Advantages of Horizontal Machine Tool Processing Titanium Alloy Hinge_Hinge Knowledge_Tallsen 1

At present, titanium alloy materials are widely used in hinge materials due to their excellent properties. However, these materials have a low thermal conductivity, which can lead to tool wear and reduced tool life if chip removal is not performed timely during cutting. This can also result in poor surface quality of the finished product. In this article, we will discuss the efficient processing method of a certain type of machine part made from titanium alloy.

The part we will analyze has a complex structure and profiles in six directions, requiring multiple stations to complete the processing. The raw material for this part is TA15M, a die-forged titanium alloy, with an outer dimension of 470×250×170 and a weight of 63kg. The dimensions of the part itself are 160×230×450, with a weight of 7.323kg and a metal removal rate of 88.4%. The part has a hinged structure with profiles in six directions, making the structure extremely irregular. The clamping part is not open, which affects its stability during processing. Additionally, many wall thickness dimensions of the part can only be formed in multiple stations, making it crucial to ensure the wall thickness during the process. The grooves in the part have a maximum depth of 160mm and a small width of only 34mm, with a small corner radius of R10. There is an overlapping relationship when assembling these corners, requiring strict size control. The part also requires a tool with a large length-to-diameter ratio for CNC machining, which presents a challenge due to the poor rigidity of the tool.

To efficiently process this part, a determination of the processing plan is needed. Initially, the part was considered for vertical CNC machine tool machining. However, due to the complexity of the part and the need for multiple fixtures, it was determined that vertical machining was not suitable. Instead, horizontal CNC machine tools were chosen for machining the part.

In the horizontal CNC machining plan, a five-coordinate high-rigidity horizontal machining center was selected. This machine tool has good rigidity and two interchangeable worktables, which improves work efficiency. It has a swing angle of 90/-90 degrees in angle A and 360 degrees in angle B. The machine tool also has good cooling equipment, allowing for quick chip removal and prolonging the tool's service life.

The processing flow was established using both vertical and horizontal machining. Part A, which serves as the benchmark for subsequent processing, was processed using the five-coordinate vertical machine tool. Part B required two sets of fixtures for clamping, while part C required three sets of fixtures. Parts D and E were transferred to the horizontal machine tool for processing using a set of special fixtures. This approach eliminated the need for multiple fixtures, reducing manufacturing costs and improving efficiency. The parts were positioned on surface A, and only one set of fixtures was used to rotate through the worktable, completing the processing of each part.

To compile the processing program, the rigidity of the process system was considered to improve the overall rigidity of the part during processing. The program at both ends of the part took into account the machine tool's rigidity and the processing system, dividing the depth of the end into layers for processing using a milling cutter. For the deep groove in the part, three different series of tools were used for processing. The lug and notch in the part were milled using a 10R2 milling cutter, with separate roughing and finishing stages to ensure the thickness and width of the features. Cutting parameters such as revolutions, feed per tooth, and feed speed were selected based on the specific requirements of each milling operation.

To validate the processing procedures, VERICUT simulation software was used to check the NC program for correctness. This software allows for the verification of cutting allowances, tool collisions, machine tool interference, and machining residues. The use of simulation software ensures the accuracy and effectiveness of the processing program before actual production.

In conclusion, the horizontal machine tool proved to be an effective choice for processing the complex part made from titanium alloy. By eliminating the need for multiple fixtures and utilizing the machine tool's capabilities, the processing cycle of the product was shortened and the quality of the parts was guaranteed. This approach not only improved efficiency but also accumulated valuable experience for future processing of similar products. Tallsen, being customer-oriented, is dedicated to providing the best products and services in an efficient manner. With years of experience in producing hinges, Tallsen is known for its high-quality and innovative products. The company focuses on technical innovation, flexible management, and upgrading processing equipment to improve production efficiency. Tallsen's continuous pursuit of excellence and dedication to customer satisfaction make it a reliable partner in the industry.