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简体中文 Process Comparison: Mass Production vs. Small-Batch Production
Mass Production: The unit cost of a single product is relatively low, but the initial investment in molds, special fixtures, and other equipment is huge. It is suitable for the manufacturing of standardized and generalized parts.
Small-Batch Production: With low initial investment and strong process flexibility, it is ideal for the manufacturing of parts for FA equipment and customized equipment.
Mainstream Processes for Small-Batch Production and Their Applicable Parts
| Process Type | Applicable Part Characteristics |
|---|---|
| Bearbeitung | Mechanical parts, parts requiring high strength/stiffness/precision, and secondary processing of can-making products |
| Sheet Metal Processing | Cover plates, housings, and other thin-plate parts with no strict requirements for strength, stiffness, or precision |
| Welding Processing | Can-making parts assembled from angle bars and pipes (such as frames and skeletons) |
Four Core Types of Bearbeitung: Equipment and Process Characteristics
Milling: The Core of Machining
Process Characteristics: High versatility, capable of realizing multiple operations such as drilling, surface cutting, groove machining, and profile machining.
Tool Selection: The core tool is the end mill. Different shapes and sizes of tools are selected and used according to processing requirements. Cemented carbide end mills have become the first choice for high-precision milling due to their high hardness and wear resistance.
Core Equipment: Universal milling machines, CNC milling machines (core equipment for NC processing), machining centers, and five-face machining centers.
Lathe Processing (Turning): The Efficient Choice for Coaxial Parts
Turning is a processing method that cuts materials by rotating the workpiece and pressing the cutter against the material surface. It is another core type of machining.
Process Characteristics: It can efficiently and neatly process coaxial cylindrical or tubular shapes. Its high-precision characteristics make it the preferred process for parts such as shafts and rods.
Typical Application: Complex parts such as impellers usually adopt a composite process of “turning + milling on machining centers”.
Core Equipment: Universal lathes, CNC lathes (key equipment for NC processing), multi-tasking lathes, turning centers, and automatic lathes.
Electrical Discharge Machining (EDM): A Special Solution for High-Hardness Materials
Process Characteristics: It is not limited by material hardness. As long as the material is conductive, it can be processed. It can achieve high-precision machining such as sharp corners and flat bottoms that cannot be completed by milling machines.
Subtypes: Wire electrical discharge machining (WEDM) for contour cutting, and sinker electrical discharge machining for various shapes through contact with symmetric electrodes (mostly used in mold making).
Core Equipment: WEDM machines and sinker EDM machines.
Grinding: The Final Step of Precision Finishing
Process Characteristics: Mainly used for the final precision finishing of parts, such as the joint surfaces between parts, precision planes, the outer surfaces of cylinders, and the inner diameters of holes.
Core Equipment: Surface grinders, cylindrical grinders, jig grinders, and honing machines.
In-Depth Analysis of Milling: Core Application Scenarios of NC Processing
Basic Principle of Milling
Achievable Processing Operations: Surface cutting, profile cutting, drilling, grooving, curved surface cutting, etc.
Process Advantages: High versatility. Multiple processing requirements can be achieved by replacing different types of tools. The application of cemented carbide tools further improves processing efficiency and precision.
Types of Milling Equipment: From Manual to CNC Upgrading
Universal Milling Machine: The operator manually changes tools and operates the machine, suitable for small-batch processing of simple shapes.
CNC Milling Machine: It realizes the automatic operation of spindle rotation and table movement through numerical control, which is the basic equipment for NC processing.
Machining Center: A CNC milling machine equipped with an Automatic Tool Changer (ATC). It can automatically change multiple tools to complete various processing operations in one clamping, which is the high-efficiency equipment for NC processing.
The Core of NC Processing: NC Program Programming Methods
Direct Input Method: Programs are directly input on the machine controller, suitable for processing parts with simple shapes. It is easy to operate and does not require additional software.
CAM Software Programming Method: Professional Computer-Aided Manufacturing (CAM) software is used to create processing data, which is then transmitted to the machine controller. It is suitable for processing parts with complex shapes, such as free-form surfaces and multi-axis simultaneous machining. It is the core method of NC processing in high-precision and complex part processing.
Workpiece Machining Capabilities of Machining: Full Coverage from Simple to Complex Shapes
1~2 Axis Machined Parts: The Most Basic Machined Parts
Typical Parts: Screw holes on planes, drilled base plates, blocks with local notches or chamfers, etc.
Equipment Requirements: Universal milling machines or basic CNC milling machines. The NC processing program programming is simple.
Multi-Face Machined Parts: Workpieces Requiring Re-Clamping
Typical Parts: In addition to profile, hole, and groove processing on the front, parts that also require hole or groove processing from the side.
Equipment Requirements: CNC milling machines or machining centers. The NC processing program needs to consider the processing paths of multiple directions.
3-Axis Machined Parts: Precision Processing of Free-Form Surfaces
Typical Parts: Parts with free-form surfaces, curved parts scanned from humans and animals, injection mold parts, etc.
Equipment Requirements: 3-axis machining centers. The NC processing program needs to be compiled by professional CAM software. Ball-end mills are usually selected as tools.
Multi-Axis Machined Parts: Processing of Complex Integral Shapes
Typical Parts: Aerospace parts, core parts of complex machinery, etc.
Equipment Requirements: 5-axis machining centers. The programming of NC processing programs is difficult, and high requirements are put forward for the precision and wear resistance of tools.
Multi-Axis Simultaneous Machined Parts: Ultra-High Precision Complex Parts
Typical Parts: Rotor blades, impellers, etc.
Equipment Requirements: 5-axis simultaneous machining centers or multi-tasking machines. The NC processing program requires highly accurate synchronous control, which is the highest application level of NC processing technology.
