A five axis CNC grinder is an equipment that achieves precision machining of complex surfaces by controlling five motion axes (usually X, Y, Z linear axes and A, B rotational axes) through a CNC system.
The gradual upgrading process of CNC grinding machines from three-axis to four axis and then to five axis reflects the technological evolution of the manufacturing industry from basic machining to high-precision and complex direction.
1. Three axis CNC Grinding Machine: Basic Machining Platform
(1) Technical features: The three-axis CNC grinder has three linear motion axes of X, Y, and Z, forming a basic Cartesian coordinate system. These three axes work together to achieve precise movement of the tool in space, completing the manufacturing tasks of the vast majority of conventional flat, slotted, and prismatic parts.
(2) Application scope: Mainly used for process operations such as flat cutting, drilling, and milling, suitable for structurally simple components such as flat parts, straight grooves, etc. In the machining of automobile engine cylinder blocks, three-axis machine tools can accurately mill various planes and hole systems, meeting the strict requirements of the engine for part accuracy and size.
(3) Limitations: When facing parts with complex surfaces, due to the limitations of motion degrees, multiple clamping and complex programming are often required, which not only reduces machining efficiency but also makes it difficult to ensure machining accuracy.
2. Four axis CNC Grinding Machine: Breakthrough in Multi face Machining
(1) Technological upgrade: The four axis CNC grinder has added a rotating axis (usually the A-axis) on the basis of the three-axis, allowing the workpiece to tilt or rotate during the machining process, opening a new chapter in multi-faceted machining.
(2) Core advantages:
-Multi sided machining capability: By rotating the axis, the workpiece can be positioned and machined at different angles, reducing the number of clamping times
-Improved machining accuracy: reduces the number of clamping times and error accumulation, which can better ensure machining accuracy
-Process scope expansion: capable of processing parts with complex geometric features such as inclined surfaces and inclined holes
(3) Application scenario: In the machining of aviation components, many parts have irregular shapes and inclined surfaces. Four axis machine tools can rotate the workpiece to allow the tool to cut in at a better angle and complete the machining of multiple surfaces at once.
3. Five axis CNC grinder: a powerful tool for complex surface machining
(1) Technological breakthrough: The five axis CNC grinder has added two rotating axes (usually A-axis and C-axis) on the basis of the three-axis, which can achieve relative motion between the tool and the workpiece at any angle, and has the powerful ability to control all five axes simultaneously.
(2) Core advantages:
-Complex surface machining: Breaking the spatial constraints of traditional machining, making the machining of complex surface parts more efficient and accurate;
-One clamping completion: Through the linkage of five axes, almost any angle of machining can be completed in one clamping;
-Machining precision revolution: Cutting tools can always maintain the optimal cutting angle with the workpiece surface, achieving more precise cutting and forming;
(3) Technical features:
-RTCP function: Having RTCP (tool tip following) function is the key to true five axis linkage, which can compensate in real time for the offset of the straight line coordinates of the tool center point caused by the rotation of the tool holder;
-High precision control: Through precise numerical control system and servo drive technology, it can accurately control the movement of five axes, achieving a contour machining accuracy of 0.002mm level;
4. The changes brought about by technological upgrades
(1) Improved processing efficiency: From three-axis to five axis, the processing efficiency has achieved a qualitative leap. Taking aircraft engine blades as an example, three-axis machining takes 8-10 hours, while five axis machining can compress to 3-4 hours, increasing production efficiency by more than 50%.
(2) Precision control revolution: Five axis linkage can achieve high-precision machining of complex three-dimensional surfaces, meeting the demand for high-precision parts in aerospace, automotive manufacturing, mold manufacturing and other fields. The machining accuracy has been improved from ± 0.02mm for three-axis to ± 0.005mm for five axis.
(3) Expansion of application areas: From simple flat part processing to precision manufacturing of high value-added products such as aerospace engine blades, medical device implants, and complex automotive molds.
5. Technological development trends
(1) Intelligent upgrade: Modern five axis CNC grinding machines have achieved full process automation from raw material feeding to finished product production through intelligent upgrade. The integrated application of advanced sensors, control systems, and intelligent algorithms significantly reduces manual intervention.
(2) Composite development: Five axis machining centers typically integrate multiple functions such as milling, drilling, boring, and tapping. One device can replace the work of 2-3 traditional machine tools, effectively saving workshop space resources.
(3) Localization process: Continuous innovation in domestic five axis CNC system technology.
This technological upgrade process not only promotes technological progress in the manufacturing industry, but also provides key support for the transformation of China's manufacturing industry from 'scale manufacturing' to 'precision manufacturing'.