Review of CIMT2015 Special Machine Tool Exhibits (I)

Abstract: Through the on-site investigation, data collection and discussion with exhibitors of various special processing machine tools exhibited at the 14th China International Machine Tool Show (CIMT2015), EDM machines and laser processing machines at home and abroad New products, new technologies, new processes and development trends such as material manufacturing equipment have been thoroughly reviewed and systematically reviewed, and market demand has been analyzed.

The 14th China International Bed Exhibition (CIMT2015) was held in Beijing on April 20-25, 2015. The exhibition area reached 131,000 square meters, the largest scale ever, including the world's top 100 machine tool manufacturers. 1554 well-known machine tool manufacturers from 28 countries and regions participated in the exhibition, including 780 exhibitors and 774 exhibitors from overseas.

There are 65 exhibitors at home and abroad for special processing machines, including 44 domestic (including Sino-foreign joint ventures) and 21 overseas, with a total of 129 machine tools. Among them, there are 89 machine tools in the exhibition and 40 machine tools in the world. The main products are still all kinds of electric machine tools and laser processing machines.

First, CNC EDM machine tool
The CNC EDM machine tool (NCSEDM) exhibited at this exhibition has made certain progress in terms of technical performance and process indicators.

1. From stand-alone automation to complete processing technology and initial flexible manufacturing system development
From stand-alone automation to complete processing technology to complete automated processing systems, AgieCharmilles Switzerland has been prepared 15 years ago. It has successively acquired the Swiss Mikron company, which is mainly based on HSM production. The system 3R company, which mainly produces precision fixtures and robots (manipulators), has been able to make complete sets of processing technology after years of running-in. In 2015, the company name was changed to "GF processing plan".

There is a development process from stand-alone automation to complete automated processing systems. That is to say, it is “open”, which is required for a certain workpiece (mold) to be processed by NCSEDM, HSM or precision electric discharge wire cutting. For this reason, the complete processing equipment (machine tool) and complete processing technology are provided by the supplier. And these machine tools are used in general precision fixtures to complete all machining. For example, in 2014, GF had hundreds of large orders on the LED production line, which is a complete set of equipment and complete processing technology consisting of NCSED, HSM and WEDM. The Japanese Makino company bundled NCSEDM and HSM up to 400 a year. The number of Taiwan is enough to show that this sales method is from single-machine sales to complete sales, with turnkey engineering elements, and the development trend of technical services becoming the focus of manufacturing companies.

The further development of complete processing technology has become a complete automated processing system consisting of NCSEDM, HSM and system 3R systems. The complete automated processing system exhibited at this exhibition has reached a higher stage, and GF calls it an automated flexible processing system (see Figure 1). The flexible processing system exhibited by the GF processing program is a high-speed milling HSM400LP and FORM200 precision NCSEDM connected by a mobile system 3R TRANSFORMER. The system3R automatically exchanges the workpiece/electrode in the workpiece/electrode library and passes the car and the sea. The electrode measurement and automatic compensation system of the Kexang coordinate measuring machine are connected, and the whole system GF is called an automated flexible processing system.

This kind of automatic flexible system can greatly shorten the standby time of the machine tool, avoid the operator's intervention in the machining process, make the uninterrupted machining of the parts become a reality, and ensure the consistency of the processing parameters. This processing and manufacturing system is particularly suitable for the processing and manufacturing of batch parts, and there is basically no batch problem for mold manufacturing, so the complexity is increased.

2. NCSEDM has a good market prospect in the aerospace industry
(1) Great market potential in the aerospace industry From the current exhibition, the demand for aerospace engines has received a lot of attention from the industry. The characteristics of aerospace engine manufacturing are mainly the difficulty in processing materials and structures, and these are the advantages of NCSEDM.

(2) Application of NCSEDM in aerospace field At the exhibition, Swiss GF arranged the aerospace room in the form of aircraft cabin, and held a small aerospace seminar to demonstrate the aero-engine blade, bracket parts and blade cooling holes. During the machining process, the DRILL300 five-axis EDM machine for machining the cooling holes of the blades was also demonstrated.

