Buy LJ-855 Vertical Machining Center | Technical Fit, Daily Output, Inquiry Tips

Suggest choose FANUC system + high speed tool magazine, optimize tool path and set 36m/min fast move to elevate efficiency.

Technical Fit

Working Envelope

LJ-855 worktable cast iron panel length width is 1000mm multiply 500mm. X axis run to dead only has 850mm. Throw a piece of 900mm long steel plate up there, two ends respectively have 25mm blind zone, spindle tool fundamentally cannot reach edge.

Even if put 800mm long strip rail seat, two ends left for tool setter hit indicator gap also only left 25mm. Operating master shakes handwheel slightly faster a bit, hit on hard limit will trigger machine tool alarm.

Workshop inside no one takes glue take parts stick on table surface to work. This 850mm physical stroke has to with flat jaw vise grab territory.

· Single unit 160 pneumatic flat jaw vise occupies 450mm

· Two units side by side install leave 100mm wrench gap

· Edge finder probe hit point leave 20mm distance

· Fourth axis bridge plate single side occupies away 200mm

Y axis theoretically has 500mm, truly stuff enter a 480mm wide square box, worktable towards back push to bottom, sheet metal bevel will constantly rub part edge.

Y axis guideway front has a root flush water chip removal pipeline, pipe compared to table surface high out 30mm around. Must install 490mm wide thin plate, cutter head turn to most outside will take chip removal water pipe cut rotten. Actual can stably work width at most 460mm.

Towards up look Z axis, 550mm stroke in vertical direction ledger has to according to millimeter calculate. Spindle end face to table surface distance in 150mm to 700mm between. 700mm high rough iron block fundamentally stuff not enter.

BT40 tool holder plus tool blade, one piece 63mm standard face milling cutter total length almost 120mm. Change to hit deep hole U drill lengthen holder, total length easily break through 250mm.

Pad block base 100mm, pneumatic bottom plate thick 50mm, workpiece itself 200mm high, again plus 250mm long drill bit. These few items stack up add to one piece exactly 600mm.

Spindle retract enter ceiling highest point 700mm position, tool tip leave part top only left 100mm. Spindle change tool still has to towards down drop a section go loose tool, mechanical arm one turn, on the spot will take part top end hit to mush.

Encounter 300mm gun drill hit deep water hole, Z axis this space thoroughly no way use, all rely master one by one hand change.

· 210 rotary table motor cover width 280mm

· Tailstock width 120mm

· Rotary table center high 160mm

· Workpiece rotation radius 150mm

Fourth axis occupies away X axis 400mm, left give part effective length only has 450mm. Part highest point leave table surface reach 310mm. Z axis hit indicator tool setting all in 310mm mid-air operate.

Tool magazine inside inserting 150mm long boring tool, spindle change tool point is stuck deadly. Process with flange pipe fitting, rotary table flip 90 degrees, flange edge very easily rub to behind sheet metal. Fixture drawing calculate wrong 1mm, can on the spot hit bend value 6000 bucks spindle pull rod.

Worktable writing 500kg maximum load bearing, here inside hiding dynamic deformation. Put a piece of 600 multiply 400 multiply 200mm 45 steel up there weigh 370kg, plus 80kg big vise, basically push to head.

Once move to X axis or Y axis most edge on, cantilever effect will let slider single side receive pressure, Z axis verticality immediately produce 0.015mm tiny tilt.

· 18mm wide T type slot total 5 strips

· Slot spacing 100mm restrict punch hole

· Eccentric load 300kg drop 0.01mm accuracy

· Table surface edge receive force cutting easy vibrate tool

Facing 400kg big casting spray cutting fluid, flush water angle very receive suffocation. Iron block block live two sides spindle annular spray water flow, deep cavity inside iron chips flush not out, master only can holding air gun hard blow.

855 level machine tool base span 800mm around. Forcefully stuff 1000mm wide big plate, two sides each suspend in air 100mm. Tool walk suspend in air section, take dial indicator hit on edge can see 0.03mm runout.

