Summary of horizontal turning and milling composite machine tools

Horizontal turning and milling composite machine tool is an advanced processing equipment, which combines two processing methods, turning and milling, and can efficiently complete the processing tasks of various complex parts.This article will introduce the functions, processing characteristics, and structural characteristics of horizontal turning and milling composite machine tools.

1. The function of horizontal turning and milling composite machine tools

Structurally, it can be with Y-axis or B-axis, the latter has richer processing functions!

Horizontal turning and milling composite machine tool is a kind of high-precision and high-efficiency processing equipment, which can realize the following functions:

Turning: Horizontal turning and milling composite machine tools have the function of ordinary lathes, which can turn shafts, discs and other parts, and can realize functions such as automatic feeding and automatic clamping to improve production efficiency.

Milling: Horizontal turning and milling composite machine tools also have the function of milling machines, which can perform various milling of parts, such as planes, grooves, gears, etc.At the same time, multi-axis linkage can also be realized to complete the processing of complex parts.

Drilling: Horizontal turning and milling composite machine tools can complete the drilling of various holes, such as straight holes, oblique holes, deep holes, etc.

Tapping: Horizontal turning and milling composite machine tools can complete the tapping of various threads, such as straight threads, tapered threads, etc.

Other processing: Horizontal turning and milling composite machine tools can also complete various other processing tasks, such as cutting, grinding, engraving, etc.

2. Processing characteristics of horizontal turning and milling composite machine tools

The processing characteristics of horizontal turning and milling composite machine tools are mainly reflected in the following aspects:

High precision: Horizontal turning and milling composite machine tools use advanced CNC technology to achieve high-precision machining.At the same time, due to its structural characteristics, the consistency and stability of machining accuracy can be effectively guaranteed.

High efficiency: Horizontal turning and milling composite machine tools can realize the linkage processing of turning and milling, which can greatly improve the processing efficiency.At the same time, due to its automatic feeding and automatic clamping functions, it can reduce the labor intensity of workers and improve production efficiency.

Wide processing range: horizontal turning and milling composite machine tools can complete various types of processing tasks, such as the processing of various parts such as shafts, discs, gears, etc.At the same time, it can also complete various processing tasks such as drilling and tapping of complex shapes.

High degree of automation: horizontal turning and milling composite machine tools use advanced CNC technology to realize automated processing.At the same time, it can also realize functions such as automatic detection and automatic alarm to improve production efficiency and product quality.

High reliability: The horizontal turning and milling composite machine tool adopts advanced hydraulic system and electrical system, which has high reliability and stability.At the same time, its structural characteristics can also effectively ensure the reliability of long-term use.

3. Structural characteristics of horizontal turning and milling composite machine tools

The structural characteristics of horizontal turning and milling composite machine tools mainly include the following aspects:

Bed structure: The bed of the horizontal turning and milling composite machine tool adopts an integral casting structure, which has high rigidity and high stability.At the same time, a lubrication system is arranged inside the bed, which can ensure the stability and accuracy retention of long-term use.

Spindle system: The spindle system of horizontal turning and milling composite machine tools adopts electric spindle or high-speed spindle, which has high speed, high precision and high stability.The bearing seat of the spindle is made of cast iron material, which can ensure the stability and accuracy retention of long-term use.

Feed system: The feed system of horizontal turning and milling composite machine tools adopts ball screw transmission method, which has high precision and high efficiency.At the same time, the guide rail of the feed system is made of high-quality wear-resistant materials, which can ensure the stability and accuracy retention of long-term use.

Tool magazine and tool system: Horizontal turning and milling composite machine tools have an automatic tool change system, and the tool magazine and tool system use robotic arms or pneumatic methods to realize automatic exchange.At the same time, the clamping method of the tool adopts pneumatic clamping or hydraulic clamping, which can ensure the firm fixation of the tool and the stability of long-term use.

Control system: The control system of horizontal turning and milling composite machine tools adopts advanced CNC systems or computer control systems, which can accurately control and adjust the machine tools to realize automated processing.At the same time, the control system can also monitor and record the processing process in real time to facilitate the adjustment and control of the processing process.

Three advantages of turning and milling composite machine tools

Turning and milling composite machine tool is an efficient and high-precision machine tool with many advantages, three of which are as follows:

Improve production efficiency

The turning and milling composite machine tool integrates the two functions of turning and milling, and can complete a variety of processing operations in one clamping, reducing the number of clamping and handling of workpieces, thereby improving production efficiency.In addition, the turning and milling composite machine tool is also equipped with an advanced CNC system, which can realize automated processing and further shorten the processing time.

