Five axis CNC precision machining - dedicated to integrated manufacturing of complex surfaces and irregular structural components

1、 Core service advantages
Precise molding of complex surfaces, breaking through the limitations of machining dimensions
Relying on the five axis linkage (X/Y/Z linear axis+A/C rotating axis) technology, "multi angle, no dead angle" machining can be achieved, which can accurately mill complex contours such as spherical, helical, and free-form surfaces. The surface contour error is ≤± 0.005mm, and the surface smoothness can reach Ra ≤ 0.4 μ m. Compared to traditional multi process machining, there is no need to adjust the workpiece posture multiple times, avoiding accumulated positioning errors, especially suitable for parts such as aircraft engine blades and medical artificial joints that require extremely high surface fitting.
Integrated manufacturing of irregular structures, reducing processes and improving efficiency
For special-shaped structural components with hollow out, irregular contours, and multiple intersecting surfaces (such as robot articulated arms and new energy equipment special-shaped brackets), "one-time clamping, full structure processing" is achieved, integrating multiple processes such as milling, drilling, and chamfering, reducing the number of processes by more than 40% and shortening the processing cycle by 30% -50% compared to traditional processes. At the same time, avoid structural misalignment caused by multiple clamping, and ensure that key indicators such as hole coaxiality and surface contour parallelism of the irregular parts meet the design standards.
Wide material compatibility, balancing the processing of hard and easily deformable materials
Hard material processing: For high-strength materials such as titanium alloys, high-temperature alloys, tungsten carbide, etc. (with a hardness of HRC50 or above), equipped with a high rigidity spindle (maximum torque of 80N · m) and ultra-fine grain hard alloy cutting tools, combined with a high-pressure cooling system (cooling pressure of 100bar), to solve the problems of easy tool breakage and low efficiency in hard material processing. It can stably process high-strength irregular structural parts in the aerospace field;
Processing of easily deformable materials: For materials such as aluminum alloys and engineering plastics (such as PEEK, POM) that are prone to thermal deformation, low-temperature cutting technology and flexible fixtures are used to reduce processing thermal stress, avoid complex curved surface warping and dimensional deviations of irregular structures, and adapt to precision electronic device casings and other scenarios.
The quality of the entire process is controllable, ensuring consistency of complex parts
Establish a closed-loop control system of "design processing testing": simulate complex surface machining paths through CAD/CAM software before machining to predict collision risks; Real time monitoring of spindle load and cutting temperature during processing, automatic compensation for tool wear; After processing, a three coordinate measuring instrument (with an accuracy of ± 0.001mm) and a blue light scanner (with a 60% increase in full-size inspection efficiency) are used to conduct comprehensive inspections of complex curved surfaces and irregular structures. Inspection data is retained for each batch of parts to ensure consistency in mass production.
2、 Core application areas
aerospace field
Customized aircraft engine turbine blades (complex surfaces+high-temperature alloy materials), fuselage irregular frames (multi-faceted staggered structure), satellite antenna reflectors (high-precision parabolic surfaces), five axis machining can meet the strict requirements of aerospace for lightweight, high-strength, and high-precision parts, and adapt to extreme flight environments.
Medical equipment field
Produce artificial joints (made of titanium alloy material+complex curved surfaces that fit the human body), surgical robot end effectors (shaped clamping structures), and precision chambers for diagnostic instruments (hollow shaped structures), with processing accuracy that meets medical grade standards (such as surface roughness Ra ≤ 0.2 μ m for artificial joints), ensuring the safety and adaptability of the equipment.
new energy sector
Processing the irregular shell of wind power gearbox (multi axis hole staggered structure), complex curved support of photovoltaic tracking system (aluminum alloy material), high-precision electrode holder of energy storage equipment (irregular conductive structure), the high stability of five axis processing can improve the operating efficiency of new energy equipment and adapt to complex outdoor working conditions.
High end automotive manufacturing field
Customized new energy vehicle motor shaped end caps (complex structure with integrated heat dissipation channels), lightweight racing chassis shaped components (carbon fiber composite materials+complex curved surfaces), and automatic driving LiDAR housings (high-precision spherical windows), balancing the strength, lightweight, and assembly accuracy requirements of automotive parts.
Industrial automation field
Production robot articulated arms (complex surfaces with multi axis linkage), precision fixture shaped positioning blocks (irregular contours), automated production line transmission system shaped rollers (wear-resistant rubber+metal composite structure), five axis machining can ensure the motion accuracy and stability of automated equipment, and improve production efficiency.
