The five-axis linkage turning and milling machining center is the shining pearl in the crown of lathe products. It is developed based on the three-axis turning center. It can be clamped in a single turning and milling center to carry out all turning, milling, drilling, reaming, tapping and even heat, laser and other treatments. Its wide range of processes and strong capabilities have made it the current leader in composite processing. machine tools which. It is the most effective way to treat turbines, blades, marine propellers, heavy-duty generator rotors, steam turbine rotors and large diesel engine crankshafts.
After the five-axis linkage compound turning and milling machining center is clamped once, the machine tool executes multiple processes such as turning, milling and cutting according to different processing procedures, selects and replaces automatically tools and dynamically changes the spindle speed of the machine tool. , the feed speed and the relative position of the tool. The motion traces and other auxiliary functions of the workpiece are used to complete the machining of the complex spatial surface of the workpiece in sequence, resulting in higher product precision and smoother processing. However, the technology is complex and processing and manufacturing are difficult. Domestic enterprises have just entered the five-axis turning and milling center, and the market share is basically monopolized by foreign countries. Domestic users have also used a large number of imported milling lathes for processing complex parts, scientific research and manufacturing new products. According to the structure of the machine tool, five-axis linkage turning and milling centers can be divided into two categories: vertical and horizontal. This article mainly introduces some situations of five-axis horizontal linkage turning and milling centers.
1. Development process
The concept of five-axis linkage turning and milling centers originated in Europe. Austrian company WFL Milling and Turning Technology is a pioneer in the Japanese composite processing machinery industry. Currently, the machine tools are located in Germany and Switzerland. have the highest precision and most complete Overall, Germany has the highest level, Japan has the greatest production value and has the highest global market share.
China’s five-axis turning and milling center started late. The first five-axis turning and milling center was the SSCKZ63-5 five-axis turning and milling compound machining center produced by Shenyang Machine Tool (SMTCL) and German MAX MULLER. company at the Beijing Exhibition in 2001. Exhibited, the parameters of the era reached the international level in the late 1990s. The machine tool can control the X, Y, Z, B and C axes, the diameter maximum rotation of bed is Φ800mm, spindle is 2000rpm, main motor is 37kW, tool magazine has 12 tools and it is equipped. with a Siemens 840D CNC system. In recent years, large domestic machine tool companies have also launched five-axis turning and milling centers. Although the development of compound processing machines in my country started late, domestic users have also used a large number of imported turning and milling compound processing machines for complex workpiece processing, scientific research and production. manufacturing of new products.
2. Horizontal five-axis overall structure
The author believes that the current current structures of five-axis linkage horizontal turning and milling machining centers in the world are divided into three types: servo Y-axis, direct Y-axis and Y-axis. vertical.
Servo Y axis, inclined bed structure, realizes the function of Y axis through the synthesis of the tilting movement of the X axis and the tool holder, and interpolation. Representative machine models are MAZAK INTEGREX IV series, DMG GMX linear series, DOOSSAN PUMA MX and SMTCL. HTM63150iy series. At present, most companies adopt this structure, and the idea is similar to that derived from towers, focusing on tower processing. The two-axis interpolation realizes the function of the Y axis and has a compact structure, but the travel of the Y axis is limited by the structure. For example, the DMG GMX500 five-axis machining center has a rotating diameter of Φ610mm and a Y-axis stroke of 210mm; The MAZAK INTEGREX 400-IV five-axis machining center has a rotating diameter of Φ760 mm, the travel of the Y axis is 230 mm.
Direct Y axis, inclined bed structure, the tool holder moves up and down along the vertical direction of the X axis to realize the function of the Y axis, representative machine models WFL M series, SMTCL series HTM40/80. First developed by the Austrian company WFL, the design concept is based on lathes and the processing is based on turning and milling. The travel of the Y axis and the overall rigidity of the B axis tool holder are limited by the structure of the machine tool. For example, the WFL M35 turning and milling machining center has a maximum turning diameter of Φ520mm and a Y shaft stroke of 250mm.
The vertical Y axis has been developed in recent years based on the structure of horizontal machining centers and lathes. It has a flat top overall frame structure, and the tool holder moves in the vertical direction to realize the function of Y axis. Representative models include MORI SEIKI NT DCG series, MAZAK INTEGREX eH series, SMTCL HTM63150 , etc. The travel of the Y axis is large and limited by the structure of the whole machine. For example, MORI SEIKI’s NT4000 DCG turning and milling machining center has a turning diameter of Φ660 mm and a Y-axis travel of 420 mm. axis travel and a wider milling range than other machine tools with similar structures.
For the above reasons, MAZAK five-axis horizontal machines are divided into two series. The INTEGRX IV series uses a servo Y-axis structure for turning diameters below φ760mm. The INTEGRX eH series uses a vertical Y-axis structure for large turning diameters. φ610-920mm. MORI SEIKI abandoned the servo Y-axis structure, completely shifted to the vertical Y-axis structure, and proposed the concept of box-in-box structure machine tool.
