Application Analysis of Machine Tool Online Inspection in Mold Manufacturing
The laser tool setter provides a fast and automated method for verifying the size of the tool, especially in mold making, which plays a key role in testing tool wear after long-term machining. The laser tool setting instrument is an effective method for high-speed, high-precision tool adjustment and tool breakage. It has good cost-effectiveness. Under working conditions, when the tool is indexed by laser beam or rotated at normal speed, it can be quickly measured. Its length and diameter. Laser detection with spindle speed identifies errors due to uncoordinated and radial vibrations of the spindle, tool and tool holder. This feature is not possible with static tool setting systems. Some NC tool setting instruments can detect broken tools at the highest lateral stroke to further minimize non-cutting time.
The strain gauge probe is testing the injection mold of a computer mouse. This strain gauge testing technique overcomes the disadvantage of measuring unevenness with conventional contact-trigger probes because parts with complex geometries need to be approached from all directions. This omni-directional probe maintains the machining accuracy of Western Industrial Tooling in Redmond, Washington, between +0.0000 and -0.013 mm, and produces parts with a precision that meets 25% of customer tolerances. Drive mechanisms that are fast, labor-saving, and more flexible produce industrial focus away from traditional post-process quality management. In most workshops, the most expensive and invaluable job is the inspection of parts. Testing unqualified parts wastes time and wastes money and manpower. The focus now is not on the late detection, but on the prevention of the previous period. The aim is to produce 100% qualified products from the outset with particularly tight tolerances and minimal processing times. Under this aim, a variety of practical techniques have been applied to the machine tools for better process control purposes. Automated process inspection keeps processes and parts under control to minimize downtime due to operator intervention.
These improvements in process control are critical to the mold manufacturing industry. Most mold processing has a one-shot feature because higher cumulative error values ​​are transferred to complex molds, which requires us to complete all processing at once. At the same time, shorter lead times and global competition also require faster tooling. In order to minimize the interference of operators and other factors, these process control systems add a pair of monitoring eyes to the mold manufacturer, which is beneficial to monitor the machining of the machine in the long-term processing and the second and third processes.
Machine tool processing capability
In order to prevent defects from occurring, companies must have the ability to edit process documentation and the process accuracy of the machine. In order to achieve this, it is necessary to follow the standards recognized and accepted by the state, such as in accordance with ISO 230 or ASME B5.54. Both standards require the use of a club and laser interferometer to test the accuracy of the machine in accordance with the recommended procedures. The purpose of using these standards is not to specify that the machine must meet certain accuracy, but to find out what level of precision the machine can achieve. The written data of the parts stipulates that the precision of the machine tool of the enterprise must be able to produce qualified parts and set the precision benchmark in this place. Tested to give you an idea of ​​how high your machine can reach. As long as the machine can reach that accuracy benchmark, it has the ability to process.
Modern machine tools are equipped with test and calibration techniques and are also available to ensure that the machine is accurate and up-to-date. More and more factories and large workshops have their own laser interferometers and electronic equipment, while small factories can use a variety of channels to commercialize and acquire equipment and inspection services at a competitive price. .
In fact, it is now possible to provide a retractable ball detector for any shop for rapid inspection of the machine, and the inspection task can be completed in as little as 15 minutes to maintain the machining accuracy of the machine. The club inspection can accurately evaluate the machine's geometric accuracy, roundness and stick/slip error, servo gain mismatch, vibration, backlash, repeatability and mismatch of the scale. Some club software provides diagnostics for specific errors based on ISO 230-4 and ASME B5.54 and B5.57 standards, and then provides a common English list that lists the various errors in order of overall impact on machine accuracy. source. This allows machine tool maintenance personnel to work directly on the problem area.
Phased club testing keeps pace with the performance trends of machine tools. Preventive maintenance facilitates planning in advance of the machine's ability to deviate from process capability. Industry generally tends to calibrate machine tools as needed, rather than time. There is no reason to take care of a good machine that is being produced for maintenance. When it is found that something is not normal, let the test club and the produced parts be determined. Production can continue during the test.
