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Machining center process design
When designing a machining process, the main focus is on achieving both precision and efficiency. Typically, the principles followed include starting with the face before the hole, using a reference surface first, and performing rough machining before finishing. The machining center is designed to complete all surfaces that can be machined in a single setup. However, for holes requiring high positional accuracy, special attention must be given to the sequence in which they are machined. If the order is not properly planned, it may introduce backlash from the machine’s transmission system, directly affecting the final positioning accuracy.
For example, when processing the part shown in Figure 5.6a, if the machining sequence follows the route in 5.6b, the Y-direction backlash could cause an increase in error. This is because the 5.6% hole and the 1.2.3.4 holes are aligned along the Y-axis, and any backlash in this direction will impact the accuracy of these holes. To avoid such issues, the machining route shown in Figure 5.6c is recommended, as it minimizes the risk of introducing backlash during the process.
a) Part Drawing
b) Processing Route 1
c) Processing Route 2
Figure: Boring Processing Route
During the machining process, reducing the number of tool changes can improve efficiency. One way to achieve this is by using the tool centering method, where the same tool is used to machine different parts of the workpiece, and then a second tool is used for further operations. However, for hole systems that require high precision, this approach may not be suitable. If the part is positioned by rotating the table, repeated positioning errors can occur, making it unsuitable for high-accuracy applications. Therefore, careful planning of the machining sequence is essential to ensure both accuracy and efficiency in the overall process.