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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 led to higher demands for product quality, which in turn requires greater precision in the manufacturing of curved surfaces. By analyzing the experience gained from CNC machining of molds, this paper explores the key factors that influence the quality of CNC machining. It covers various aspects such as machine tools, tool holders, cutting tools, machining processes, software, and cutting parameters, and presents measures taken to enhance the quality of CNC machining. **Keywords:** mold manufacturing; CNC machining; processing quality; machining process; CAM software Chengdu Aerospace Molding Co., Ltd. is a specialized company focused on the production of molds and automotive interior and exterior parts. The company boasts a highly skilled R&D and design team, connected through over 60 workstations using the most advanced global software. With 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, the company has been utilizing CNC equipment for nearly 20 years. It has come to realize that modern mold manufacturing is increasingly dependent on CNC technology. CNC machining is known for its high accuracy, quality, speed, and automation. As a result, it has become an essential process in mold making and will continue to grow in importance. The number and level of sophistication of CNC equipment have become key factors in determining the competitiveness of a mold manufacturing company in the market. In today’s mold manufacturing industry, the complexity of cavity profiles is growing, especially with the rising proportion of free-form surfaces in automotive molds. This has led to stricter requirements for product quality, placing even higher demands on the precision of surface manufacturing. The accuracy of the mold manufacturing process system, the precision of the CNC system, and the CAM technology used all play a critical role in determining the final 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 CNC machining centers at Chengdu Aerospace Molding have been in operation for a long time. Although there are strict operating procedures and regular maintenance, some degree of precision loss is inevitable over time. To ensure consistent product quality, we conduct regular inspections and maintenance of our CNC equipment, define the processing accuracy of each machine, and assign tasks accordingly. We clearly separate rough and finish machining equipment. Rough machining prioritizes speed and material removal rate but has lower accuracy, causing more wear on the machine. Therefore, we allocate the oldest, most durable machines for roughing, while newer, more precise equipment is reserved for finishing. This strategy optimizes resource utilization, reduces the impact of machine tool performance on machining quality, and helps protect expensive CNC equipment, extending its lifespan. When machine upgrades are not possible, the influence of tool holders and cutting tools becomes more significant. In any rotating tool system, the connection between the spindle and the collet (or similar) is the foundation of tooling performance. Our company commonly uses BT and HSK tool holders. The BT shank has a 7:24 taper that connects with the machine tool spindle, suitable only for low-speed machining. At higher speeds, centrifugal force increases the taper clearance, negatively affecting machining quality. When the machine operates at up to 15,000 rpm, the HSK shank is typically used. The HSK arbor features a preloaded design, ensuring a secure and standardized connection with the machine tool. Under tension, the short taper and end face of the arbor align perfectly with the machine, ensuring stability and precision during high-speed operations.

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