3、 Core technical support
High end five axis CNC system
Equipped with Siemens 840D SL and Fanuc 31i-B five axis CNC system, it supports NURBS curve interpolation function and can accurately fit complex surface machining paths with a control accuracy of 0.1 μ m. Simultaneously equipped with dynamic accuracy compensation functions (such as thermal error compensation, geometric error compensation), real-time correction of machining deviations, ensuring the accuracy stability of long-term machining of complex parts.
High rigidity machine tool structure
The machine bed is made of cast iron and undergoes three aging treatments to eliminate internal stress and reduce machining vibration; Adopting a cradle style dual turntable structure (A-axis rotation range -120 °~120 °, C-axis rotation range 0 °~360 °), the turntable positioning accuracy is ± 0.001 °, providing stable support for multi angle machining of complex surfaces and multi-faceted machining of irregular structures.
Specialized cutting tools and cutting processes
Tools: Equipped with ball end milling cutters and rounded corner milling cutters (with a cutting edge accuracy of ± 0.002mm) for complex surfaces, and molded and non-standard cutting tools for irregular structures to improve machining efficiency and surface quality;
Process: High speed milling technology (spindle maximum speed 18000rpm) is used to machine complex curved surfaces of aluminum alloy, with surface roughness up to Ra ≤ 0.4 μ m; Adopting layered milling technology to process stainless steel irregular deep cavities, avoiding tool chatter and ensuring the verticality of cavity walls.
Digital integration technology
Introduce CAD/CAM/CAE integrated platform: complete 3D modeling of complex surfaces and irregular structures through software such as SolidWorks and UG; Generate a five axis machining path using Mastercam and PowerMILL, simulate the machining process, and optimize parameters; Combining with MES production execution system, achieve order progress tracking, equipment status monitoring, and detection data traceability, and create a "digital and transparent" integrated manufacturing process.
4、 Frequently Asked Questions (FAQ)
Q: What is the maximum size range for complex curved surfaces and irregular structural components that can be machined? Can it support the processing of ultra large parts?
A: The conventional processing size range is 1200mm in length, 800mm in width, and 600mm in height; ultra large parts (such as wind turbine shaped components with a length of over 2000mm) can be achieved through "segmented processing+precision splicing" technology, and a 3D model needs to be provided in advance. The technical engineer will evaluate the feasibility of the structure and develop an exclusive plan.
Q: Is there a difference in machining accuracy between complex surfaces and irregular structural components? What are the specific accuracy indicators?
A: Due to different structural characteristics, there are slight differences in accuracy indicators: the contour error of complex surfaces is ≤± 0.005mm, and the surface roughness Ra is ≤ 0.4 μ m; The coaxiality of the hole position of the irregular structural component is ≤± 0.003mm, and the parallelism of the surface contour is ≤± 0.004mm. The precision parameters can be further optimized according to the specific purpose of the part.
Q: What technical information is required for customizing complex parts? If there are processing difficulties in the design scheme, can you assist in optimizing it?
A: Suggest providing detailed 3D models (in STEP, IGS, or X_T formats) and 2D engineering drawings (indicating tolerances, materials, and surface treatment requirements); If there are processing difficulties in the design scheme (such as excessively steep surfaces or thin walls in irregular structures), our engineers can provide DFM (Design for Manufacturability) optimization suggestions, adjust structural parameters to improve processing feasibility and efficiency, without additional charges.
Q: How long is the delivery cycle for processing complex surfaces and irregular parts? Can urgent orders be expedited?
A: Regular small batch orders (1-20 pieces): simple and complex curved parts are delivered within 7-10 days, and complex irregular structural parts are delivered within 10-15 days; Large scale orders (over 100 pieces) can be produced in parallel with multiple machines to shorten the lead time, and the specific delivery time can be negotiated. Urgent orders (such as aerospace repair parts) can be provided with 72 hour expedited service, and prior communication is required to confirm production capacity.
Q: Can we provide sample trial production services for complex components? Mass production after the sample is qualified?
A: Support sample trial production service! For complex curved surfaces and irregular structural components, 1-3 samples can be made first. After the customer confirms the accuracy, appearance, and assembly compatibility of the samples, mass production can be initiated. The sample trial production cycle is 2-3 days shorter than regular orders. During the trial production process, processing parameters can be adjusted according to customer feedback to ensure that the final product meets expectations.