Large diameter cutter head run out edge need eat away many hidden strokes. Take 80mm face milling cutter scrape 600mm long face, two ends each leave 45mm enter retreat tool distance. X axis truly run up trajectory has 690mm long.

Rough blank margin put 5mm, first tool resistance extremely big, retreat tool over-travel amount need add to 60mm wait spindle rotate speed lift up, this section stroke absolutely save not down.

Machine tool inside three axis limit switch front installing 3mm thick hard block anti-collision sticker. Computer software calculate out exactly good 849mm walk tool path, send to machine tool run, system discover brake distance not enough.

Tool holder hit on 3mm buffer zone, servo motor immediately report overload cut power. Drawing stroke send to workshop, all have to honestly honestly towards inside shrink 5% give machine operator leave out evade room. If every day work 800mm above long strip pieces, not as good as add a bit money buy 1060 machine tool.

Spindle Specs

Buy LJ-855 choose spindle, just is in rotate speed and torque between do single choice question. Standard equipped BT40 taper spindle hole, pull tool force usually set in 800kg to 900kg between. Every day change tool 500 times, two years later disc spring fatigue, pull force drop to 600kg, heavy cutting time tool holder will in spindle hole happen tiny slip.

Old factory mostly buy 8000 revolution or 10000 revolution belt spindle, motor power mostly standard equip 11kW or 15kW. Belt pulley reduction ratio design, take motor torque in low rotate speed interval magnify.

Rotate speed drop to 1500 revolutions per minute, belt spindle can erupt out 50 to 70 Newton meters cutting force. Take one piece 63mm diameter 4 flute face milling cutter, go scrape 45 number carbon steel black skin rough blank. Cut depth down to 2.5mm, feed speed push to 800mm/min, spindle load meter pointer will steadily stop at 65% around, sound low deep not suffocate car.

Encounter HT250 gray cast iron machine tool base roughing, change on 80mm coarse tooth milling cutter. Belt spindle formidable pull force can carry live intermittent cutting impact, iron chips like raindrops same smash on sheet metal. Spindle motor current instant soar to 25A, belt transmission permit this kind physical level brief overload.

Factory inside receive P20 mold steel order, hardness reach HRC30 around. Use 10mm alloy end mill full slot roughing, rotate speed set at 2500 revolutions, eat tool depth 5mm. Belt spindle one breath run finish 4 hours rough processing program, tool wear normal, spindle box surface temperature only elevate high 8 degrees.

Belt transmission use long V type belt will lengthen age. Run to 8000 revolutions limit time, belt slap produce resonance all conduct to tool tip on. Take dial indicator hit spindle taper hole inner generatrix, new machine tool runout in 0.003mm within, three years belt aging after, high rotate speed under dynamic deflection can run to 0.015mm.

This 0.015mm deflection put in fine processing inside very want life. Use 4mm ball nose cutter go polish mold curved surface, workpiece surface leave down one strip strip naked eye visible fish scale pattern. Roughness even Ra1.6 all keep not live, fitter take sandpaper polish has to extra spend two hours wipe butt.

· Standard equip V type belt life usually in 4000 hours up down

· Full load 10000 revolutions continuous run 2 hours belt cabin internal exceed 50 degrees

· Spindle end face flange counterweight block fall off will trigger 0.02mm abnormal runout

· Belt tension test need maintain in 45-50Hz vibration frequency interval

Specially do aluminum alloy and 3C parts factory, uniform color change become 12000 revolution or 15000 revolution direct connect type spindle. Motor and spindle rely a nylon plum blossom pad block coupling connect at together. No belt lateral pull, rotate speed pull to 12000 revolutions, water cup put on machine tool even water ripples all not have.

Direct connect type spindle equip is 7.5kW or 11kW motor, thoroughly give up low speed torque. Cut 6061 aluminum alloy, change on 12mm 3 flute aluminum use high gloss milling cutter. Rotate speed pull full to 12000, feed push to 4500mm/min, cut down aluminum chips like snowflakes same fine white.

