Construction machinery
Machine building and supply of precision support frames to 0.01 mm for high-speed lines.
Research by Jaroslav Miklušák from MECASYS & Ján Habovštiak & Jozef Medvecký, Pavol Gužik from MECASYS Design Labs
Summary
Machine building and production of precision load-bearing frames for high-speed lines of the required dimensions with a critical tolerance parameter of maximum deviation of 0.01 mm.
The required extremely small deviation is necessary to achieve the quality of the final product. MECASYS, by careful planning and also by optimizing all technological procedures, has ensured that every single step in the process contributes to achieving perfect precision in every part of the final product.
When manufacturing support frames for high-speed lines, it is crucial to achieve extremely precise dimensions. Even small deviations can affect the overall performance and reliability of the system. It is critical to design the manufacturing process to minimize errors and ensure consistent frame quality.
To design the technological process of welding, heat treatment and 5AX CNC machining is a challenging task. It is important to precisely synchronise and optimise each step to achieve the required accuracy to within 0.01 mm. Ensuring that the different technologies (welding, heat treatment, machining) complement and work together perfectly is key. The ultimate goal is to create support frames that meet the required precision and durability. Verification of functional dimensions and quality is a critical point to ensure perfectly flawless operation of high-speed lines.
Description of the problem
A fundamentally important factor in the production of support frames for high-speed lines is the achievement of extreme precision to 0.01 mm. Even small deviations can have a critical impact on the overall performance of a high-speed line and the reliability of the complex system of the intended line function. Accuracy and consistency are extremely important because even minimal inaccuracies can cause serious consequences in terms of the functionality and safety of the high-speed line system.
In addition to 5AX CNC machining, it is also important to consider the heat treatment of the material. Heat treatment affects the mechanical properties of the material such as hardness, strength and wear resistance. Proper heat treatment can minimize deformation and improve the overall quality of load-bearing frames. The manufacture of load frames for high-speed lines is therefore a complex process that requires precise planning, optimization of technological processes and careful adherence to tolerances. Each step in the process must contribute to achieving the required accuracy to within 0.01 mm to ensure the flawless functionality of high-speed lines.
The support frames for high-speed lines must always meet extremely tight tolerances, which generally ensure the faultless operation of the entire system.
5AX CNC machining is an integral part of the technological process for achieving the tolerances required for the precision production of precision support frames and components for high-speed lines. This modern method of producing the highest quality products achieves high precision and repeatability of results. It is key in the production of complex parts and enables the creation of complex geometric shapes that cannot be realised by manufacturing on
conventional milling machines. 5-AX machining involves the efficient
processing of shape-intensive components, shortening the production cycle and maintaining high standards of quality and precision. This process is widely used in industry and especially in the manufacture of aerospace and automotive components. In the context of manufacturing, this 5AX CNC advanced technology allows machining from multiple angles and tool positioning in different axes, resulting in complex shapes and precise dimensions. The 5-axis CNC machines are capable of machining in three linear axes (X, Y, Z) and two rotary axes (A,C).
Solution
In the pre-project phase, before the start of the implementation activity, MECASYS thoroughly analyzed not only the client's specific requirements and submitted documents, but also identified their hidden expectations.
By analysing the existing situation and the client's documents, MECASYS subsequently optimised the technological procedures and cycles for the realisation of load-bearing frames for high-speed lines in order to achieve higher efficiency, productivity and quality of production not only with regard to safety and cost savings, but also by taking into account other important aspects.
MECASYS designed and implemented the technological procedure of welding, heat treatment, 5AX CNC machining and verification of functional dimensions to achieve the required accuracy of 0.01 mm with final surface treatment and validation of the achieved parameters with the client prior to export of the realized result of the project of load-bearing frames for high-speed lines.
Before the first physical implementation phase, MECASYS designed a welding procedure, subsequently applied by implementation and in a way from previous own researches from MECASYS Labs, which have been systematically collected over a long period of time not only from the domestic market, but also during the participation or overall implementation of projects from all over the world, and proven manufacturing and business experience in the field of industrial automation.
Subsequently, after welding, the heat treatment ensured the improvement of the mechanical properties of the material of the manufactured load-bearing frames and achieved the necessary structural and overall properties of the semi-finished product.
To realize and achieve the critical parameter of tolerance of maximum deviation within 0.01 mm, which is an extremely small tolerance, the production procedure was applied using a modern 5AX CNC machining center. By selecting a suitable machine with 5-axis milling capability, the required accuracy was ensured. Achieving an accuracy of 0.01 mm by grinding, cutting or countersinking technologies was not the optimal technological procedure in this case.
Verification of the accuracy of achieving the critical tolerance of the maximum deviation was ensured by Mecasys with highly accurate and precise 3D coordinate technology, in the manner of CMM measurement.The CMM measurement, which measures points directly on the surface of the component and then analyzes this measured data. In this way, extreme precision has been ensured during the production of support frames for high-speed lines. The final finishing process was carried out by a wet spray painting process.
Prior to export, the validation of the achieved parameters was carried out with the client in the form of output from the CMM measurement process. A report, certificate and digital model with documentation with 2D and 3D model options are an essential part of this process and demonstrate the achieved precision accuracy of each realised product. CMM measurement is a suitable and desirable measurement technology even for high-end and precision products with the required IT4 accuracy.
Results and benefits
By selecting 5-axis milling of welded and heat-treated workpieces, the required perfect precision accuracy of the produced fixtures was achieved.
The supplied support frames with surface finish for the high-speed lines met the required precision and MECASYS also took care of the thorough and safe packaging, ensuring the protection of the supplied frames during transport.
The client also benefits from the supplied CMM report, a certificate of measurement accuracy, which saves the Swiss client time and money in terms of input during assembly due to the possibility of skipping the post-delivery quality check. The client can also place a repeat request at any time in the future, which will be realized and delivered in a very short time.
Conclusion
of a maximum tolerance of deviation of up to 0.01 mm, was Switzerland. MECASYS analyzed the existing condition and the client's documents, designed the welding procedure, heat treatment, CNC machining and CMM measurement.
The design was implemented using a 5AX CNC machining center and the results were verified by CMM measurement. The achieved parameters were then validated with the client.
The final surface treatment realized by wet painting, spraying and thorough and safe packaging for export to the client, for whom MECASYS realized the requirement with several modern technologies and all this in one place in Orava Polhora. Accuracy to 0.01 mm was a key and decisive factor!
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References
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