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Analysis of the factors affecting the quality of CNC machining

**Abstract:** The increasing use of free-form surfaces in automotive molds has raised the bar for product quality, placing higher demands on the precision of curved surface manufacturing. By summarizing the experience of CNC machining in mold production, this paper analyzes the key factors that influence the quality of CNC machining. It explores various aspects such as machine tools, tool holders, cutting tools, machining processes, software, and cutting parameters, and presents effective measures to enhance the overall quality of CNC machining. **Keywords:** molding company; mold; processing quality; process; software Chengdu Aerospace Molding Co., Ltd. is a specialized manufacturer of molds and automotive interior and exterior components. The company boasts a highly skilled R&D and design team, connected through more than 60 workstations using the most advanced global software. With integrated CAD/CAM/CAE technology and dozens of CNC machining and injection molding machines, it has established a world-class product development system with strong mold manufacturing and injection molding capabilities. Since introducing CNC machining centers nearly 20 years ago, the company has fully embraced CNC technology, recognizing its critical role in modern mold production. CNC machining offers high accuracy, quality, speed, and automation, making it an essential part of mold manufacturing. As the industry evolves, the number and sophistication of CNC equipment have become key factors in gaining a competitive edge in the market. In today’s mold manufacturing sector, cavity designs are becoming increasingly complex, especially in automotive molds where the proportion of free-form surfaces is rising. This trend has led to stricter quality requirements, which in turn demand greater precision in surface manufacturing. The accuracy of the mold manufacturing process, the precision of the CNC system, and the CAM technology all play a vital role in ensuring surface quality. Most molds with free-form surfaces are now programmed automatically using various CAM software and then machined using CNC machines. Many of the company's CNC machining centers have been in operation for a long time. Although strict operating procedures and regular maintenance are followed, some degree of precision loss is unavoidable. To maintain product quality, we conduct regular inspections and repairs, clearly define the processing accuracy of each machine, and assign tasks accordingly. We strictly separate roughing and finishing equipment because rough machining prioritizes speed and material removal rate over precision, and the wear on the machine during this phase is greatest. Therefore, we designate older, less precise equipment for roughing, while newer, high-precision machines are used for finishing. This approach optimizes the use of existing resources, reduces the impact of machine tools on processing quality, and extends the lifespan of expensive CNC equipment. When upgrading machines is not possible, the influence of tool holders and cutting tools becomes more significant. In any rotary tooling system, the connection between the spindle and the collet (or tool holder) is the foundation of tool performance. Our company commonly uses BT and HSK tool holders. The BT shank has a 7:24 taper, suitable for traditional low-speed machining. However, at higher speeds, centrifugal force can increase the taper clearance, negatively affecting machining quality. When machine speeds exceed 15,000 RPM, HSK shanks are typically used instead. These shanks are over-positioned and provide a secure connection with the machine tool, ensuring tight engagement between the short taper and end face of the arbor and the machine spindle under tension. This improves stability and accuracy, especially at high speeds.

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