High speed light cut state under, direct connect spindle make out surface roughness easily reach Ra0.8 level. Process mobile phone middle frame or communication cavity, tool in 3mm thin wall on fast wander. Front end ceramic bearing avoid receive belt pull wear, life compared to belt spindle long 30%.

Direct connect spindle torque curve extremely steep. Rotate speed drop to 2000 revolutions below, torque even 20Nm all squeeze not out. Take one piece 20mm U drill go give P20 mold steel punch hole, drill bit just contact workpiece surface, spindle because torque insufficient instant stuck dead, servo drive immediately report out spindle overload alarm.

High rotate speed bring astonishing friction heat generation amount. 12000 revolutions run half an hour, no external cooling intervene, spindle bearing temperature soar to 65 degrees. Spindle outer sleeve receive heat expand, Z axis direction will towards down physical elongate 0.02mm to 0.03mm.

This 0.03mm thermal elongation in process deep cavity chamfer time extremely easy cause waste product. Program set chamfer 0.5mm corner, machine tool run hot tool tip towards down probe, actual chamfer out corner become 0.53mm. Assemble fit parts will appear obvious high low drop scrape hand feeling.

A machine 1.5 horsepower cooling capacity equipment, internal circulate 10 liters low viscosity spindle oil. Cooling oil in spindle sleeve outside spiral water channel inside run one circle, take bearing heat bring back cold row, spindle temperature rise is forcibly suppress in room temperature plus 2 degrees interval.

· 12000 revolution spindle mostly use front three back two ceramic ball bearing configuration

· Plum blossom coupling buffer pad normal wear replace cycle 6000 hours

· Oil cooler set temperature need compared to workshop room temperature low 1 degree prevent outer shell condensation

· Spindle air curtain must keep 0.2MPa air pressure prevent cutting fluid backflow

Heavy cutting condition under bearing clearance more change more big, light cutting require clearance more small more good. A machine 855 equip 12000 revolution direct connect spindle, hard receive 45 steel heavy flange plate business. Three days heavy cutting work finish, front row ceramic balls bear not live impact force produce internal tiny cracks.

Cracks appear after spindle turn up carry high frequency whistle sound. Again take go process aluminum parts smooth surface, workpiece surface all is wave pattern. Change a set P4 level high precision spindle bearing, material fee plus manual overhaul inspect, no 8000 bucks down not come.

Use cooling fluid flush tool, cutting water along spindle end face towards up climb. Spindle air curtain seal use 0.2MPa clean air towards outside blow take water block live. Air compressor water filter broken, compressed air carry water blow enter spindle internal, not arrive one month bearing lubricating grease emulsify turn white thoroughly fail.

Spindle taper hole 7:24 taper fit towards cleanliness require extremely high. Iron chips stick on tool holder taper surface, mechanical arm take tool forcefully stuff enter spindle, few hundred kilos pull force one drag, spindle inner taper surface is pressed out 0.05mm pit.

Guideways

LJ-855 configure guideways, need in move speed and anti-vibration damping between calculate a sum long-term account. Market on 855 machine model nine tenths assemble three axis linear guideway, small part old craft factory spend money customize three axis hard guideway.

Linear guideway camp inside subdivide out ball and roller two factions. 35 spec or 45 spec roller linear guideway, internal rolling body is cylinder shape. Slider with guideway contact area compared to ball big out 30%, load bearing capacity vividly pull high a section. X axis install two roots 45 spec roller linear guideway, fast move speed run to 36m/min even 48m/min very easy.

Ball linear guideway run extremely fast, cutting slightly heavy extremely easy shiver. Roller linear guideway take surface contact exchange 40% rigidity elevate, stable sit 855 level machine tool main force position.

Servo motor send command let worktable move 0.001mm, linear guideway rolling friction resistance extremely small, worktable can accurately move one micrometer. Process 3C communication equipment aluminum alloy outer shell, walk tool speed push to 6000mm/min, reverse direction hit arc not have any stuck. Dial indicator hit out repeat positioning accuracy steadily fall in ±0.003mm interval inside.

