The same machine tool, why the production efficiency is several times different? The conclusion reached is that the fixtures selected for the CNC machine tools are not suitable, so that the production efficiency of the CNC machine tools is greatly reduced. This article describes in detail the reasonable choice and application of CNC machine tool fixtures.
How to improve the utilization of CNC machine tools? Through technical analysis, the use of fixtures has a great relationship. According to incomplete statistics, the proportion of unreasonable fixtures for CNC machine tools used by domestic enterprises is more than 50%. By the end of 2010, the number of CNC machine tools in China was nearly one million. That is to say, there are more than 500,000 CNC machine tools. The phenomenon of “dwelling†has emerged due to unreasonable fixture selection or improper application; from another perspective There are many articles on the selection and application of CNC machine tool fixtures, because of the considerable potential economic benefits.
The right choice of the type of fixture is the basis for efficient machining. Currently, machining can be divided into two categories according to the production volume: one is a single, multi-category, small batch (referred to as small batch production); the other is a small variety, large quantities (referred to as mass production). The former accounted for about 70~80% of the total output value of machining, and it is the main body of machining.
Low-volume production cycle for CNC machine tools Small batch production cycle = Production (preparation/waiting) time + Workpiece processing time Since the "workpiece processing time" is very short for small batch production, the length of "production (preparation/waiting) time" for processing The cycle has a crucial influence. If you want to increase productivity, you must find ways to shorten the production (preparation/waiting) time.
The following three types of CNC machine tool fixtures that are preferred for small batch production are recommended:
Combination jig fixture is also called “block fixtureâ€. It is composed of a series of fixture components with standardized design, different functions and different specifications. Customers can quickly assemble them like “building blocks†according to processing requirements. Various types of machine fixtures. Because the combined fixture eliminates the design and manufacture of special fixtures, the production preparation time is greatly shortened, thereby effectively shortening the small-batch production cycle, ie, increasing the production efficiency. In addition, the combination fixture also has the advantages of high positioning accuracy, large mounting flexibility, repeated use of the cycle, manufacturing of energy-saving materials, and low cost of use. Therefore, small batch processing, especially when the product is relatively complex in shape, can be preferentially considered using a combination fixture.
Precision combination pliers Precision combination pliers actually belong to the "assembly" in the combination fixture. Compared with other combined fixture components, its versatility is stronger, the degree of standardization is higher, the use is simpler, and the clamping is more reliable. Therefore, it is global Widely used within the scope. The precision combination pliers have the advantages of quick installation (removal) and quick installation, which can shorten the preparation time and improve the production efficiency in small batches. At present, the commonly used precision combination flat-clamp setting range is generally within 1000mm, and the clamping force is generally within 5000Kgf.
It should be noted that the precision combination pliers mentioned here is not an old-fashioned machine with a vise. The old machine with a single vise has a single function, a low manufacturing precision, and cannot be used in groups. Its service life is short. It is not suitable for CNC machine tools and machining centers. Used on.
The precision combination pliers mentioned here is a series of new type pliers that originated in industrial developed countries such as Europe and the United States. It is specially designed for the characteristics of CNC machine tools and machining centers. This type of product has a large clamping flexibility, high positioning accuracy, and fast clamping. , can be used in groups and other characteristics, especially suitable for CNC machine tools, machining centers.
Electric permanent magnet fixture is a new type of fixture designed with modern magnetic circuit principle based on new permanent magnet materials such as neodymium iron boron as magnetic source. A large number of machining practices show that electric permanent magnet fixtures can greatly improve the overall processing performance of CNC machine tools and machining centers.
The clamping and releasing process of the electric permanent magnet clamp is only about 1 second, so the clamping time is greatly shortened; the positioning element and the clamping element of the conventional machine tool fixture occupy a large space, while the electric permanent magnet fixture does not have such space occupied. Components, so compared with conventional machine tool fixture, electric permanent magnet fixture clamping range greater, which is conducive to take full advantage of the CNC machine tool table and processing stroke, help to improve the overall processing efficiency of CNC machine tools. The attraction force of the permanent magnet fixture is generally 15~18Kgf/cm2. Therefore, it must be ensured that the suction force (clamping force) is sufficient to resist the cutting force. Under normal circumstances, the adsorption area should not be less than 30cm2, that is, the clamping force should not be less than 450Kgf.
