The hottest heidenhaiitnc530 CNC system

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Heidenhain itnc 530 numerical control system and high-speed mold machining


high speed machining (HSM or HSC) is an advanced machining technology that developed and applied rapidly in the 1990s. It usually refers to milling at high spindle speed (10, 000r/min) and high feed speed (40m-180m/min). In practical application, high-speed machining can solve the processing problems of new materials, adapt to the processing of three-dimensional curved surfaces with high surface quality, high precision and complex shape, reduce and avoid inefficient EDM, and solve the processing problems of thin-walled parts. NC High-speed composite machining can also reduce the times of handling and clamping, and avoid the processing errors caused by repeated positioning, which not only improves the processing quality, but also improves the processing efficiency. High speed machining technology is gradually applied to the processing of cast iron and duralumin alloy, especially the processing of large-scale panel stamping die, forging die, die-casting die and injection mold. At present, high-speed machining technology is mainly used in the field of machining complex surfaces such as molds, aerospace and automotive industry. The research and application of domestic high-speed machining technology began in the 1990s, and it is also mainly used in mold, aerospace and automotive industry, but the high-speed cutting CNC machine tools, high-speed cutting tools and cad/cam software are mainly imported

high speed machining generally adopts high milling speed and fast multiple tool walking to improve efficiency. Small diameter tools, appropriate feed rate after normal use of the experimental machine, small radial and axial cutting depth, that is, cutting volume. With the increase of milling speed, the processing time is greatly shortened, and the cutting force is reduced and the vibration is small, especially the radial cutting force is greatly reduced, and the part deformation is small. Because a large amount of cutting heat is taken away by chips during cutting, the surface temperature of the workpiece is low. Due to the above characteristics of high-speed milling, high-speed machining has outstanding advantages over conventional machining: high productivity, stable work, high processing surface quality, no need for other surface treatment processes, conducive to the processing of thin-walled parts and high-strength, high hardness brittle materials, can shorten the delivery time, reduce the number of equipment and workshop area, and reduce the number of workers. Although the equipment investment cost increases in the initial stage, the comprehensive benefits of high-speed milling process are still significantly improved

1 high speed processing and mold manufacturing

at present, plastic molds are becoming more and more sophisticated, and the structure is becoming more and more complex. The required mold closing times are close to or more than 800000 times. The hardness of the mold steel used is getting higher and higher, and some even exceed HRC 64, while the delivery time of the mold is required to be shorter and shorter. These market characteristics have brought great pressure to mold manufacturers. The emergence of high-speed machining technology has brought new development opportunities for mold manufacturing, especially in the processing of small and medium-sized precision plastic molds

most die materials have high hardness and good wear resistance, which makes it difficult to process. EDM micro cutting is widely used in traditional technology, and the production efficiency is very low. As long as the oil cylinder and piston are cleaned, high-speed machining technology has a great impact on the mold processing technology. It has changed the complex and lengthy process flow of "EDM → polishing" used in traditional mold processing, and even can replace all the original processes with high-speed machining. In the machining process of high hardened steel parts (hrc45 ~ 65) of the die, the use of high-speed cutting can replace the processes of electric machining and grinding and polishing, avoiding the electrode manufacturing and time-consuming electric machining time. In addition to being applied to the direct machining of the hardened die cavity (especially semi finishing and finishing), high-speed machining technology has also been widely used in EDM electrode machining, rapid sample manufacturing, etc. A large number of production practices show that the application of high-speed cutting technology can save about 60%-100% of the manual polishing time in the subsequent processing of molds, reduce the EDM process and time, save nearly 30% of the processing cost, and double the cutting efficiency. This saving has been truly reflected in many foreign mold manufacturers

using high-speed milling to process molds can not only use high speed and large feed, but also complete rough and finish machining at one time, which greatly improves the production efficiency. Adopt high-speed cutting to process hardened steel mold, with a hardness of more than 60HRC and a surface roughness of ra0.6 μ m. The efficiency is several times higher than that of electric machining, which not only saves a lot of polishing time, but also replaces most of the electric machining processes

2 requirements of high-speed machining on CNC system

high speed machining is an advanced and complex system engineering technology. Compared with traditional processing technology, it has higher requirements on machine tools, cutters, tool handles, processing technology, control system, cad/cam software and other indicators. Due to the particularity of mold processing and the characteristics of high-speed machining technology, higher requirements are put forward for mold high-speed machining process system (machining machine tool, CNC system, cutting tool, etc.) than traditional mold processing

advanced numerical control system is the key factor to ensure the quality and efficiency of high-speed machining of mold complex surfaces. Its characteristics are reflected in addition, subtraction, pre compensation, feedforward control, accurate vector compensation, optimal corner deceleration, safety protection and real-time monitoring. The basic requirements of mold high-speed machining for CNC system are:

high-speed digital control loop, such as 64 bit parallel processor and extremely short linear motor sampling time

feedforward control of speed and acceleration, crawling control of digital drive system

advanced NURBS based spline interpolation calculation method to obtain good surface quality, accurate size and high geometric accuracy

preprocessing function. CNC is required to have a large capacity buffer register, and multiple program segments (such as 1000 ~ 2000 program segments) can be read and checked in advance, so that when the shape (curvature) of the machined surface changes, measures such as changing the feed speed can be taken in time to avoid overcutting, etc

error compensation function, including thermal error compensation caused by heating of linear motor, spindle, quadrant error compensation, measurement system error compensation and other functions

in addition, mold high-speed machining requires high data transmission speed. The transmission speed of traditional data interfaces, such as RS232 serial port, is 19.2kb, while high-speed machining centers have adopted Ethernet for data transmission, and the speed can reach 200KB