Roller linear guideway encounter 45 steel intermittent cutting, short board expose no remain. Face milling cutter cut out casting edge empty load, one head hit enter iron block, alternating impact force all smash on linear guideway slider few hundred pieces rollers. Machine tool run hot, linear guideway lack absorb vibration oil film buffer, vibration follow casting conduct, mill out flat surface leave down one strip strip extremely deep vibration pattern.

Optional install two linear one hard or three axis hard guideway, cast iron guideway surface all rely pure manual intervene. Fitter take scraper in guideway surface scrape out few micrometers deep fine mesh pattern. Mesh pattern gap use to store 68 number guideway oil, hard vividly pad out a layer 0.01mm thick hydraulic oil film.

Manual scrape grind out every square inch 15 to 20 contact points, load bearing area crush few hundred pieces rollers. Few tons heavy cutting reaction force smash down, hard guideway oil film is instant squeeze, high frequency vibration is swallow clean clean. Take 80mm face milling cutter cut 45 steel intermittent surface, even blade all not easy chip edge.

Hard guideway rely sliding friction work, X axis run fast will produce serious thermal deformation. Fast move speed is deadly lock in 15m/min to 20m/min between. Do mobile phone outer shell hole position many, run half an hour, back forth move friction heat let base rise temperature 5 degrees. Positioning accuracy follow thermal expansion drift to 0.015mm beyond.

Take 10mm/min extremely slow speed go mill big arc, worktable happen naked eye look not see walk walk stop stop. Industry inside call it crawl phenomenon. Arc surface test out profile error will run to 0.02mm above.

Z axis hang 300 kilos spindle box, cut power instant all rely servo motor brake hold dead. Linear guideway friction force extremely small, hold dead instant spindle box towards down drop 0.02mm, drill bit on the spot smash bad workpiece surface. Hard guideway static friction big, cut power spindle steadily stop in mid-air, drop tool probability extremely low.

· Pure linear guideway machine tool specialize do aluminum parts, copper parts and ordinary steel parts continuous cutting, daily production 200 pieces batch order rely speed grab profit space.

· Two linear one hard (Z axis hard guideway) keep X, Y axis 36m/min move speed, Z axis hard guideway deadly resist 20mm U drill hit deep hole vertical reverse push force.

· Pure hard guideway machine model exclusively supply heavy mold factory, full slot eat tool 5mm without any quiver, sacrifice 50% move time exchange tool life extend 30%.

Volume type lubrication pump set every 15 minutes pump oil once, every time inject oil 3 milliliters. A machine pure linear guideway 855 machine tool one day open 20 hours, one month just 68 number guideway oil drink away 15 liters.

Guideway oil leak enter cutting water tank, surface float up a layer thick oil film. Cutting fluid two weeks stink grow green hair, waste fluid treatment fee one ton hand over 3000 bucks.

Leave factory optionally equip add 3000 bucks change install grease lubrication system very cost-effective. Every 30 minutes pump 0.5 gram 2 number lithium base grease enter slider. Lubricating grease not run off, half year not need empty cutting water tank. Roller slider internal is grease fill full, cutting water and tiny iron chips enter not go, dustproof wiper life extend one fold.

Linear guideway slider broken, spend 4000 bucks buy a set same spec remove screw change on, pull indicator adjust level big half day recover production. Hard guideway wear pull hurt a strip 0.5mm deep groove, repair up take whole worktable hoist away. Invite master newly shovel scrape stick plastic, stop machine one week start step, repair fee according to ten thousand calculate.

X axis guideway install datum surface straightness leave factory polish to 0.005mm. Hexagon screw lock tight torque use torque wrench strictly stuck at 110Nm. Assembly worker difference 10Nm not screw tight, machine tool run two years after screw tiny loose, Y axis in 400mm stroke inside straightness deviation out 0.018mm. Whole number rely lock tight screw physical connect tolerate not half bit assembly sloppy.