Spain's Ona Company highlighted the application in the aerospace field in the background wall and samples of the booth, and gave examples of processing for key parts such as aerospace blade profiles, seals, sealing grooves, leading edges and trailing edges. .

Through the support of major national science and technology projects, domestic NCSEDM has made significant progress in aerospace applications.

The DK7140 precision NCSEDM (see Figure 2) exhibited by the Suzhou Electric Machine Tool Research Institute can realize the five-axis linkage of X, Y, Z, A and C, which can process the twisted blade shape and other complex profiles of the overall turbine disk with crown. It can efficiently and stably process high temperature heat resistant alloys, titanium alloys, etc., and the best surface roughness Ra0.1~0.2 μm. Beijing Dimeng CNC Technology Co., Ltd. exhibited A series of machine tools, and Beijing Dimeng Carter Electromechanical Equipment Co., Ltd. exhibited a number of products for the mid-range and high-end markets, such as CTM series machine tools. Beijing Dimon CNC's A30 precision CNC EDM machine tool (see Figure 3) uses finite element technology to fully implement national safety standards with higher accuracy than national standards. The machine tool solves the problem of large twisted whole impeller EDM, and solves the processing problems of the overall turbine head with a blade crown and the closed impeller of the engine for key aerospace related enterprises. The CTM550-ABC machine exhibited by Beijing Dimeng Carter is equipped with a two-dimensional precision turntable, six-station tool electrode library, which expands the application range of the machine tool, and has multi-axis linkage and online monitoring functions, which can realize points at any angle of space. Processing of bits, grooves and complex surfaces can be applied to aerospace-related parts processing. Beijing Ande Jianqi Digital Equipment Co., Ltd. exhibited the AF1300 four-axis full-function CNC EDM machine (see Figure 4). The four axes of X, Y, Z and C can be servo-machined, equipped with 4-station electrode automatic switching device. With the rotation function of the C-axis, circular and square translation in any direction can be realized, and three-dimensional translation processing such as reaming processing and spherical shape can be performed. Can be applied to aerospace related parts processing. 3. Several issues worthy of attention in NCSEDM
Although the development of NCSEDM in China has made considerable technological progress, compared with foreign advanced level and development ideas, there are still many gaps, and there are still some issues that deserve our attention.

(1) Machine structure technology with high-speed tool lifting function: NCSEDM has greatly improved acceleration and movement speed since the high-speed tool lifting technology. At present, NCSEDM's machine tool structure is closer to HSM. Today's HSM has adopted linear motor drive, and has adopted new technologies such as high and low rail layout, synchronous double drive, and center of gravity guidance, which have reference value for NCSEDM. The NCSEDM structure of Japan Makino is based on the structure of the machining center.

(2) Intelligent conformal control technology: Generally speaking, the processing area of ​​the cavity machining will change during the processing, and some processing areas vary greatly. The procedure for manually converting the processing energy is often complicated and not Accurate, if there is a problem, there will be excessive electrode loss when the processing area is abrupt, and even arcing occurs. Because of the problems existing in the manual method of converting the machining energy program in the process of machining, the CAD modeling technique of the workpiece cavity and the electrode is adopted, and even if the cavity is pre-milled in the HSM, the pre-processing can be utilized. The CAD/CAM technology of the milling and the CAD technology of the electrode make the two models (graphics) continuously “follow the shape” during the machining process, and constantly change the processing parameters and the corresponding servo lifting parameters to ensure the safe and efficient processing. .

(3) NCSEDM's processing technology in the aerospace industry: processing with crowned turbine blades as a typical object, systematic research on the processing technology of aerospace special parts and special materials. The crowned turbine blade is a three-dimensional channel with variable cross-section. It requires more than five axes of NCSEDM. Therefore, it is necessary to study the coordinate combination of specific trajectories, the distribution of machining allowance, machining efficiency and surface quality. In particular, the study of surface integrity of processing is particularly important in the aerospace industry.

