In the field of iron mold machining, several common issues often plague manufacturers. One of the most prominent problems is excessive vibration during the machining process. This vibration can lead to a series of negative outcomes, such as poor surface roughness of the machined parts. For instance, in some traditional machining methods, the surface roughness of iron molds can reach up to Ra 3.2 - 6.3μm, which is far from the precision requirements of high - end mold manufacturing. Another issue is the low machining accuracy, which directly affects the quality and functionality of the final products.
The bridge - type double - column structure is characterized by a fixed cross - beam and a movable worktable design. This design provides a stable foundation for the machining process. The fixed cross - beam reduces the interference caused by the movement of the main spindle during operation, while the movable worktable allows for flexible positioning of the workpiece. In contrast to traditional vertical or gantry machine tools, the bridge - type double - column structure has a more compact and rigid layout. For example, in a comparison test, a bridge - type double - column CNC milling machine could achieve a positioning accuracy of ±0.005mm, while a traditional vertical machine tool only reached ±0.01mm.
When compared with traditional vertical and gantry machine tools, the bridge - type double - column structure shows significant advantages. Traditional vertical machine tools often have limited stability due to their open - frame design, which makes them more susceptible to vibration during heavy - cutting operations. Gantry machine tools, on the other hand, may have a large footprint and relatively complex structures, resulting in higher costs and more difficult maintenance. The bridge - type double - column structure, with its fixed cross - beam and movable worktable, can effectively reduce vibration transmission. In a vibration test, the vibration amplitude of a bridge - type double - column machine tool was only 1/3 of that of a traditional vertical machine tool during heavy - cutting operations.
The high - precision application value of the bridge - type double - column structure can be clearly seen in practical cases. In the machining of large cast iron parts, such as engine blocks, the bridge - type double - column CNC milling machine can ensure high - precision machining of complex contours. For example, in a large - scale engine block machining project, the bridge - type double - column machine tool could complete the machining of a large cast iron engine block with a dimensional accuracy of ±0.01mm, which is crucial for the performance of the engine. In the processing of inserts, the bridge - type double - column structure can also provide high - precision machining, ensuring the fit and function of the inserts.
The guide rails are the key components for the movement of the worktable and the main spindle. Regular cleaning and lubrication of the guide rails can reduce friction and wear, ensuring smooth movement. It is recommended to clean the guide rails at least once a week and lubricate them with high - quality lubricants. For example, using a high - performance lubricant can reduce the friction coefficient of the guide rails from 0.1 to 0.05, which significantly improves the movement accuracy.
Thermal expansion is a common problem in machine tool operation, which can affect the machining accuracy. Thermal balance management involves controlling the temperature of the machine tool components. For example, installing a temperature - control system can keep the temperature of the spindle within a range of ±1°C, effectively reducing the impact of thermal expansion on machining accuracy.
Pre - heating the spindle before operation can improve its thermal stability. It is recommended to pre - heat the spindle for about 15 - 20 minutes before starting heavy - cutting operations. This can reduce the thermal deformation of the spindle during operation, ensuring high - precision machining.
Regular precision calibration is essential for maintaining the high - precision operation of the machine tool. It is recommended to calibrate the machine tool at least once a month. Through precision calibration, the positioning accuracy and repeatability of the machine tool can be ensured, which is crucial for long - term stable operation.
Vibration monitoring can detect potential problems in the machine tool operation in time. Installing vibration sensors on the machine tool can monitor the vibration amplitude and frequency in real - time. If the vibration amplitude exceeds the normal range, it indicates that there may be problems with the machine tool components, such as loose parts or abnormal wear, which need to be addressed immediately.
By following these maintenance key points and operating the machine tool in a standardized manner, users can ensure the long - term stable and high - precision operation of the bridge - type double - column iron mold processing equipment. For example, the Kaibo DC1113, with its bridge - type double - column structure, has served over a hundred precision mold customers worldwide. If you want to learn more about how to extend the service life of your bridge - type double - column iron mold processing equipment and improve its machining efficiency, click here.
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