Daily Output

Three Big Elements

A machine LJ-855 machine tool run finish a set program spend away total minute number, by tool tip touch material cutting consume time and machine empty run consume time piece together become. Spindle from static accelerate to 10000 rpm roughly need 1.2 seconds. Machine head in X axis and Y axis on with per minute 36 meters speed fast move find position. Change tool action take spindle lift high, grab tool, loose open, whole coherent action do finish run away 2.5 seconds. CNC system read one line code only need 0.001 seconds, physical mechanical move follow not up code send out extreme speed command.

Machine own bring 24 pieces round disc tool magazine rotate one grid consume time 0.8 seconds. Find most far end that piece tool has to turn half circle, this one under just lose 3.5 seconds. One day process 200 pieces parts, every part change 5 times tool, alone calculate wait tool disc turn circle just lose almost 1 hour. Workshop arrange production according to single shift 8 hours calculate, machine empty run pause take whole day can output goods cut away very big one piece. Optimize program inside change tool sequence, neighbor tools put at together, every day can extra out 15 pieces machine run time.

· Spindle belt transmission drop speed to 8000 revolutions

· Z axis move before give nitrogen cylinder charge pressure 0.5 seconds

· Change tool before cutting fluid flush tool holder 0.3 seconds

· Cylinder loose pull tool action consume 0.6 seconds

Take a piece 6061 aluminum plate put enter machine tool, one piece 50mm diameter face milling cutter can open to 2500 mm/min speed towards front push. Iron chips like snow flakes same fly out, chip conveyor every minute need bring away 3 kilos fragments. Single piece do finish only need 4 minutes. Change to cutting hardness HRC35 P20 mold steel, same size tool only can with 400 mm/min speed slow slow gnaw.

Hard steel material let spindle load meter pointer straight stop at 85% red line edge. Do same appearance size 150mm rectangular cuboid base, mold steel machine processing consume time is pull long to 22 minutes. Exterior with 3D arc curved surface communication base station outer shell, ball nose cutter need on curved surface walk few ten thousand lines program. Every time walk tool only towards down cut 0.15mm, spindle keep 8000 rpm high speed straight turn, a palm big curved surface has to fine mill on 45 minutes.

Drawing on only need mark a Ra0.8 surface roughness require, spindle rotate speed just has to deadly maintain at 12000 rpm run. Operator dare not take magnification knob open to 120%, born fear surface leave down one strip naked eye visible tool mark. Do simple hit M6 hole tap thread parts one day output 300 pieces, do curved surface mold parts one day output not arrive 10 pieces.

· Aluminum alloy rotate speed meter set as 100%

· S136 steel material every tooth feed amount adjust low 0.05mm

· 3mm ball nose cutter cut width fix at 0.1mm

· Tap M4 thread bottom hole use 3.3mm drill bit

Take one piece inner hexagon wrench go screw tight flat jaw vise screw, hand strength big a bit or small a bit, part press tight strength difference out dozen kilos. Use thickness 0.02mm feeler gauge go measure workpiece bottom surface have not have pad flat, skilled worker need spend away 40 seconds. Just enter trade new person do this action has to consume near 2 minutes.

Encounter with step non-standard piece, align hit indicator take parallelism adjust to 0.01mm within has to spend on 3 minutes. Machine tool at master manual align time completely stop down, electric meter still at walk word, spindle yet a bit not turn. Clamp one piece waste away 3 minutes, one day work 100 pieces calculate down machine at original place white white wait 300 minutes.

Change on with air pressure hydraulic fixture, press one under switch cylinder in 0.2 seconds inside provide 800 kilos clamp tight force take part deadly bite hold. Fixture base install on 800mm long worktable on, one time row open place on 6 pieces size same rough pieces. Master only need install one time piece, close on door press green start key, machine tool can one breath continuous work 40 minutes. Machine not stop turn straight output iron chips, one shift 12 hours deliver goods quantity according to proportion water rise boat high.

OEE & Output

Morning 8 o'clock workshop pull down power switch, LJ-855 main motor power on. Spindle rotate speed from 0 climb to 10000 revolutions need run 3 minutes warm up program. Winter workshop room temperature not arrive 10 degrees, lead screw inside lubricating oil very thick, machine head empty run friction resistance become big. Not do warm up, front 5 pieces aluminum parts hole distance size will drift out 0.015 millimeters.