(4) Rsm for mold processing: EDM can realize direct processing of precise and complex cavities, but for some molds, not only the requirements of Ra, but also Rsm (the arithmetic mean of the peak and valley width of roughness) ) requirements. Studies have shown that larger Rsm values ​​allow for easy demolding, less bonding, and a stylish textured appearance of molded parts. For semiconductor plastic molds, it is important to release molds and bond less.

In this exhibition, Japan Sodick Company developed IC PIKA power supply, which can achieve larger Rsm value under the same Ra condition compared with other power sources (see Figure 5), but this aspect has not attracted the attention of Chinese manufacturers. . (5) Emphasis on the research of complete processing technology: As mentioned above, foreign countries have developed from open-type processing technology to complete automatic processing system, and further developed into a preliminary flexible manufacturing system, while China is still in the stage of single-machine production. In fact, NCSEDM and HSM are complementary processing technologies, which have great complementarity, especially for cavity mold processing, which often requires NCSEDM and HSM to complete together. Therefore, in China, we can consider the cooperation between NCSEDM and HSM development and production enterprises, research on complete process technology, develop common fixtures, provide complete solutions for users, change the production mode of single machine, and gradually develop to complete processing systems.

Second, EDM wire cutting machine 1. One-way wire EDM wire cutting machine
A total of 15 one-way wire cutting machine tools were exhibited at the exhibition, including 8 overseas brands and 7 domestic brands. Compared with the previous exhibition, there is no major breakthrough in the main processing indexes of such machine tools. The overseas exhibition machines have made significant progress in detailing the straightness and multiple cutting performance of one cutting, and the overall performance of the domestic wire cutting machine has been improved. . The technical performance index of the one-way wire cutting machine of this exhibition is from the best surface roughness Ra0.6 μm to Ra0.008 μm, the maximum cutting efficiency is from 200 to 500 mm2/min, and the product sales price is from 300,000/set to more than 200. 10,000/set, all levels of related machine tools are displayed.

(1) Market competition strategy to improve cost performance In order to compete for China's big market, several famous electric processing manufacturers in Japan and Europe have adopted different competition strategies to meet the needs of customers at different levels. At the same time, it develops new practical technologies on the mid-range machine tools with the largest sales volume in the market, and improves the surface roughness and part processing precision of the parts that are cut and repaired to attract more customers to purchase such products. Some latter manufacturers can only take a combination of price and new technology applications to gain some market share.

(2) Technical improvement of processing precision and comprehensive processing efficiency Exhibitors of this exhibition pay more attention to the promotion of practical processing performance indicators to users. The most prominent highlight is the straightness control technology in one cutting. Different manufacturers have adopted different straightness control strategies. For example, the U6 machine tool of Japan Makino has developed the GS-CUT (convex sprite) technology, which realizes the micro-vibration or micro-vibration method of controlling the wire in the orthogonal direction of the cutting path. The high straightness of one cut. The shape control power supply (Digital-AEII) of Mitsubishi Electric's MV series machine tool realizes the high straightness of one cutting by controlling the ratio of the input energy of the upper and lower electric blocks. Japan Sodick SL400GS one-way wire cutting machine with TMP control technology, the straightness of one cut is 2 μm/100 mm (one side).

(3) EDM wire cutting machine based on oil-based working fluid The AP250L exhibition machine of Japan Sodick Company adopts oil-based working fluid, X, Y, U, V four-axis linear motor drive, door type column structure, equipped with "Super Pika Oil's finishing circuit, the best surface roughness is Ra0.008 μm, and the precision of small mold processing is controlled at ±1.5 μm. This machine represents the highest technical level of similar exhibitions at this exhibition.

(4) Linear motor drive technology is more popular Linear motor drive is becoming more and more popular in precision one-way wire cutting machine tools. In addition to the linear motors used in the four exhibitions of Japan's Sodick and Mitsubishi Electric Corporation, the two exhibition machines of Taiwan Qinghong Company also used linear motors. Japan's Sodick Company has used linear motors for 15 years and 30,000 units. After 10 years, the machine tool coordinate accuracy is still very good. The residual value of the 10-year one-way wire-cutting machine has 50% of the original value. As linear motor costs become lower and lower, this technology will be widely used in most single-way wire cutting machines in recent years.