Improve machining accuracy

The machining accuracy of turning and milling composite machine tools is very high, which can meet the machining needs of various high-precision parts.In the processing process, the turning and milling composite machine tool adopts advanced CNC technology, which can accurately control the trajectory and cutting parameters of the tool, so as to ensure the quality and accuracy of the machining surface.In addition, turning and milling composite machine tools also have stable machining performance, which can maintain high-precision machining for a long time.

Reduce production costs

Turning and milling composite machine tools can reduce the scrap rate in the processing process, because they can complete a variety of processing operations in one clamping, avoiding the accumulation of errors caused by multiple clamping.In addition, turning and milling composite machine tools also have a high processing efficiency and degree of automation, which can reduce labor costs and labor intensity, thereby reducing production costs.

In addition to the above three advantages, turning and milling composite machine tools have other advantages, such as:

Suitable for multi-variety, small batch production

Turning and milling composite machine tools can be adapted to multi-variety, small-batch production methods because they have a variety of processing functions and high flexibility.In production, different tools and processing strategies can be selected according to different parts requirements to achieve rapid production replacement and production adjustment.

Reduce footprint and space

Turning and milling composite machine tools integrate a variety of processing functions in one, which can reduce the number and footprint of traditional machine tools.At the same time, the turning and milling composite machine tool also adopts a compact design structure, which can maximize the use of space resources and reduce the waste of space.

Reduce energy consumption and environmental pollution

Turning and milling composite machine tools use advanced energy-saving technologies and environmentally friendly materials, which can reduce energy consumption and environmental pollution.In addition, the turning and milling composite machine tools are also equipped with environmental protection equipment such as wastewater recovery systems and environmental protection filtration devices, which can minimize the negative impact on the environment.

In short, turning and milling composite machine tools have many advantages, which can meet the requirements of modern manufacturing in terms of high efficiency, high precision, low cost, and environmental protection.In the future development of manufacturing, turning and milling composite machine tools will play an increasingly important role.

Combined milling and turning of large parts

Compound processing is an advanced manufacturing technology that combines several different processing techniques on one machine tool. Turning and milling combined processing is the most difficult composite processing. It is equivalent to the combination of a CNC lathe and a machining center. It is widely used in today’s society.

 

At present, most turning and milling combined processing is completed on turning centers, and ordinary turning centers only replace the ordinary turret tool holder of CNC lathes with a turret tool holder with powered tools. Due to the limitations of the turret tool holder structure and outer dimensions, the power head has small power, low rotational speed, and cannot install larger tools. This kind of turning center is mainly for turning, and the milling and drilling functions are only for some auxiliary processing.

Lansheng provides German DMCFD series turning and milling compound CNC machine tools, which unifies milling and turning technology into one machine tool based on the 5-axis milling machine. The workbench has a rotation function and can reach a rotation speed of 1,200rpm, which is equivalent to the workbench of a vertical CNC lathe and has turning capabilities.

The CNC swing milling head has a B-axis function and can rotate around the Y-axis, so that 5-side machining and 5-axis simultaneous milling can be achieved.

DMCFD series turning and milling compound CNC machine tools are equivalent to a combination machine tool of a CNC vertical lathe and a five-axis linkage machining center.

Because the DMCFD series turning and milling compound CNC machine tools have a main motor power of 47kW, a torque of up to 6,200Nm, and a maximum load-bearing capacity of the workbench of 2,500kg.

Therefore, the DMCFD series turning and milling compound CNC machine tools are very suitable for a variety of milling and turning compound processing applications of large parts. Turning and milling can be realized with one clamping.

High-precision grinding of bevel gears by CNC vertical grinder

Bevel gears are bevel gears, which are used for transmission between intersecting shafts. Bevel gears have the characteristics of smooth transmission, low noise and large load-bearing capacity, and are used in high-speed and heavy-load applications. The curved bevel gear transmission operates smoothly, the transmission power can reach 3700 kilowatts, and the peripheral speed can reach more than 40 meters/second.

 

The Japanese NVGⅡ series dual-spindle CNC vertical compound grinder provided by Lansheng Company is a high-precision and high-performance vertical grinder. One-time clamping realizes high-precision grinding of the inner circle, outer circle, and end face of the gear umbrella, which not only ensures the processing accuracy, but also reduces the time for installing workpieces, reduces manufacturing costs, and improves work efficiency and product quality.