Day shift quota 10 hours, total have 600 minutes can run time. Worker midway go two trips restroom consume away 15 minutes, noon holding lunchbox eat meal occupy away 40 minutes. Cutting fluid tank standard equip 200 liters, work to afternoon 3 o'clock liquid level alarm. Carrying 25 kilos plastic bucket add water mix cutting oil, stop down machine dry wait 12 minutes.

Equipment stop at there a bit iron chips all not output, report form inside call it unplanned stop machine. Every day take miscellaneous stop pause add together, spindle truly in cut iron time can gather enough 480 minutes just very not bad. 80% run rate in many processing factories is normal state.

· Every day clean chain plate chip conveyor iron dregs consume away 10 minutes

· Guideway oil pump oil tank fill VG68 machine oil consume away 3 minutes

· Operation panel on button input tool compensation data consume away 5 minutes

· Machine tool three color light light yellow light alarm eliminate consume away 8 minutes

Program set feed speed is 1500 mm/min. Day shift master feel sound pierce ear, casually take panel on feed magnification knob adjust to 80%. Tool actual run up speed drop to 1200 mm/min. Theoretically run finish a face mill operation need 4 minutes, panel knob one turn, consume time quietly pull long to 5 minutes.

Spindle rotate speed magnification similarly is adjust low to 90%. Tungsten steel blade every tooth feed amount become small, iron chips thickness from 0.1 millimeters drop to 0.08 millimeters. One day work 100 pieces job, in rotate speed and feed be discount run circumstance under, get off work count quantity only have 85 pieces.

Calculate a sum account can look clear one day time lose. Process one piece 150x100mm aluminum outer shell, tool cutting need 8 minutes, manual open close door load unload material 2 minutes.

Whole day theoretically use 600 minutes divide by 10 minutes single piece consume time, capacity table on writing 60 pieces. Take table inside lose 100 minutes deduct away, machine tool spindle truly carry cutting load turn time left 500 minutes. Output qualified product quantity only have 50 pieces. Calculate out equipment run value stuck at 83.3%.

Workshop inside still have scrap rate come pull low output. Work one day do out 50 pieces, use go no-go gauge one by one test M6 thread. Have 2 pieces tap chip tooth, bottom hole inside stuck break drop high speed steel tap. Use spark machine hit away break tap electrode fee compared to aluminum rough blank even expensive, hit bad 2 pieces only can throw enter scrap basket.

Output number instant turn back 48. Machine and electricity fee spend away, processing time use away, output scrap product equals let LJ-855 front that more than one hour electric meter white turn. Three axis linear guideway wear and guideway oil consume all hit water float.

Program inside take G00 fast positioning height from 50 millimeters drop to 10 millimeters. Tool tip paste part upper surface fly past, single time action save down 0.5 seconds. A communication base station base need drill 40 holes, lift tool height drop down, single piece consume time vividly pick out 20 seconds.

Change tool point position towards workpiece above move. Spindle not need run back Z axis mechanical origin again go grab tool holder. Every time change tool Z axis stroke shrink short 200 millimeters. According to servo motor 36 m/min highest move speed calculate, back forth one trip save down nearly 1 second.

· 24 pieces tool magazine disc ahead of time prepare tool rotate find right position

· M08 cutting fluid water pump open with spindle rotate sync

· Air pressure set 6 kilos ensure loose tool cylinder 0.3 seconds push open

· Panel emergency stop button side magnification switch lock dead 100%

Night 8 o'clock night shift worker take over operate. Sleepiness float up time, take 15 kilos heavy vise change to pneumatic switch. Air pressure one push, 0.2 seconds clamp tight rough block. Load unload time from 2 minutes is forcibly press back 1 minute 30 seconds. Single piece total consume time from 10 minutes become 9 minutes 30 seconds.