(5) Automatic processing technology The main technology of automatic processing and unmanned operation of one-way wire cutting machine is automatic threading technology and core waste maintenance technology. The automatic threading system continuously increases the wire diameter success rate of less than 0.1 mm and the threading success rate on curved or hollow workpieces. Japan's Mitsubishi Electric, Japan's Makino and Japan's Western Electric Company have demonstrated to customers the automatic threading technology of 0.2 mm diameter wire on multi-stage hollow parts, combined with core multi-point welding technology, cutting cores and parts The main body performs multi-point welding, which makes it easier to realize automatic processing without one.

(6) Variable section with shape intelligent control technology and double nozzle processing technology Direct import and processing of 3D graphics of wire cutting machine tools of Japan Mitsubishi Electric Corporation, Japan Sodick Company, etc., realize the process of WEDM process of variable height workpiece The intelligent control of the parameters reduces the interruption of the machining and reduces the occurrence of the cross-section processing stripes. The upper and lower nozzles of the Japanese Makino machine are separately supplied with water by two high-pressure pumps. Each nozzle can provide higher flushing pressure, which is very helpful for improving cutting efficiency.

(7) Segmentation of one-way wire cutting machine The application of one-way wire cutting machine is also shifting to some market segments. Japan's FANUC's exhibition machine α-C400iA, equipped with British Renishaw probe and German high-precision indexing axis, realizes automatic alignment and automatic processing of stick-shaped and disc-shaped tools. Germany Volmer PCD tool processing special one-way wire cutting machine QDW760, with five-axis linkage function, configure tool cutting programming software, provide a variety of tool shape standard graphics library, just need to find the corresponding tool shape, the necessary size Fill in and you will be able to directly generate processed graphic files. An AE1100 large-scale one-way wire cutting machine exhibited by Beijing Ande Jianqi Digital Equipment Co., Ltd., with the best surface roughness: Ra<0.3 μm, maximum cutting efficiency: 250 mm2/min, to meet the high-precision machining of large-scale automotive molds. It is the first large-stroke one-way wire cutting machine in China.

2. Reciprocating wire EDM wire cutting machine
A total of 13 domestic-funded enterprises exhibited reciprocating wire EDM wire cutting machines, all of which are medium-cut wire cutting machines. Compared with the previous exhibition, domestic exhibits have made great progress in the overall appearance quality and practical processing indicators.

(1) All of the participating wire-cutting machines have adopted a closed liquid tank structure to enhance the environmental performance of the machine.
(2) Introducing industrial design technology to greatly improve the appearance and color tone of machine tools.
(3) The integrated structure has been gradually adopted by manufacturing companies, saving floor space.
(4) Started the production of high-end medium-cut wire cutting machine tools with T-bed and C-type structure, indicating that the industrial upgrading is underway.
(5) Performance indicators such as processing speed are further improved. Most of the wire-cutting machines have a machining efficiency of >200 mm2/min and some products >300 mm2/min. The optimum surface roughness is generally Ra0.8 μm, and individual products reach Ra 0.6 μm.
(6) Pay more attention to the practicality of machine tools, highlighting the average efficiency, surface roughness, and wire loss of multiple cuts.
(7) With the development of various technologies, cutting fluids, guide wheels, masks, etc. related to the middle-cut wire cutting machine tools have certain technical improvements, and manufacturers pay more attention to the application of machine tools in market segments.
(8) Learn from the one-way wire-cut EDM wire cutting technology and seek breakthroughs in its own technology. It is more prominent in the advantages of the middle wire cutting machine in processing large thickness and large taper parts.
(9) The middle wire cutting machine will develop towards the comprehensive strength of reliable performance, stable precision, simple operation and convenient maintenance. (To be continued)

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