3heidenha1) the single transverse slope structure will cause the shear lag coefficient of the low side of the web to increase. In itnc 530 CNC system

Heidenhain company is a multinational group company with a history of more than 100 years specializing in the production of high-precision measuring elements and CNC systems. The high-performance CNC system and measurement feedback components produced by the company have been widely used in the field of mold processing and high-precision machining

Heidenhain's itnc 530 control system is a general control system suitable for milling machines, machining centers or machining processes that need to optimize tool path control. The data processing time of the system is 8 times faster than that of the previous TNC series products. The equipped "Fast Ethernet" communication interface can transmit program data at the rate of 100mbit/s, which is 10 times faster than that before. The new programmer has large program capability and can quickly insert and information program segments. In the new system, the company separated the NC master computer from the drive control unit for the first time, and installed Intel processors. The machine adopts 15 inch high-resolution XGA display (1025 × 768) or 10.4 inches (640 × 480) VGA display. Any operator familiar with TNC system will soon be able to master the operation of this new system. Machinists do not need to memorize the G code, but only need to use the key combination to compile the line segment, arc segment and cycle program

for the complex surface processed by mold, if you want to realize high-speed, high-precision and high surface quality processing, you must have a good hardware foundation, good servo performance and high-speed control ability

the main feature of the high-speed 3D controller Heidenhain itnc530 is that it uses a 400 MHz AMD processor with a faster speed. All real-time tasks of the itnc530 are completed under the real-time operating system (heros) developed by itself, and it can also provide a host computer with two processors, one for running the Heidenhain operating system, that is, the core "new heros" of CNC, and the other for running the MS Windows 2000 operating system. It can not only ensure the real-time calculation and stable performance of the system, but also meet the needs of users for Windows applications

The processing time of Heidenhain itnc530 program segment is 0.5ms. The more complex the geometry is and the stricter the tolerance requirements are, the higher the density of points will be. When machining with high-speed feed, the corresponding NC code must be processed faster to avoid the so-called data hunger to limit the feed speed. When there is no data in the cache of the NC program segment being processed, the motion will stop or jump due to the lack of positioning instructions. The CNC of HSM is characterized by the processing time of program segments as short as 1ms or even shorter. Itnc530 is fully qualified for CNC system required by high-speed machining (HSM)

NC programs in high-speed machining applications are generated on an external cam system. Generally, NC programs have only a few hundred kilobytes, and there are often programs as high as hundreds of megabytes. Therefore, the CNC system used by HSM is characterized by a fast Ethernet interface with high-speed data transmission capability. The transmission speed of Ethernet interface is 100 Mbit/s, which is the standard speed of conventional networks nowadays. The new Heidenhain CNC system host unit is equipped with various data communication interfaces (ethernet/rs232/rs422/usb, etc.), and the equipped Fast Ethernet communication interface can transmit program data at the rate of 100MB/s

itnc 530 system adopts limited acceleration value and uses filter to smooth the acceleration speed. During high-speed feeding, if any axis is suddenly reversed, it will lead to excessive acceleration and acceleration, which will cause vibration of the machine tool structure. It is a good way to reduce or eliminate this effect to realize the speed, acceleration and acceleration smoothing scheme through CNC

heidenhain itnc 530 supports the automatic replacement function of sister tools. In order to automatically deal with tool wear or fracture, it is necessary to replace with milling cutters of the same size, which must be paid attention to by the whole industry. If CNC supports this function, the operator can load multiple tool changing devices of the same milling cutter, and identify these same milling cutters as sister cutters for the call of NC program. CNC will automatically replace the worn or broken milling cutter with these specific sister tools and continue to complete the NC program

the "read ahead" function of Heidenhain itnc 530 is 256 lines. The so-called "read ahead" function calculates the correct speed and acceleration that should be used in each program segment in advance, and generates a speed and acceleration configuration scheme to meet the programmed tool path requirements. The pre calculated information is read into the cache in the CNC system and called from the cache according to the program requirements in processing. Once there is no data in the cache, because the calculation speed of the CNC system cannot keep up with the feed speed, the machine tool will stop moving until the next pre calculated behavior is reached. This problem is called data hunger. The processing time of program segment in modern CNC system is getting shorter and shorter, and the number of lines that need to be pre read by CNC system to avoid data starvation is also getting smaller and smaller

with the support of powerful hardware, the itnc 530 adopts full digital drive technology. Its position controller, speed controller and current controller all realize digital control. Digital motor control technology can achieve very high feed rate. Itnc 530 interpolates at the same time

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