed drive In principle, the position of the linear NC axis can be measured with the pitch of the feed screw and the rotary encoder or linear encoder mounted on the lead screw.
In the case of a rotary encoder on the feed screw, the ball screw has two functions: as a drive system, it must transmit a large driving force; but in order to achieve high-precision positioning, it also requires a precise pitch and good repeatability. . However, the position control loop only has a rotary encoder measuring device that provides screw rotation speed and subdivision information per revolution. In this case, the positional changes caused by the wear and temperature of the drive mechanism are not included in the measured values.
The drive system has unavoidable positioning errors and seriously affects the quality of the workpiece. If the carriage position is measured with a linear scale, the position control loop includes all feed mechanisms. At this time, the axial clearance and error of the machine motion transmission element cannot affect the position measurement accuracy. The measurement accuracy depends only on the linear scale accuracy and mounting position.
Example of integral component processing Typical monolithic components use high-speed feed and high-speed machining on high-performance high-speed cutting (HSC) machines. Different roughing and finishing feed rates make the ball screw expansion coefficient very different. If the feed drive does not use a linear encoder, the size of each machined part will vary when producing in small batches and short lead times. Therefore, thermal expansion may make machining tolerances unsatisfactory. When the end face is milled at a feed rate of 10 m/min, the ball screw heats up. The left side is the workbench and the right side is the servo motor. The temperature log shows a temperature of 25 ° C (dark blue) to 40 ° C (yellow).
Low-volume and single-piece production of linear encoders from HEIDENHAIN improves machining accuracy, speed measurement and position measurement. If linear encoders are used, these errors can be avoided and the thermal expansion effects of the ball screws can be fully compensated.
The test results shown in the figure clearly show the error caused by the heat generated when the linear encoder is not processed. The aircraft's aluminum links are machined from 10 mm deep with aluminum blanks. After 20 empty knife cycles above the workpiece, the lower end of the link is milled. The influence of the temperature change of the feed axis can be clearly seen from the edge of the workpiece. The workpiece processed using the linear encoder in the test does not have this edge. Therefore, it is possible to ensure high precision with the first piece.
The influence of mold processing The mold processing requires high shape accuracy. At the same time, high-speed feed must be used to reduce machining time. The time that the first and last paths must match to avoid high-speed feed savings will be offset by a large amount of repair work. The shape of the test piece is the shape of the Watzmann peak. In order to visually understand the difference between the use of a linear scale and the processing of the mold without a linear scale, the machining is intentionally started from the middle of the workpiece. The first and last paths are adjacent, and the visible edges clearly reflect the effects of temperature changes. For machines using linear encoders, the Watzmann peak shape does not have this edge.
Position measurement method of the feed axis, the Vazman peak of the free-form surface: the case of no linear scale on the left side and the use of a linear scale on the right. Conclusion: If the machine has high thermal stability, the production order can be completed very successfully. . The feed axis must have the required accuracy over the entire stroke, including when the speed and cutting force vary greatly. These requirements can be met by machines using linear encoders.
Linking, machining twice with no linear encoder with the same blank (left): Linear encoder with sharp temperature changes (right): no edge due to temperature and temperature changes
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