Suitable for mass production of CNC machine tools Large batch machining cycle = processing waiting time + workpiece processing time + production preparation time "Processing waiting time" mainly includes the workpiece clamping and tool replacement time. The traditional manual machine tool fixture "workpiece clamping time" can reach 10~30% of the large batch processing cycle, so that "workpiece clamping" has become a key factor affecting the production efficiency, and it is also the key object of the machine tool fixture "dig potential". Therefore, large-scale processing should adopt special fixtures for quick positioning and quick clamping (releasing). The following three types of machine fixtures can be given priority:
Hydraulic/Pneumatic Fixtures Hydraulic/Pneumatic Fixtures use hydraulic or pneumatic pressure as a power source to achieve positioning, support, and compression of the workpiece using hydraulic or pneumatic components.
The hydraulic/pneumatic clamp can accurately and quickly determine the mutual position between the workpiece and the machine tool and tool. The position accuracy of the workpiece is ensured by the fixture, and the machining precision is high; the positioning and clamping process is rapid, and the clamping and releasing of the workpiece are greatly saved. Time; At the same time, it has the advantages of compact structure, multi-position clamping, high speed heavy cutting, and automatic control.
The above advantages of the hydraulic/pneumatic fixture make it particularly suitable for use in CNC machine tools, machining centers, and flexible production lines, and is particularly suitable for high-volume processing.
The electric permanent magnet fixture electric permanent magnetic fixture has the advantages of fast clamping, easy multi-position clamping, multi-face machining with one clamping, stable and reliable clamping, energy saving and environmental protection, and automatic control. Compared with the conventional machine tool fixture, the electric permanent magnet fixture can greatly shorten the installation time, reduce the number of fixtures, and improve the clamping efficiency. Therefore, it is not only suitable for small batch production, but also suitable for mass production.
Glossy fixture bases Glossy fixture bases are not widely used in China, but are widely used in industrialized countries such as Europe and the United States. It is actually a precision-machined jig base rough blank. The positioning of the component and the machine positioning part and the positioning surface of the part on the fixture have been finished. Users can make special fixtures according to their actual needs.
The smooth fixture base can effectively shorten the cycle of manufacturing special fixtures and reduce the production preparation time, which can shorten the period of mass production and improve the production efficiency; at the same time, it can reduce the manufacturing cost of special fixtures. Therefore, the light fixture base is particularly suitable for mass production in tight cycles.
Reasonable use of fixtures, excavation equipment potential experience shows that, in order to improve the efficiency of CNC machine tools, only "choose right" CNC machine tool fixture is not enough, but also must be "well-used" CNC machine tool fixture work hard. Here are three commonly used methods:
The basic principle of the multi-position method multi-position method: By clamping multiple workpieces at a time, the purpose of shortening the unit clamping time and extending the effective cutting time of the tool is achieved. Multi-station fixtures have multiple fixtures that position clamped locations.
With the development of CNC machine tools and the need for users to increase production efficiency, the use of multi-station fixtures is increasing. Multi-station design is becoming more and more common in the structural design of hydraulic/pneumatic fixtures, combination fixtures, electro-magnetism fixtures, and precision combination pliers.
Grouped use of the same number of fixtures on the same work table, can also achieve "multi-station" clamping purposes. The fixtures involved in this method should generally be "standardized design, high-precision manufacturing," otherwise it is difficult to achieve the requirements of CNC machine tool processing.
The group use method can make full use of the CNC machine tool stroke, which is conducive to the balanced wear of the machine tool transmission components; at the same time, the related fixtures can be used independently to realize multiple pieces of clamping and can be used in combination to realize the clamping of large-size workpieces.
Local quick-change method Local quick-change method is to rapidly replace the part (positioning element, clamping element, knife-setting element, and guide element) of the CNC machine tool fixture to achieve the purpose of rapidly changing the function or mode of the fixture. For example: Quick-change combination pliers can be changed by quick-change jaws, for example, from clamping material to clamping bar material; clamping elements can also be changed by quick replacement of clamping elements, eg From manual clamping to hydraulic clamping. The local quick change method greatly shortens the time for replacing and adjusting the fixture, and the advantage is more obvious in small batch production.
