cnc machining

Different from the digital twins technology in the past, which is often dominated by PC commercial software manufacturers such as CAD/CAM/PLM, TIMTOS x TMTS in 2022 has seen that the machine tool industry has begun to introduce CNC systems as the core. Digital Doppelganger Solutions. It is not only used to more accurately evaluate the entire line/factory automation equipment and the actual moving line of the fixture to prevent interference or collision, but also assist a single machine to simulate the processing path and optimize the program before processing to improve quality and production. Efficiency, will contribute to the early realization of the net zero carbon emissions vision.

For example, Tongtai has integrated its group resources for this purpose, and the proposed digital transformation strategy follows the current trend of virtual-real integration that digital avatars and physical CNC systems are more closely integrated, so as to meet the needs of more product choices and life cycle. The shortening has caused the manufacturing industry to face flexible production requirements ranging from variable variables to mass customization. It must be able to overcome the challenges of short lead times and frequent line changes, even if it is a single first piece (Lot One) It must be produced correctly.

Then use the CPS virtual-real integration as the core, horizontally integrate PLM and value chain across the product life cycle at the IT level, and vertically integrate with the OT-level manufacturing to help customers gradually enter the five levels of smart manufacturing: networking, visualization, and transparency , predictive, intelligent, to meet customer needs and value.

Dongtai Smart Manufacturing Solution Digital clone integrated machine-side computing platform

Zeng Wenpeng, associate manager of the Smart Technology Division of Dongtai Precision Machinery Co., further pointed out that in fact, the machine tool industry has introduced digital avatar and virtual-real integration technology for many years before the advent of the industrial metaverse concept, and Dongtai also began to invest in research and development in 2016 and 2017. So far, the entire series of models that have left the factory have almost completed the construction of digital clones, and support European and Japanese brand controllers to assist customers.

It can even add TLM that is close to the process execution system (MES) function of Dongtai, covering the situation of single-machine to whole-line automatic processing, and continuously producing good products. After the successful delivery of the machine tool, in line with the customer's production line changes and upgrade needs, Dongtai only needs to interact with the digital avatar at hand, and the virtual adjustment completes 90% of the work, and then the foreign client completes the last 10% of the adjustment and testing operations. That's it.

For stand-alone intelligent applications, Dongtai uses four sets of self-developed software: TiOPERATOR, TiHMI, and TiMS to form a computer-side computing intelligent platform, and makes good use of its own knowhow accumulated over the years in TiHMI, self-made sensors, DAQ system, etc. Build an App development environment that allows users to operate the machine tool as easily as a smartphone, even with lower-end CNC controllers.

In addition, in response to the needs of emerging industries such as electric vehicles, wind power generation, and aerospace, machine tools must become more flexible and complex. Through intensive engineering, turning, drilling, and tapping can be completed on a single machine at one time, saving time, space, and Jig. When the customer's multi-axis and composite models are officially put into production, the TiMS digital clone can simulate the processing path of the single-machine process, output the optimization program, and perform supplementary optimization to predict whether the surface quality of the workpiece is warped, deformed, or needs to be Revise the design.

In addition to showing the real machine this year, Dongtai also released the digital clone of the TD series turn-milling machine, emphasizing that only one laptop can perform 99% consistent machining simulation, interference checking and verification. To this end, the application benefit of first-piece processing is to ensure the actual processing effect and predict the quality, thereby greatly reducing the traditional engineering development time and seamlessly integrating the on-site manufacturing process. The application benefits of mass production processing can be optimized through the friendly work order scheduling interface; the deep imaging system is equipped to accurately locate and fetch objects; and the online measurement system can be used to monitor and improve the yield.

Adaptive cutting of European and Japanese controllers takes into account machining accuracy, efficiency and quality

Although some European and Japanese CNC system manufacturers have successively introduced adaptive cutting functions in the past, such as HEIDENHAIN, which emphasizes that it provides the most complete intelligent cutting solutions in the industry, the key components of each series of modular controllers include soft , hardware, and even provide advice and consultation on verifying equipment.

Among them, the "dynamic efficiency" solution can be used to fully exploit the potential of machine tools and tools. Whether rough milling or heavy cutting in difficult-to-cut materials, it can become more efficient, improve cutting force and The material removal rate, thus reducing and limiting the load on the machine during cutting, will more effectively reduce machine wear and extend tool life.

This in turn provides cutting strategies that save machining time, such as Active Chatter Suppression (ACC) to reduce tool chatter during heavy cutting; Adaptive Feed Control (AFC) to maintain optimal machining feed rates; The wire cutting function can easily achieve its machining strategy through the built-in machining programming, and reduce the tool wear during rough milling of grooves, which increases the material removal rate by about 20%~25%, and greatly improves the economic efficiency.

The dynamic precision solution is a series of control functions used by HEIDENHAIN to realize the precision potential of the machine tool, thereby compensating for the dynamic deviation of the machine tool, improving the machining feed rate, contour accuracy and surface quality, and shortening the workpiece. Move time to avoid time-consuming secondary processing.

This year, HEIDENHAIN also participated in the exhibition and released a complete data product TNC7 controller for designing and developing reliable processes; and other valuable evaluation information; and the virtual-real integration environment "Digital Shop Floor", which will continue to act as an innovative partner for machine tool manufacturers and end users, providing corresponding products, technologies and software solutions to meet market development.