3. Reference model
Austrian WFL (13501282025) Turning and Milling Technology Company, as the inventor of turning and milling technology and the largest professional manufacturer of turning and milling machine tools in the world, has installed more than 1,200 machines -five-axis tools in the world. WFL-M series turning and milling machining center sets the direction and benchmark in the research and development of high-end machine tools.
The WFL M series five-axis turning and milling unit uses a 60° gray cast iron tilt bed. The turning, boring and milling unit is gear driven and equipped with a special mechanical design and hydraulic clamping system. This series of machine tools can also carry out online measurement, deep hole drilling, inner diameter processing, gear hobbing, inner diameter spline forming, high precision machining, etc. Using the B axis, the machine tool can perform machining at any angle to the centerline. Through the five-axis linkage, parts with various complex geometric shapes can be processed efficiently, especially special materials such as stainless steel, titanium, Inconel, nickel-based alloys, etc. can be treated safely and effectively. The humanized design of the machine tool allows the operator to approach the working area without any barriers. To improve safety, WFL offers offline 3D simulation software. In order to avoid potential collision risks caused by program errors or operator errors, WFL provides real-time collision avoidance software – Collision Protection. WFL machine tools are mainly used to process aircraft landing gears, jet engine shafts, large crankshafts, camshafts, valve bodies and housings in the oil and gas industry, printing cylinders, generator shafts, turbine rotors, etc.
Machining center composed of milling and turning representative model M30 MILLTURN, maximum turning diameter Φ520 mm, maximum processing length 2000 mm, maximum turning spindle speed 4000 rpm, maximum milling spindle speed 6000/ 9000/12000 m/min optional, B axis swing angle range -110°～110°. Equipped with an intelligent tool management system that can automatically modify tool data. The machine tool is suitable for six-sided processing of complex shaft and disc parts. It combines turning, milling and drilling processes and can realize five-axis linkage processing. It can also select corresponding modules according to needs to achieve gear or deep processing. hole treatment.
4. Domestic models have made great progress
As user demands are faster, higher and stronger, machine tools must evolve in the direction of high efficiency, high precision and high reliability. This is one of the highlights of the CIMT2023 national machine tool exhibition. Five-axis composite machines. Axis linkage machine tool products have different structural forms, but each has its own characteristics. This trend will surely accelerate the development, progress and popularization of applications of domestic five-axis linkage machines. tools. However, domestic five-axis machine tools still have a long way to go in terms of intelligence and industrialization.
–Kode CNC Co., Ltd. KCX 1200 TM five-axis horizontal milling and turning machining center. Equipped with double opposing turning spindles, two lower turrets and milling spindles. The maximum processing diameter is Φ400mm and the maximum processing length (when supported by two chucks) is 1200mm; The main and auxiliary rotating spindle housings use internal cooling torque motors and are equipped with high-precision electromagnetic angle encoders + hydraulic clamping. The control system adopts Code GNC62 system, optionally equipped with BMT65 power tool turret and programmed tailstock center. The tailstock clamping force can be programmed and controlled based on the diameter and size of the workpiece.
–Machining center composed of horizontal milling and turning Qinchuan Group Baoji Machine Tool BHR800V. The maximum rotating diameter of the bed is Φ820mm, the maximum rotating spindle speed is 2700/1680rpm, the maximum milling spindle speed is 5000rpm, and the rotating range of axis B is -110°~90°. The spindle box adopts dual-motor master-slave mode, connected to a gearbox and has two speeds. The maximum spindle output torque is 3340 Nm, and the spindle clamping force is adjustable. It adopts independent storage tool store and is equipped. with a robot to achieve rapid replacement of tools and accessory heads, it can be implemented; Nowadays, it can do all kinds of high precision complex machining such as turning, milling, boring, drilling, gear milling and grinding. It is effective in processing deep holes, with a maximum processing hole depth of up to 1500mm. used in power transmission, aerospace and large marine diesel engine processing.
–Tianshui Xinghuo Machine Tool Co., Ltd. CNCX630 five-axis milling and turning compound machining center. It is jointly developed by Xinghuo and its wholly-owned French subsidiary SOMAB. The maximum rotating diameter of the bed is Φ630mm, the maximum processing length is 4000mm, and the control system is Huazhong HNC-840DI, fully closed-loop control. Equipped with hydraulic self-centering chuck, hydraulic self-centering center frame, program-controlled hydraulic tailstock, B-axis motorized tool turret and tool magazine automatic tools. Used for turning, drilling, milling, thread milling, tapping and other processing of high-strength steel parts.
–Shandong Plissen Group Co., Ltd. CH6163-5 milling and turning compound machining center. The maximum processing diameter is Φ630mm and the maximum processing length is 1000mm. The spindle unit has separately controlled hydraulic damping and hydraulic braking systems to ensure the machine tool spindle’s stable resistance to vibration during high-speed milling and low-speed gravity milling; the Y axis is a virtual axis interpolated between the X axis and the X axis; U axis at an angle of 60° to each other. Great trip, just. Good performance: The 24-bit tool magazine is installed on the rear of the sliding saddle and feeds simultaneously with the Z axis. It can install and change tools at any position of the slide travel. Z axis, which reduces traditional breakdowns. Fixed tool magazine for installing and changing tools, and greatly reduces time. The auxiliary tool change time is determined.
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