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Machining center process design
When designing a machining process, it is essential to balance precision and efficiency. The general principles followed are: first process the face, then the hole; use a reference surface before others; and perform rough machining before finishing. Machining centers are designed to complete all machinable surfaces in a single setup, which helps reduce errors and improve productivity.
For holes that require high positional accuracy, special attention must be given to the sequence of machining. Improper sequencing can introduce backlash from the machine's transmission system, directly affecting the accuracy of the hole positions. For example, when processing the part shown in Figure 5.6a, if the holes along line 5.6b are machined first, the Y-direction backlash may cause an error. This happens because the 5.6% hole and the 1.2.3.4 holes are aligned in the Y-direction, making them more susceptible to this type of error.
By following the route shown in Figure 5.6c, the introduction of backlash can be avoided, ensuring better positional accuracy for all holes. This approach demonstrates how careful planning of the machining sequence can significantly impact the final quality of the part.
During the machining process, reducing the number of tool changes is often beneficial. One method to achieve this is through tool centering, where the same tool is used to machine corresponding sections of the part, and a second tool is used for further operations. However, for high-precision hole systems, this method may not be suitable. If the part’s position is determined by rotating the table, repeated positioning errors could occur, leading to inaccuracies. Therefore, alternative methods must be considered to maintain the required level of precision.