6061 Aluminum Alloy Processing

6061-T6 state aluminum plate rough blank hardness at HB90 up down. Thickness 40mm aluminum block fix at worktable, spindle clamp one piece diameter 12mm 3 flute aluminum use tungsten steel milling cutter. Panel rotate speed meter value dial to 12000 rpm. Feed speed F value set as 3000 mm/min.

Tool cut enter rough blank instant, every minute peel leave nearly 500 cubic centimeters metal. Three flute milling cutter chip space compared to four flute tool extra out 30%. Aluminum chips in tool slot inside roll not will serious squeeze friction produce extremely high heat.

Mistake take process steel parts 4 flute tool go cut, not arrive 10 seconds high temperature will let aluminum chips become soft turn sticky. Aluminum paste stick at tool blade surface meet cold solidify, knot become thickness 0.2 millimeters hard block built-up edge.

· Cutting eat tool depth press in 15mm inside, full blade cutting increase chip removal burden

· Tool rake angle at grinding wheel machine polish to 15 degrees, blade edge keep razor same sharp

· Chip removal slot send go surface polish, roughness value reach Ra0.2

· Spindle load meter needle at down tool cut enter point jump to 65% scale again return drop

Milling cutter stick on aluminum block run sound dull. Originally drawing require process surface reach Ra1.6 smoothness, aluminum part surface is pull out one strip strip 0.05 millimeters deep rough groove. Scrap one piece 150x100mm base, material fee single piece lose nearly 20 yuan.

Operator use plum blossom wrench loose open ER32 collet take out stick tool milling cutter. Take go diamond grinding wheel machine on manual polish drop attach aluminum block consume 5 minutes. Newly install tool run Z axis tool setter height set, spend away 1 minute. Single day happen 5 times stick tool fault, machine stop turn exceed half hour.

Emulsion fluid in this processing link consume amount extremely big. Cut aluminum parts not use pure cutting oil, according to 8% volume proportion mix tap water blend. Machine tool own bring water pump provide pressure value in 2 kilos up down. Water column flush at every minute 12000 revolutions tool holder side, liquid drop is strong centrifugal force instant towards outside throw fly.

Tool tip actual contact arrive cooling water drop extremely few. Bottom hole deep reach 30 millimeters blind hole, water column pressure not enough enter not go, drill out aluminum piece fragments completely discharge not out. Temperature soar break 400 degrees, diameter 5 millimeters high speed steel twist drill bit at hole bottom twist fracture.

· Add install 20 bar pressure level high pressure center output water water pump

· Spray water hole copper pipe bend, water column fall point distance tool tip control in 10 millimeters inside

· Liquid tank internal add install cold water machine maintain 22 to 25 degrees Celsius interval

· Draw water pump filter net mesh number increase to 100 mesh, intercept tiny suspend aluminum powder

Carry pressure water flow from spindle internal pierce pass tool center hole hole spray shoot down come. 30 kilos physical water pressure like wash car water gun direct attack hole bottom. Broken aluminum chips is water flow forcefully reverse push flush out hole outside, single root drill bit continuous drill hole quantity from 300 pieces jump ascend to 800 pieces.

Process 5G communication cavity outer shell, wall thickness most thin side edge size only 1.2 millimeters. Feed speed run to 4000 mm/min, tool towards aluminum wall side surface exert about 15 kilos lateral cutting push force. Thin wall receive force happen 0.08 millimeters elastic bend deformation.

Take outer diameter micrometer measure, size compared to drawing marked tolerance upper limit big out 0.05 millimeters. Machine tool lead screw positioning accuracy can do arrive 0.005 millimeters inside, aluminum part physical receive force deformation take equipment mechanical accuracy hard vividly swallow drop.

Need pull back tolerance size, program inside add one tool 0.1 millimeters margin fine repair. Rotate speed meter drop to 8000 rpm, feed speed put slow to 1000 mm/min. Rely extremely small cutting force again go lightly scrape drop surface thin thin one layer aluminum skin.

