The processing time of the Heidenhain iTNC530 block is 0.5ms. The more complex the geometry, the stricter the tolerance requirements, the higher the density of the points. When machining with high speed feed, the corresponding NC code must be processed faster to avoid the so-called data starvation limited feed rate. When there is no data in the buffer of the processed NC block, the motion will stop or mutate due to the lack of positioning instructions. The HSM's CNC is characterized by a short processing time of 1ms or even shorter. The iTNC530 is fully qualified for high speed machining (HSM) CNC systems.
NC machining NC programs in high speed machining applications are generated on an external CAM system. Usually, NC programs are only a few hundred kilobytes, and often there are hundreds of megabytes of programs. Therefore, an important feature of the CNC system used by HSM is the fast Ethernet interface with high-speed data transmission capability. The Ethernet interface has a transfer speed of 100 MBit/s, which is the standard speed of today's conventional networks. The new Heidenhain CNC system main unit has various data communication interfaces (Ethernet/RS232/RS422/USB, etc.), and the fast Ethernet communication interface is equipped to transmit program data at a rate of 100 Mb/s.
The iTNC 530 system uses a limited acceleration value and smoothes the jerk with a filter. During high-speed feed, if any one axis suddenly changes direction, it will cause excessive acceleration and acceleration, which will cause vibration of the machine structure. Speed, acceleration and acceleration smoothing schemes through the CNC are a good way to reduce or eliminate this effect.
The Heidenhain iTNC 530 supports the automatic replacement of sister tools. In order to automatically handle tool wear or break, it is necessary to replace it with the same size milling cutter, and if the CNC supports this function, the operator can load multiple tool changers of the same milling cutter, and identify these same milling cutters as sisters. The tool is used for the call of the NC program. The CNC will automatically replace the worn or broken milling cutter with these specific sister tools and continue with the NC program.
The Heidenhain iTNC 530 has a "read-ahead" function of 256 lines. The so-called "read-ahead" function pre-calculates the correct speed and acceleration that should be used for each block and generates a speed and acceleration configuration to meet the programmed tool path requirements. The pre-computed information is read into the cache in the CNC system and recalled from the cache as required by the processing program. Once there is no data in the buffer, the machine will stop moving until the next pre-calculation action is reached because the CNC system's calculation speed cannot keep up with the feed rate. This problem is called data starvation. The processing time of the block of modern CNC system is getting shorter and shorter. In order to avoid data starvation, the number of lines pre-read by the numerical control system is also less and less.
Supported by powerful hardware, the iTNC 530 features fully digital drive technology. Its position controller, speed controller and current controller are all digitally controlled. Digital motor control technology achieves very high feed rates. The iTNC 530 also enables the CNC spindles with speeds up to 40,000 rpm to achieve the required cutting speeds when simultaneously interpolating up to 5 axes.
The system is versatile and suitable for five-coordinate control. When the tool path control needs to be optimized, its powerful control ability can calculate the actual coordinate system, thus simplifying the programming of the machining cycle. The system calculates the geometry of a single machine when the 3D shape program is off-line, so the same program can be used for different machines.
4 Conclusion
The high-speed machining technology of molds has been widely used in the mold manufacturing industry in developed countries. However, the application range and application level in China still need to be improved. With the development of China's mold industry, the use of high-speed cutting production molds has become a major trend in mold manufacturing. High-speed cutting has gradually replaced EDM finishing molds. It has been widely used in mold manufacturing enterprises abroad. High-speed cutting production molds have become a major trend in mold manufacturing, greatly improving mold production efficiency and quality. Since the production of molds by HSC technology in Germany, the production cost and processing time have been greatly reduced. Compared with the previous EDM method, the cost of producing forging dies has dropped by 50 to 60%, while the processing time has dropped by about 70%. It shows its great benefits for mold makers.
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