On-board probe detection
The accuracy and repeatability that standard machine tools can achieve today are close to the level that only CMM coordinate measuring machines can achieve in the past. This function allows the machine itself to automatically detect the workpiece with a probe during critical machining processes. Once the measuring instrument is installed on the machine, the measuring probe becomes the operator's CNC meter. The inspection program can be programmed as part of the machining process and automatically run at various points to detect size and position and provide the necessary compensation. This eliminates the need for operators to use dial gauges and plug gauges to measure and eliminate artifacts caused by fixtures, parts and tool offsets in the control system. On-board inspection has become a part of the process, an improved and powerful process tool that produces qualified parts for the first time in the shortest production time.
Can be used to automatically determine the position of the part, and then establish a working coordinate system, on-board inspection can reduce the set-up time, improve the utilization of the spindle, reduce the cost of the fixture and eliminate the non-production processing transit time. In the complex part processing, it took 45 minutes to debug the fixture. The application of the detection device is only 45s and all of them are automatically operated by CNC. When starting to machine castings or forgings, the inspection device determines the shape of the workpiece, avoids wasting time due to empty cutting, and helps determine the optimum tool entry angle. The control during the process is to use the detection device to monitor the machine characteristics, size and position during the cutting process, and to verify the exact dimensional relationship between the various features of each process to avoid problems. The probe can be programmed and the actual machining results at each stage can be tested programmatically and then automatically compensated for tool offsets, especially after roughing or semi-finishing.
The reference test compares the feature of the part to a reference template of a size template or known position and size. It enables the CNC to determine the positioning gap and then generate an offset to compensate for this difference. By performing inspection of the counterfeit template before the critical machining, the CNC can check its own positioning for the known dimensions of the template and then program the offset. If the size template is mounted on the machine and exposed to the same environmental conditions, the reference test can be used to monitor and compensate for the thermal expansion coefficient. The result is a closed loop process that is not affected by the operator.
Each machine has many inherent small errors in its motion and in its structure. Therefore, there is always a slight gap between the programmed position of the CNC and the actual position of the tool tip, even in both. After laser compensation, the adjustment is fairly consistent. Programmable artificial template testing is a good way to further compensate for the rest of the machine. It provides feedback for process control and enables positioning accuracy to be close to the specifications of machine repeatability. This closed-loop process control allows the machining center to achieve machining levels that are comparable to those of boring mills and other precision machine tools.
Many probe detection operations are done using a memory-resident macro program. The update of the working coordinates, the change of the tool geometry and the measurement of the parts are automatically determined by the CNC after the successful completion of the probe detection cycle. This eliminates the serious errors caused by incorrect information links or incorrect calculations. For post-processing part inspection, probe inspection can reduce the length and complexity of off-line inspections, and in some cases even eliminate them all. Since large and expensive workpieces are very difficult to move and time consuming, on-board inspection is particularly advantageous for large and expensive workpieces.
Here, two methods can be used to complete the reference detection, that is, using the machine tool correlation detection method to compare the measured data on the machine with the previous CMM measuring machine data; or using the counterfeit sample detection method to compare the on-board data with the known size. The traceability of the model was compared for comparison. In making this comparison, the CNC is able to determine if the machine has actually reached the specified machining tolerances. Based on these results, an informed decision can be made to take the correct approach to the artifacts that remain on the machine.
Non-contact laser tool setting
When the tool moves through the laser beam, the system electronics detects the interruption of the laser beam and sends an output signal to the controller. The NC system accurately measures tools with a minimum diameter of 0.2 mm anywhere in the laser beam. When the laser beam exceeds the 50% threshold and is blocked by the detected tool, the system is triggered. The non-contact tool setting system uses a red visible light diode laser that is reliable under processing conditions.
Advanced electronics and simplified design make contactless tooling a replacement for contact systems. Since there are no moving parts, the NC system can actually be saved from maintenance. This design does not have the framework and actuators required for a contact system. Some NC laser tool setting tools are equipped with a protection system that is mounted in a rugged stainless steel unit with uninterrupted compressed air to prevent contamination, chips, graphite and coolant even during measurement. Intrusion. These systems can be installed on machines of all sizes and shapes, without any impact on the machine's work.
Mature applications and the availability of these technologies, such as powerful tools to improve the process level, are great for improving the automation of mold processing and achieving better process control. They enable moldmakers to produce molds faster with higher geometric accuracy and dimensional accuracy, with virtually no operator involvement, rework or manual finishing.
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