Here is the data of a gear umbrella manufacturer’s processing case. The processing material is SCM series. The size of the original gear umbrella is an inner diameter of 460mm, an outer diameter of 700mm, and a processing height of 100mm. After the workpiece is processed, the inner circle is 400mm and the outer diameter is 400mm. The circle is 630mm, the processing height is 75mm; the roughness can reach 3μm for inner circle, 6μm for flatness and 17μm for right angle. The above data proves that Japan’s NVGⅡ CNC vertical compound grinder is a rare high-precision grinder on the market. Its biggest advantage is that it is a dual-spindle grinder, which can save more than half of the working time when processing workpieces.

Solution for high-precision grinding of deep holes in breaker cylinders

The hydraulic breaker is already an important working component of the hydraulic excavator. The power source of the hydraulic breaker is the pressure oil provided by the pump station of the excavator or loader. The hydraulic breaker mainly consists of a piston, a main body bolt, a front part of the main body, an oil cylinder, It consists of important parts such as the rear part of the main body.

 

The cylinder of the hydraulic breaker mainly uses machine tools such as CNC (CNC machine tools) and large grinders to complete the inner diameter grinding process to improve the surface roughness and product finish.

The Japanese NVG-7LH deep hole grinding vertical CNC grinder provided by Lansheng Company can process deep holes up to 1000mm, providing a perfect solution for high-precision grinding of deep holes in the breaker cylinder.

The deep hole grinding vertical CNC grinder is equipped with two spindles, a coarse spindle and a fine spindle. The coarse spindle is used for grinding first and then the fine spindle is used for grinding. Through one clamping, the inner hole, outer circle and end face of the breaker cylinder can be ground. Grinding processing has more than doubled the work efficiency.

 

With the increasing investment in domestic urban infrastructure construction and the rapid development of the domestic hydraulic excavator industry, the market demand for hydraulic breakers, one of the main working parts of hydraulic excavators, has also increased rapidly, and Japan’s NVG-7LH deep Hole grinding vertical CNC grinding machines can create maximum benefits for enterprises in the shortest time.

Vertical compound grinding of high-precision small cylinders

Vertical grinders have the advantages of high grinding precision, high processing efficiency, small footprint, and high degree of automation. Especially in the clamping of large workpieces, it has advantages that horizontal grinders do not have. With a vertical grinder, gravity can be used to hold the workpiece in place without the spindle deforming. In addition, compared to horizontal grinders, the clamping force used to hold the workpiece is smaller, and the workpiece itself undergoes almost no deformation. By utilizing the mass of the workpiece itself, it can be closely attached to the fixed side end surface, thereby maintaining a stable seating position of the workpiece.

 

For small hydraulic cylinders, the Japanese IGV-3NT small composite vertical CNC grinder provided by Lansheng Company. Has the following characteristics:

1. The machine tool covers an area of only 4.7 square meters.

2. The inner diameter, outer diameter, and end face can be ground in one clamping operation, which not only saves clamping time but also ensures grinding accuracy;

3. It is equipped with an internal grinding shaft and an external grinding shaft, and the grinding wheel shaft can be selected according to the processing conditions;

4. The ATC tool magazine can accommodate 6 grinding wheel heads, which shortens the grinding wheel exchange time and enables composite processing.

The processing capabilities of the IGV-3NT small composite vertical CNC grinder:

1. Grindable hole diameter (14)~200mm;

2. Grinding outer diameter range Max.200mm;

3. The maximum grinding length is 150mm;

4. The rotation diameter of the spindle is Φ300mm;

5. The height of the workpiece that can be installed is 150mm;

6. The spindle worktable can bear a weight of 100kg.

High-precision grinding of large-diameter thin-walled intermediate sleeves

In the trailer-type concrete pump truck, there is a typical large-diameter thin-walled part – the intermediate sleeve. The inner hole diameter is 202mm, the outer diameter is 212mm, the wall thickness is only 5mm, and the shape and position of the various dimensions of the part are The accuracy requirements are high, the outer surface roughness Ra is required to be 0.4µm, and the outer roundness error is required to be less than 0.010mm. Due to the thin wall thickness of the part, if no measures are taken when grinding the outer circle, the workpiece will often be greatly deformed due to clamping force, grinding force, grinding heat, internal stress, etc., and the parts cannot be guaranteed. The processing quality is to reduce the deformation of parts.