How to improve the utilization of CNC machine tools? Through technical analysis, the use of fixtures has a great relationship. According to incomplete statistics, the proportion of unreasonable fixtures for CNC machine tools used by domestic enterprises is more than 50%. By the end of 2010, the number of CNC machine tools in China was nearly one million. That is to say, there are more than 500,000 CNC machine tools. The phenomenon of “dwelling†has emerged due to unreasonable fixture selection or improper application; from another perspective There are many articles on the selection and application of CNC machine tool fixtures, because of the considerable potential economic benefits.
The right choice of the type of fixture is the basis for efficient machining. Currently, machining can be divided into two categories according to the production volume: one is a single, multi-category, small batch (referred to as small batch production); the other is a small variety, large quantities (referred to as mass production). The former accounted for about 70~80% of the total output value of machining, and it is the main body of machining.
Low-volume production cycle for CNC machine tools Small batch production cycle = Production (preparation/waiting) time + Workpiece processing time Since the "workpiece processing time" is very short for small batch production, the length of "production (preparation/waiting) time" for processing The cycle has a crucial influence. If you want to increase productivity, you must find ways to shorten the production (preparation/waiting) time.
The following three types of CNC machine tool fixtures that are preferred for small batch production are recommended:
Combination jig fixture is also called “block fixtureâ€. It is composed of a series of fixture components with standardized design, different functions and different specifications. Customers can quickly assemble them like “building blocks†according to processing requirements. Various types of machine fixtures. Because the combined fixture eliminates the design and manufacture of special fixtures, the production preparation time is greatly shortened, thereby effectively shortening the small-batch production cycle, ie, increasing the production efficiency. In addition, the combination fixture also has the advantages of high positioning accuracy, large mounting flexibility, repeated use of the cycle, manufacturing of energy-saving materials, and low cost of use. Therefore, small batch processing, especially when the product is relatively complex in shape, can be preferentially considered using a combination fixture.
Precision combination pliers Precision combination pliers actually belong to the "assembly" in the combination fixture. Compared with other combined fixture components, its versatility is stronger, the degree of standardization is higher, the use is simpler, and the clamping is more reliable. Therefore, it is global Widely used within the scope. The precision combination pliers have the advantages of quick installation (removal) and quick installation, which can shorten the preparation time and improve the production efficiency in small batches. At present, the commonly used precision combination flat-clamp setting range is generally within 1000mm, and the clamping force is generally within 5000Kgf.
It should be noted that the precision combination pliers mentioned here is not an old-fashioned machine with a vise. The old machine with a single vise has a single function, a low manufacturing precision, and cannot be used in groups. Its service life is short. It is not suitable for CNC machine tools and machining centers. Used on.
The precision combination pliers mentioned here is a series of new type pliers that originated in industrial developed countries such as Europe and the United States. It is specially designed for the characteristics of CNC machine tools and machining centers. This type of product has a large clamping flexibility, high positioning accuracy, and fast clamping. , can be used in groups and other characteristics, especially suitable for CNC machine tools, machining centers.
Electric permanent magnet fixture is a new type of fixture designed with modern magnetic circuit principle based on new permanent magnet materials such as neodymium iron boron as magnetic source. A large number of machining practices show that electric permanent magnet fixtures can greatly improve the overall processing performance of CNC machine tools and machining centers.
The clamping and releasing process of the electric permanent magnet clamp is only about 1 second, so the clamping time is greatly shortened; the positioning element and the clamping element of the conventional machine tool fixture occupy a large space, while the electric permanent magnet fixture does not have such space occupied. Components, so compared with conventional machine tool fixture, electric permanent magnet fixture clamping range greater, which is conducive to take full advantage of the CNC machine tool table and processing stroke, help to improve the overall processing efficiency of CNC machine tools. The attraction force of the permanent magnet fixture is generally 15~18Kgf/cm2. Therefore, it must be ensured that the suction force (clamping force) is sufficient to resist the cutting force. Under normal circumstances, the adsorption area should not be less than 30cm2, that is, the clamping force should not be less than 450Kgf.
