At present, CAD system is mainly used to design car parts, and the design of parts is completed through reverse engineering and various experiments. CAM software is used to process the messy appearance of mold. However, how to ensure the accuracy of design and processing depends on NC machining, In the following, the author analyzes the relationship between the application of five axis machining center in die processing and the quality of car die.

1對(duì)深腔模具的加工

1. Processing of deep cavity mold

轎車模具制作的進(jìn)程傍邊，加工深腔模具時(shí)如運(yùn)用五軸加工，要想完結(jié)有必要加長刀柄和刀具，但是運(yùn)用五軸加工加工比較深與比較陡的型腔時(shí)，要想給模具加工發(fā)明較好的工藝條件能夠經(jīng)過工件或主軸頭的附加回轉(zhuǎn)和搖擺，能夠使刀具長度得到適當(dāng)?shù)乜s短，然后杜絕刀具同刀桿以及型腔壁之間發(fā)作碰撞現(xiàn)象的發(fā)作，削減加工時(shí)刀具的抖動(dòng)與破損，刀具的運(yùn)用壽命得到延伸，模具的外表質(zhì)量和加工功率也大大進(jìn)步。

The process of car mold making is close to the side. If the five axis machining center is used to process the deep cavity mold, it is necessary to lengthen the tool handle and tool to finish. However, when the five axis machining center is used to process the deep and steep cavity, it is necessary to invent better process conditions for mold processing, which can pass through the additional rotation and swing of the workpiece or spindle head, It can appropriately shorten the length of the tool, prevent the occurrence of collision between the tool, the tool bar and the cavity wall, reduce the vibration and damage of the tool during processing, extend the service life of the tool, and greatly improve the appearance quality and processing power of the die.

2模具側(cè)壁的加工

2 processing of die side wall

對(duì)模具側(cè)壁的加工，運(yùn)用五軸加工刀具長度要比側(cè)壁深度大，也是由側(cè)壁深度來決議刀具長度的，若增加刀具的長度，其強(qiáng)度會(huì)顯著下降，若刀具長度高于3倍徑讓刀現(xiàn)象便會(huì)發(fā)作，工件的質(zhì)量將難以確保。如運(yùn)用五軸加工對(duì)模具的側(cè)壁加工，能運(yùn)用主軸或是工件的搖擺，使刀具與模具側(cè)壁呈現(xiàn)出筆直的狀況，銑模具側(cè)壁時(shí)能夠運(yùn)用平面銑刀，這樣能夠進(jìn)步工件質(zhì)量并延伸刀具的運(yùn)用壽命。

For the processing of the side wall of the die, the tool length of the five axis machining center is larger than the side wall depth, and the tool length is also determined by the side wall depth. If the tool length is increased, its strength will decrease significantly. If the tool length is higher than 3 times the diameter, the tool yield phenomenon will occur, and the quality of the workpiece will be difficult to ensure. If the five axis machining center is used to process the side wall of the die, the swing of the spindle or workpiece can be used to make the tool and the side wall of the die appear straight. When milling the side wall of the die, the plane milling cutter can be used, which can improve the quality of the workpiece and extend the service life of the tool.

3模具較平的曲面加工

3. Machining of flat curved surface of die

對(duì)模具較平的曲面加工時(shí)，五軸加工需用球刀精銑，獲取好的外表質(zhì)量，而這種情況下需求增加刀路，但球頭刀刀具的旋轉(zhuǎn)線速簡(jiǎn)直為零，在模具加工時(shí)刀具損害的程度較大，刀具的運(yùn)用壽命會(huì)縮短，而模具外表質(zhì)量也會(huì)變差。運(yùn)用五軸加工加工較平的曲面，能夠在工件上把刀具上成必定的視點(diǎn)再進(jìn)行工件的加工，這樣能夠增加工件與球頭刀間的相對(duì)線速，不但能夠使刀具的運(yùn)用壽命得到進(jìn)步，工件外表質(zhì)量也會(huì)大幅進(jìn)步。

When machining the flat surface of the die, the five axis machining center needs ball cutter finish milling to obtain good appearance quality. In this case, the tool path needs to be increased, but the central rotation linear speed of the ball head cutter is almost zero. During die machining, the degree of tool damage is large, the service life of the cutter will be shortened, and the appearance quality of the die will become worse. Using the five axis machining center to process a flat surface can make the tool into a certain point of view on the workpiece and then process the workpiece. In this way, the relative linear speed between the workpiece and the ball head cutter can be increased, which can not only improve the service life of the tool, but also greatly improve the appearance quality of the workpiece.

4對(duì)模具無方向變化直線的銑削

4 milling of straight lines without direction change of die

要想銑削沒有方向變化的一條直線，只需刀尖劃條直線便可，若是方向需求改動(dòng)，刀尖劃條曲線便可，刀具刀尖方向被改動(dòng)，這時(shí)再想要直線，就要給這條曲線以有必要的補(bǔ)償，運(yùn)用五軸加工這點(diǎn)是極其重要的?？刂葡到y(tǒng)若未考慮到刀具的長度，刀具是環(huán)繞軸來旋轉(zhuǎn)的，刀具的刀尖不能夠固定，極有可能會(huì)移出當(dāng)時(shí)的工作方位，但是在五軸加工的系統(tǒng)中具有五軸控制功能，在加工模具的操作中，運(yùn)用五軸控制系統(tǒng)盡管刀具的方向被改動(dòng)，但其刀尖的方位是能夠堅(jiān)持不變的，這個(gè)進(jìn)程中xyz軸有必要的補(bǔ)償運(yùn)動(dòng)一起也被自動(dòng)核算進(jìn)去，此時(shí)加工精度顯著進(jìn)步。

If you want to mill a straight line without direction change, you only need to draw a straight line at the tool tip. If the direction needs to be changed, you can draw a curve at the tool tip, and the tool tip direction is changed. At this time, if you want a straight line again, you need to make necessary compensation for this curve. It is extremely important to use the five axis machining center. If the control system does not consider the length of the tool, the tool rotates around the axis center, and the tool tip cannot be fixed, it is very likely to move out of the current working direction. However, the five axis control function is provided in the system of the five axis machining center. In the operation of the machining die, the five axis control system is used, although the direction of the tool is changed, However, the orientation of the tool tip can remain unchanged. In this process, the necessary compensation motion of XYZ axis is also automatically calculated. At this time, the machining accuracy is significantly improved.