Breaking Down the Science of CNC Flexion Machines: A Deep Dive
Introduction
In the realm of modern manufacturing, CNC (Computer Numerical Control) flexion machines have revolutionized the way we produce precision components with complex shapes. These machines are capable of high-speed, high-precision bending and forming of various metals, alloys, and other materials. But have you ever wondered how these machines work their magic? In this blog post, we’ll dive deeper into the intricacies of CNC flexion machines, exploring the principles, components, and control systems that make them tick.
The Anatomy of a CNC Flexion Machine
A CNC flexion machine is primarily a high-pressure press, which utilizes a complex system of pneumatic and hydraulic components to bend and shape materials with unparalleled precision. The machine’s control system, typically comprising a Proportional-Integral-Derivative (PID) controller, ensures that the entire process runs smoothly, efficiently, and accurately.
The Flexion Process in Five Stages
The flexion process can be broken down into five distinct stages: (1) Rest, (2) Descend, (3) Form/Stamp, (4) Decompression, and (5) Return.
(1) Rest
In this initial stage, the flexion machine is in a state of equilibrium, with the bent beam higher than the dead upper level. To prevent uncontrolled downward movement, the system seals the cavity of the hydraulic cylinder rod with a recirculation-off valve.
(2) Descend
In the second stage, the rapid descent of the flexion machine occurs, mainly through the force of gravity. During this process, the hydraulic cylinder without a rod generates a rear pressure, which is controlled by a proportional steering valve. The rapid advance begins at the upper dead point and ends at a maximum distance of 6 mm from the folded plate, with a brief braking phase.
(3) Form/Stamp
The form/stamping stage begins when the compression of the cavity without a rod is initiated. The stamping speed is limited by the quantity of oil supply from the oil pump and can be adjusted by a proportional valve and a directional valve. The directional valve also controls the synchronous operation of the folded beam and the positioning of the lower dead point.
(4) Decompression
In the fourth stage, the decompression of the cavity without a rod occurs, either when it reaches the lower dead point or after a brief maintenance delay, allowing the distorted material to flow for a certain period, thus improving dimensional precision. The decompression time must be as short as possible, without compromising the overall precision of the process.
(5) Return
The return journey begins from the decompression of the rod cavity at the end of the upper dead point. The return speed is determined by the pump flow rate and the pressure zone of the hydraulic cylinder’s rod chamber. The return trip also requires synchronous operation.
Hydraulic Control System
The hydraulic control system of CNC flexion machines requires a high degree of automation and synchronization in production. To achieve this, the machine must have a high integration rate, incorporating the hydraulic system into the machine. This integration rate is crucial for users with various requirements, including those with limited machine space.
Valve Blocks: The Heart of the System
There are two primary styles of valve blocks used in CNC flexion machines: the three-control valve block and the central control block.
Three-Valve Block Style
The three-control valve block style features three control valve blocks: the main control block, the oil suction valve block, and the pump control block. The main control block is composed of a proportional directional valve, an inversion valve with position monitoring, and a rear pressure insertion assembly.
Central Control Block Style
In the central control block style, all three control blocks are integrated into a single block. This design is suitable for machines with special structures or limited space.
Conclusion
In conclusion, CNC flexion machines are complex, high-precision manufacturing tools that rely on sophisticated hydraulic control systems to produce intricate shapes with precision and accuracy. By understanding the principles, components, and control systems involved in these machines, engineers and manufacturers can create more efficient, effective, and cost-saving production processes. Whether you’re an experienced engineer or an industry newcomer, this blog post has provided a comprehensive overview of the science behind CNC flexion machines.
