Shenzhen Donglai Mold Factory, effectively improving mold processing
Improving the geometric accuracy of the machine tools used for part processing, increasing the precision of fixtures, gauges, and tools themselves, controlling factors such as force and heat-induced deformations in the process system, tool wear, deformation caused by internal stresses, measurement errors, all contribute to directly reducing original errors. In order to enhance mechanical processing accuracy, it is necessary to analyze various original errors that lead to processing errors and address them with different measures based on specific situations. Enhancing mold processing accuracy has always been a challenge for many enterprises. Today, the Shenzhen Donglai Mold introduces several methods to improve mold precision.
Methods to ensure and enhance processing accuracy can be broadly summarized as follows:
1. Reduce original errors to enhance the geometric accuracy of the machine tools used for part processing, improve the precision of fixtures, gauges, and tools, control factors like force, heat-induced deformations, tool wear, deformation due to internal stresses, and measurement errors, all contributing to reducing original errors directly. To improve mechanical processing accuracy, it is essential to analyze the various original errors that lead to processing errors and take different measures to address the primary errors causing processing inaccuracies. For the processing of precision parts, it is crucial to enhance the geometric accuracy, rigidity, and control of processing thermal deformations when using precision machine tools. For parts with forming surfaces, the focus is on reducing shaping tool shape errors and tool installation errors. This method is widely applied in production. It aims to eliminate or reduce the factors that cause processing errors after identifying the main factors.
2. Compensate for original errors with error compensation methods, artificially introducing a new error to offset the original errors in the process system. If the original error is negative, the artificial error should be positive, and vice versa, with efforts made to make them as equal as possible. Alternatively, using one original error to offset another is also a method to reduce processing errors and enhance processing accuracy.
3. Transfer original errors; essentially transferring geometric errors, force deformations, and thermal deformations within the process system. There are numerous instances of error transfer methods. When machine tool precision cannot meet the part processing requirements, rather than solely improving the machine tool accuracy, it is often necessary to find solutions from the process or fixture perspectives, creating conditions to transfer the geometric errors of the machine tool to aspects that do not affect processing accuracy.
4. Adjust processing separately for each group; in mold processing, the existence of errors in the blank or the preceding process often leads to processing errors in the current step. This may be due to changes in material properties of the workpiece or modifications in the process of the preceding step (e.g., canceling cutting processes after refining the blank). To address this issue, the approach of adjusting and distributing errors evenly among groups is adopted. Essentially, the original errors are evenly divided into n groups based on their magnitudes, with each group’s range of blank errors reduced to 1/n of the original range, followed by individual adjustments within each group.
5. Equalize original errors; for axes and holes requiring high precision fits, grinding processes are commonly utilized. The grinding tool itself does not need to have high precision, but it can perform minor cutting on the workpiece during relative motion, gradually removing high points (of course, the mold also gets worn down by a part of the workpiece), achieving high accuracy on the workpiece. This process of friction and wear between surfaces is a continuous error reduction process, known as error equalization.
6. On-site processing method; in mold processing and assembly, certain precision issues involve the interaction between components or parts, which can be complex. If solely enhancing the precision of parts is challenging, or even impossible, by using an on-site processing method (also known as self-processing and fitting method), it is possible to conveniently solve apparently challenging precision problems. The on-site processing method is commonly used in mechanical part processing as an effective measure to ensure part processing accuracy.