Among the various types of intelligent machining, precision CNC broaching occupies an important position due to its unique machining method and outstanding machining accuracy.
Application Scenarios: Excelling in High-Precision Component Machining
Precision CNC broaching is mainly applied in the machining of parts that require extremely high shape accuracy and surface quality. In the automotive manufacturing industry, key engine components such as valve guides and splined shafts often adopt the precision CNC broaching process. Valve guides require high-precision inner hole shape and extremely smooth inner surface to ensure the smooth operation of valves. Precision CNC broaching can machine the inner hole to the required dimensional accuracy and surface roughness in one go, greatly improving production efficiency and product quality. In the aerospace field, precision CNC broaching also demonstrates irreplaceable advantages in the machining of tongue-and-groove at the root of aero-engine blades with complex shapes. It can accurately shape complex tongue-and-groove contours in accordance with design requirements, meeting the strict reliability requirements for components under extreme working conditions such as high temperature, high pressure and high speed of aero-engines.
Core Technical Pillars: Broach Design and CNC System Control
Precision CNC broaching involves numerous technical key points. The first is the design and manufacturing of the broach. As the core tool of precision CNC broaching, the broach has a complex structure and extremely high precision requirements. The tooth profile of the broach needs to be specially designed according to the shape of the part to be machined, and parameters such as the cutting angle and tooth lift of each tooth are accurately calculated. For example, when machining internal splines, the tooth profile of the broach must perfectly match the tooth groove shape of the spline to achieve efficient and precise cutting. At the same time, the material selection of the broach is also crucial. High-performance high-speed steel or cemented carbide is usually used to ensure sufficient hardness, wear resistance and toughness, which can withstand the huge cutting force and friction during the broaching process.
The CNC system plays a key control role in precision CNC broaching. It can accurately control parameters such as the movement trajectory, cutting speed and feed rate of the broach. During the machining process, the CNC system adjusts the position and movement state of the broach in real time according to the pre-written program. For example, when encountering uneven material hardness, the CNC system can automatically reduce the cutting speed or adjust the feed rate to avoid excessive wear of the broach or a decrease in machining accuracy. Moreover, advanced CNC systems also have a tool monitoring function, which can monitor the wear of the broach in real time. Once the broach wear exceeds the set range, it will promptly remind the operator to replace or adjust it. Notably, precision CNC broaching equipment often works in conjunction with the CNC Lathe Automatic Loading Unloading System . This system can realize automatic grabbing, positioning and conveying of workpieces, reducing clamping errors caused by manual intervention, and at the same time shortening the loading and unloading time by more than 40%, further improving the continuity of mass production and overall production efficiency.
Auxiliary Guarantees: Cooling-Lubrication System and Machine Tool Stability
The cooling and lubrication system is also an indispensable part of precision CNC broaching. A large amount of heat and chips will be generated during the broaching process. If cooling and lubrication cannot be carried out in a timely and effective manner, problems such as rapid wear of the broach, degradation of machining surface quality and thermal deformation of parts will occur. Special cutting fluid is usually used, and through reasonably designed cooling and lubrication channels, the cutting fluid is accurately sprayed to the cutting area. The cutting fluid can not only take away heat but also play a lubricating role, reducing the friction coefficient between the broach and the workpiece, reducing the cutting force, thereby further improving machining accuracy and surface quality.
In addition, precision CNC broaching has high requirements for the accuracy and stability of the machine tool. The machine tool bed needs to have sufficient rigidity to resist the cutting force during the broaching process and prevent vibration and deformation of the machine tool. The positioning accuracy and repeat positioning accuracy of the workbench must meet extremely high standards to ensure the position accuracy of the workpiece during the broaching process.
As a type of intelligent machining, precision CNC broaching plays an irreplaceable role in specific application scenarios. Its technical key points cover multiple aspects such as broach, CNC system, cooling and lubrication system, and machine tool accuracy. All links cooperate with each other to jointly realize high-precision and high-efficiency part machining, providing strong technical support for the development of many high-end manufacturing industries such as automotive and aerospace.
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