In the field of large workpiece processing, large CNC gantry milling and grinding integrates milling and grinding processes, which can give full play to the advantages of both. Milling is good at quickly removing a large amount of material, while grinding can achieve high-precision surface processing. The synergy between the two is the key to improving processing efficiency and quality. By scientifically planning the process route and optimizing equipment parameters, the processing cycle can be effectively shortened and production efficiency can be improved.
The first step to improve processing efficiency is to reasonably plan the milling and grinding processes. In the rough processing stage, the milling process is preferred. The characteristics of large feed rate and high cutting speed of the milling cutter are used to quickly remove most of the blank allowance, form the basic contour of the workpiece, and greatly reduce the amount of material processing. When the workpiece allowance is close to the final size, switch to the grinding process, and remove a small amount of remaining material through fine grinding to achieve high-precision dimensional tolerance and surface roughness requirements. At the same time, optimize the process connection between milling and grinding, reduce auxiliary time such as tool change and equipment adjustment, such as using an automatic tool change system and an online measuring device to detect the size of the workpiece after milling in real time, provide accurate data for the grinding process, and achieve a seamless transition.
The parameter setting of large CNC gantry milling and grinding equipment is crucial for the coordination of the two processes. During milling, the spindle speed, feed speed and cutting depth are reasonably adjusted according to the workpiece material characteristics and tool performance to ensure efficient cutting while avoiding excessive tool wear. During the grinding stage, the grinding wheel linear speed, feed rate and grinding pressure are accurately controlled to ensure processing accuracy. In addition, the linkage control of milling and grinding is realized through the CNC system of the equipment, so that the movement of each axis can be accurately connected during the switching process of the two processes, reducing the idle travel time. For example, after milling is completed, the machine tool can quickly locate to the starting position of grinding without manual intervention, significantly improving the processing efficiency.
Large CNC gantry milling and grinding tools and grinding wheels are the key execution components of milling and grinding processes, and their reasonable selection and management directly affect the processing efficiency. Milling tools need to select appropriate tool materials (such as carbide, ceramic tools) and tool geometric parameters (such as rake angle, back angle, and blade inclination angle) according to the workpiece material and processing requirements to improve cutting performance. For grinding wheels, different grain sizes, hardnesses and structures should be selected according to the requirements of machining accuracy and surface quality. At the same time, a life management system for tools and grinding wheels should be established to monitor their wear status in real time. When the predetermined wear degree is reached, they should be replaced or repaired in time to avoid the decline in machining quality and efficiency caused by tool or grinding wheel wear. Through the coordinated management of tools and grinding wheels, the milling and grinding processes can be ensured to be in efficient operation at all times.
The cooling and lubrication system plays an important role in the milling and grinding processes, and its optimization helps to improve the machining efficiency. During the milling process, sufficient cutting fluid can effectively reduce the cutting temperature, reduce tool wear, and increase the cutting speed and feed rate. During grinding, suitable coolant can take away the grinding heat and prevent the workpiece surface from burning. At the same time, it can also play a lubricating role and reduce the friction between the grinding wheel and the workpiece. According to the characteristics of the two processes, the cooling and lubrication system is comprehensively optimized, such as using different coolant injection methods and flow control, using high-pressure and high-flow injection in the milling area to quickly take away chips and heat; using fine spray cooling in the grinding area to improve the cooling effect and lubrication performance. In addition, regular maintenance and replacement of coolant ensure the normal operation of the cooling and lubrication system, and provide guarantee for the efficient coordination of milling and grinding processes.
Large CNC gantry milling and grinding uses sensors and monitoring technology to monitor the milling and grinding processes in real time, which is an important means to achieve efficient coordination. In the milling stage, the cutting force changes are monitored by force sensors to judge the tool wear and cutting status; in the grinding process, the acoustic emission sensor and vibration sensor are used to monitor the grinding wheel wear and the surface quality of the workpiece. Feedback the monitoring data to the CNC system, combined with the pre-set process parameters and processing requirements, to achieve intelligent control. For example, when the milling tool is detected to be severely worn, the cutting parameters are automatically adjusted or a tool change command is issued; in the grinding process, the grinding parameters are adjusted in real time according to the changes in the surface roughness of the workpiece to ensure stable processing quality. Through the monitoring and intelligent control of the processing process, the downtime caused by abnormal processing can be reduced and the overall processing efficiency can be improved.
The grinding process and milling process of large CNC gantry milling and grinding can give full play to their respective advantages and effectively improve processing efficiency through the coordination of process planning, equipment parameter matching, tool grinding wheel management, cooling and lubrication optimization, and processing process monitoring. This coordination not only shortens the processing cycle of large workpieces and reduces production costs, but also ensures processing quality, providing strong support for efficient production in the manufacturing industry. In the future, with the continuous development of CNC technology and intelligent manufacturing, the coordination of the two processes will become more intelligent and efficient.