Suitable for mass production of CNC machine tools Large batch machining cycle = processing waiting time + workpiece processing time + production preparation time "Processing waiting time" mainly includes the workpiece clamping and tool replacement time. The traditional manual machine tool fixture "workpiece clamping time" can reach 10~30% of the large batch processing cycle, so that "workpiece clamping" has become a key factor affecting the production efficiency, and it is also the key object of the machine tool fixture "dig potential". Therefore, large-scale processing should adopt special fixtures for quick positioning and quick clamping (releasing). The following three types of machine fixtures can be given priority:
Hydraulic/Pneumatic Fixtures Hydraulic/Pneumatic Fixtures use hydraulic or pneumatic pressure as a power source to achieve positioning, support, and compression of the workpiece using hydraulic or pneumatic components.
The hydraulic/pneumatic clamp can accurately and quickly determine the mutual position between the workpiece and the machine tool and tool. The position accuracy of the workpiece is ensured by the fixture, and the machining precision is high; the positioning and clamping process is rapid, and the clamping and releasing of the workpiece are greatly saved. Time; At the same time, it has the advantages of compact structure, multi-position clamping, high speed heavy cutting, and automatic control.
The above advantages of the hydraulic/pneumatic fixture make it particularly suitable for use in CNC machine tools, machining centers, and flexible production lines, and is particularly suitable for high-volume processing.
The electric permanent magnet fixture electric permanent magnetic fixture has the advantages of fast clamping, easy multi-position clamping, multi-face machining with one clamping, stable and reliable clamping, energy saving and environmental protection, and automatic control. Compared with the conventional machine tool fixture, the electric permanent magnet fixture can greatly shorten the installation time, reduce the number of fixtures, and improve the clamping efficiency. Therefore, it is not only suitable for small batch production, but also suitable for mass production.
Glossy fixture bases Glossy fixture bases are not widely used in China, but are widely used in industrialized countries such as Europe and the United States. It is actually a precision-machined jig base rough blank. The positioning of the component and the machine positioning part and the positioning surface of the part on the fixture have been finished. Users can make special fixtures according to their actual needs.
The smooth fixture base can effectively shorten the cycle of manufacturing special fixtures and reduce the production preparation time, which can shorten the period of mass production and improve the production efficiency; at the same time, it can reduce the manufacturing cost of special fixtures. Therefore, the light fixture base is particularly suitable for mass production in tight cycles.
Reasonable use of fixtures, excavation equipment potential experience shows that, in order to improve the efficiency of CNC machine tools, only "choose right" CNC machine tool fixture is not enough, but also must be "well-used" CNC machine tool fixture work hard. Here are three commonly used methods:
The basic principle of the multi-position method multi-position method: By clamping multiple workpieces at a time, the purpose of shortening the unit clamping time and extending the effective cutting time of the tool is achieved. Multi-station fixtures have multiple fixtures that position clamped locations.
With the development of CNC machine tools and the need for users to increase production efficiency, the use of multi-station fixtures is increasing. Multi-station design is becoming more and more common in the structural design of hydraulic/pneumatic fixtures, combination fixtures, electro-magnetism fixtures, and precision combination pliers.
Grouped use of the same number of fixtures on the same work table, can also achieve "multi-station" clamping purposes. The fixtures involved in this method should generally be "standardized design, high-precision manufacturing," otherwise it is difficult to achieve the requirements of CNC machine tool processing.
The group use method can make full use of the CNC machine tool stroke, which is conducive to the balanced wear of the machine tool transmission components; at the same time, the related fixtures can be used independently to realize multiple pieces of clamping and can be used in combination to realize the clamping of large-size workpieces.
Local quick-change method Local quick-change method is to rapidly replace the part (positioning element, clamping element, knife-setting element, and guide element) of the CNC machine tool fixture to achieve the purpose of rapidly changing the function or mode of the fixture. For example: Quick-change combination pliers can be changed by quick-change jaws, for example, from clamping material to clamping bar material; clamping elements can also be changed by quick replacement of clamping elements, eg From manual clamping to hydraulic clamping. The local quick change method greatly shortens the time for replacing and adjusting the fixture, and the advantage is more obvious in small batch production.
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