 

The Japanese NVGⅡ series dual-spindle CNC vertical compound grinder provided by Lansheng Company provides a good solution.

1. One clamping can complete the inner diameter, outer diameter, end face and other processes.

 

2. High precision.

Roundness: Φ120mm inner diameter: 0.65μm; Φ160mm outer diameter: 0.45μm; Φ170mm outer diameter: 0.55μm. Cylindricity Φ120mm inner diameter: 1.5μm; Φ170mm outer diameter: 1.5μm. Coaxiality Φ120mm, Φ170mm: 0.85μm. Surface roughness: 120mm inner diameter: 1.16μm Rz; Φ170mm outer diameter: 1.80μm Rz.

 

3. High efficiency

Equipped with a turret-type grinding wheel, which can be driven by a large coupling and servo motor for 3-speed positioning. By using a high-rigidity special external grinding spindle, stable and super grinding performance can be exerted, and the bevel grinding wheel greatly improves the efficiency of end face processing.

Application of milling and laser combined processing machine tools

Lansheng provides German DMG LASERTEC80 FineCutting laser milling and processing center, which can process metals, carbide, ceramics, PKD, CBN and other materials of various properties. It can process thin plates with thickness <5mm, pipes and three-dimensional workpieces with high precision, and has the smallest laser cutting seam. Within 20µm, machine tool accuracy Pmax.<10µm, with 3-axis, 4-axis or 5-axis structure.

 

Germany’s DMG’s LASERTEC80 FineCutting laser milling processing center adds a laser processing head to the high-speed milling machine, becoming a machine tool for combined milling and laser processing. The machine is equipped with a Q-switched YAG laser with a power of 100W, a beam diameter of 0.1mm, and a processing efficiency of 20mm3/min. After the workpiece (mainly the mold) is clamped once on this kind of machine tool, a high-speed milling head is used to complete most of the workload, and then a laser head is used for finishing in a layer-cutting manner to remove the milling marks on the profile and process fine details. Parts, including carved patterns and patterns.

The new LASERTEC80 productline is a general-purpose high-precision laser processing machine. Due to its modular structure, the machine can perform 2D and 3D laser cutting, laser drilling and laser welding of various parts. Has the following performance characteristics:

1. Two-dimensional and three-dimensional laser processing with the highest precision and dynamic performance

2. The X-axis and Y-axis are equipped with linear motors (acceleration >1.2g), and all rotating axes are equipped with torsion motors, achieving the highest dynamic performance.

3. Equipped with the best laser for any purpose

4. Various laser sources: GepulsteNd:YAG laser from 15 to 500 watts; CO2 laser from 500 to 3000 watts

5. Excellent accessibility to the processing area and laser

6. Wide range of use (plates, pipes, three-dimensional workpieces)

7. Use robot loading and unloading or automatic conveyor belts to realize processing automation

Application of ultrasonic vibration and milling composite machining center

Hard and brittle materials such as glass, ceramics, and cemented carbide are difficult to process using traditional processing methods. However, if high-frequency vibration motion is added to the traditional milling, drilling, and grinding processes, ultrasonic technology Combined with cutting processing technology, the processing efficiency will be significantly improved. The DMS series ultrasonic processing machine tools of the German DMG company use the converter on the spindle to convert the electrical high-frequency signal of the ultrasonic generator into 20KHz mechanical vibration motion (longitudinal motion), and then the voltage regulator amplifies and controls the vibration amplitude. Then through the patented Sauer conical tool holder, all the vibrations are transmitted to the milling cutter, drill bit or grinding wheel made of diamond particles, so that the tool continuously hits the workpiece surface 20,000 times/second during the processing, and the surface of the part is The material separates out in the form of tiny particles. Not only is its processing efficiency 5 times higher than traditional methods, but the surface roughness can also reach Ra<0.2μm. DMS series ultrasonic processing machine tools have two types: 3-axis linkage control and 5-axis linkage control. The spindle speed is 20~6000r/min. It can also be equipped with an optional tool magazine and automatic tool changer, thus becoming a machine that not only has ultrasonic processing functions, but also can A machine tool that performs multiple processes such as drilling, milling, and grinding.

Lansheng provides German DMG ULTRASONIC20linear ultrasonic vibration cutting machining center, which can be used for ultrasonic vibration milling of all dental materials, hard steel, brittle materials, ceramics, glass, carbide, etc.

