No machine tool solution can be pursued like a traditional bed type milling machine. It can be found in low-chip processing operations in all industries, making it a veritable multi-purpose production facility. Bed-type milling machines are especially suitable for the machining of large workpieces.
The advantages of bed milling machines are their versatility and ease of operation. Thanks to its large working space, easy operation and powerful drive, this milling machine can be used in a variety of different machining applications. When machining large workpieces, the selection of bed milling machines cannot often be ignored. In terms of power, the bed-type milling machine is similar to a trampoline; in terms of processing speed, the bed-type milling machine is as versatile as the machining center. In order to provide the best working parameters in the processing operations in various industries, MTE SA, a manufacturer of equipment in Itziar, Spain, uses a variety of different rail systems on its equipment – ​​flat guides for difficult-to-cut operations. Roller guides are used for fast machining applications.
Bed-type milling machines are used in a wide range of applications and can be illustrated by several examples. For example, a large press manufacturer's MTE-BF steel frame bed milling machine is equipped with flat rails. Thanks to the robust steel frame structure, the body does not vibrate when machining heavy workpieces, resulting in high quality surface finishes. Figure 1 shows that a sports car manufacturer in Stuttgart is using this type of machine to machine the engine hood. Here, a spherical milling cutter made of high-strength tool steel is used to finish the hood shape. Its material is 1.2311. The cutting data was vc=250 m/min, n=5000 r/min, fz=0.15 mm, and the cutting depth and width were ap/ae=0.2 mm. This milling operation requires a large amount of torque on the spindle. The maximum value can be easily reached by a three-stage drive with oil-cooled rocker arm. The power consumption is 40% of the maximum power of the device. In order to reduce the "jump" of the working spindle by increasing the temperature of the milling cutter, the tool spindle is also oil-cooled, so the machining accuracy of the equipment can reach ±0.008mm. In order to achieve the contouring accuracy in the entire milling range of Y = 1200 mm, the square rocker arm size is 405 mm x 405 mm.
Figure 1 Processes the machine tool of the 1.2311 high-strength tool steel, which is used to machine the engine cover of a sports car.
Success depends on power, not speed
The rail unit is mounted horizontally and vertically on the base. The wedge pin ensures precise adjustment of the gap between the components. The rail unit is quenched and ground with a Turcite plastic coating on the back. This allows vibration to be absorbed, resulting in a high surface quality and a long service life. The overall structural design is very stable. It is not the processing speed, but the power performance of the equipment that makes the machine tool a success. The concept of high performance cutting has been implemented very well.
The prototype of an automobile manufacturing plant in Saxony is an application example of this type of MTE-KT bed milling machine with INA roller guide and high feed rate (Fig. 2). Here, a hand-made plastic sports car body is used. In order to achieve efficient milling of the aluminum prototype, high cutting speeds are required. The electric spindle speed can be as high as 15000r/min, and the advanced drive technology with a feed rate of 14000mm/min ensures high-precision contour surface machining. The data of the finished car cutting is n=15000r/min, f=8000mm/min, and ap/ae=0.8mm. Due to the use of columns up to 10,000 kg, the bed-type milling machine is very stable and has excellent power. This technical equipment is also used in steel mold manufacturing. In order to machine the rear part of the workpiece, the milling head can automatically rotate 1° tooth angle. The quenched toothed ring ensures that the milling head maintains the same milling force at all positions, which is not possible with a stepless machining process. Due to the high coolant pressure, the equipment is well protected during operation.
Figure 2 For efficient milling of aluminum prototypes, high cutting speeds are required.
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