During the traditional machining process, due to the blunting of the tool and the increase in cutting force, deep damage is caused to the surface layer of the material, making the processing of super-hard or brittle materials no longer economical – ultrasonic vibration processing machine tool technology can solve such problems.

It has super-hard machining and high-speed milling in one machine tool. It has a unique drive design. The X, Y, and Z axes are all driven by linear motors. All axes are equipped with absolute measurement systems. It has the best dynamic performance, the highest precision, and a compact gantry structure. 5-axis machine tool design, optional 4th and 5th axes (swing rotary table), water-cooled USB40 machining spindle with a maximum speed of 40,000rpm, HSK-32S/HSK-32E tool holder with optional internal coolant supply device (IKZ) and chip removal ejector, intelligent process algorithm adaptive control (ADC) and acoustic monitoring (ACC) can automatically adjust the feed in real time to maintain a continuous cutting speed. Specifically the following performance characteristics:

1. Five-axis precision machine tools can be used to process all dental materials

2. Compact, covering an area of only 2m2, machine size: width x height: 800×1,800mm (can pass through 80cm standard door)

3. Integrated rotary swing table using torque technology (standard 4th/5th axis), swing range -20°/+120°

4. Standard HSK-25 spindle, speed 42,000rpm

5. The spindle is integrated with a blowing/suction device*

6. Through the integrated small 4-weight round material automatic clamping device PH2I4* or the linear tool magazine PH2I120* (integrated with 12 discs/80 parts/120 finished parts memories), unattended operation can be achieved during multi-level operations Production

7. Easy-to-operate CNC system Siemens840Dsolutionline

Compound processing of both ends of shaft parts

Compared with ordinary CNC lathes, the turret tool holder of the turning center is equipped with power tools that can rotate milling cutters, drills, and taps. At the same time, the machine tool spindle also has a tool that can accurately index according to CNC programs and coordinate with the X-axis or (and) The Z axis performs interpolation linkage with the C axis function. This kind of 3-axis (X, Z, C) controlled turning center can turn, mill, drill, boring and tap the rotary body in one clamping. It is still the most commonly used rotary body in industrial production. Compound processing machine tools.

 

However, no matter how the single-spindle turning center expands the process range, it still cannot solve the problem of secondary processing of the back side of the rotary body (that is, the processing of the workpiece clamping end) under one clamping. Therefore, a dual-spindle turning center must be used to complete it. The two spindles of a double-spindle turning center are mostly arranged opposite each other on the same axis, so that after processing the main end of the rotary body, the second spindle automatically picks the workpiece from the main spindle to process the clamping end.

Since the processing tasks at the clamping end are generally relatively simple, the second spindle is usually called the sub-spindle, and its power is relatively smaller. The dual-spindle turning center can be equipped with one tool holder, but most of them have two tool holders, which can help improve processing efficiency and fully utilize the potential of the machine tool equipment. The machine is equipped with a main spindle and a sub-spindle facing each other on the same axis above the bed. Generally, the speed of the dual spindles is 0~4000r/min, and both can be controlled by the C-axis. The sub-spindle can also move along the axis. To pick up the workpiece after one end has been processed on the spindle. There are turret tool holders with about ten tool positions above the main spindle and below the sub-spindle. Each tool position on the turret tool holder can be equipped with a power tool with a certain power and a rotation speed of 80 to 8000r/min. The tool rest is controlled by 3 axes (X1, Y1, Z1), and the lower tool rest is controlled by 2 axes (X2, Z2).

The Japanese Okuma TWINSTAR series turning and milling compound CNC machine tools provided by Lansheng include 2 models: TWIN STAR LT200-M and TWIN STAR LT300-M. Has the following performance characteristics:

•Opposing dual spindles, the main and sub-spindles have the same power and the same speed, and the upper and lower tool holders have the same power and the same capabilities.

• Four-axis turning can be performed at the same time. The main and secondary spindles can transfer and clamp the workpiece synchronously without stopping, so that all front and back processing from the blank to the finished product can be completed, greatly shortening the processing cycle of the workpiece and shortening the processing time by 40% %about.

•With milling function, the transmission power of the rotating tool spindle is 5.5kW.

•The double tool holder uses the left and right spindles and the upper and lower composite tool turrets for processing, which can integrate processing processes that previously needed to be divided into multiple processes. Using high-precision linear guides, stable processing accuracy can be maintained even if continuous processing is performed for a long time.

small_c_popup.png

Let's have a chat

Leave your information, our sales will contact you as soon as possible!