Drawing on add one pass fine repair path, single piece spindle consume time pull long 1 minute 20 seconds. Arrange production plan sheet writing daily output 100 pieces, extra scrape one layer skin extra consume nearly 2 hours equipment carry electricity run time.

· Rough processing finish add loose open flat jaw vise action release material internal stress

· Adopt vacuum suction cup replace old flat jaw vise, receive force contact area extra out 80%

· Thin wall area modify software cutting path, climb milling reduce machine tool vibration

· Milling cutter collet expose overhang length take caliper stuck at tool diameter 3 times inside

6061 aluminum block internal store have residual stress. Mill drop surface 30% metal volume, originally flat fit bottom surface towards up happen physical warp. 0.1 millimeters bottom surface warp degree let back pass lock screw assembly operation completely stuck dead install not enter.

Workshop worker take rubber hammer hit aluminum part side surface, rely ear listen sound dull or crisp judge clamp tight degree. Hit strength rely hand feeling control, use force deviate big surface leave down 0.2 millimeters deep hammer mark pit. Hit deviate light, aluminum block in high speed cutting inside fly out, hit towards machine tool sheet metal protection door.

Change on a piece length width 600x400mm custom vacuum suction cup base. Connect on vacuum pump power, negative pressure meter pointer stop at -85 kPa scale. Part bottom with suction cup grid fit, few seconds draw empty air. Atmospheric pressure force aluminum plate deadly press on machine tool worktable surface on.

Abandon screw hexagon screw lock tight action, table surface on all flat no clamp jaw block road. Face milling cutter one tool from left end scrape to right end, tool path midway no need lift high Z axis evade vise fixture. Software inside processing path walk tool total length shrink short 15%, single piece consume time hard vividly pick out 45 seconds.

Whole day cutting peel off aluminum chips total weight over hundred kilos. Regular spiral chip conveyor turn one circle bring not away few pieces hair shape fine broken aluminum wire. Long strip shape curl aluminum chips wrap dead at chip conveyor tail part motor shaft on, more wrap more tight until thermal relay emit smoke trip cut electricity.

· Change install pitch 31.75mm chain plate type chip conveyor, chain plate gap less than 1.5 millimeters

· Output water port water pipe end add strong magnetic separator absorb extremely few impurities

· Stop machine take shovel clean water tank bottom deposit white aluminum powder mud slurry

· Take high pressure air gun clean X axis guideway telescopic protection cover overlap gap

Clean block dead chip conveyor serious drag slow whole day progress. Two name operators press stop machine tool red light, take carry hook iron stick go water tank inside dig out big mass aluminum wire. Spend away 40 minutes take motor bearing on aluminum wire one point point cut break clean clean. Machine tool CNC panel on display single hour processing output become zero.

Keep aluminum part surface emit bright physical gloss degree, cutting fluid inside absolutely cannot mix enter iron powder go flush aluminum part surface. Tiny iron powder in aluminum surface scrape out 0.01 millimeters fine mark, send go electroplate factory do anodize oxidation treatment will precipitate out black spot. Water tank inside filter cotton board must keep two days flush wash once frequency.

Inquiry Tips

Parameter & Compare Price

Machine tool base extra widen 150 millimeters, machine body weight will happen change. Market on sell 13 ten thousand machine weigh 4.5 tons, sell 16 ten thousand use Meehanite high strength cast iron, weigh 5.2 tons. This extra out 700 kilos cast iron material fee need 6000 yuan.

Spindle box inside bearing pull open buy sell price difference. Taiwan Royal 8000rpm belt spindle leave factory price at 8500 yuan up down. Change on Sweden SKF or Japan NSK P4 level ceramic ball bearing, buyer need extra dig out 4500 yuan.

Cutting strength look spindle motor big small. Regular machine install 7.5kW servo motor, torque 48Nm. Add 3200 yuan can change to 11kW, torque 70Nm motor. Process 45 number steel time, rough turn link can save down 20% time.

Displacement accuracy all rely ball screw thick thin. Original factory equip 32mm thick, 12mm lead Taiwan HIWIN lead screw. Add 5500 yuan can change 40mm thick, 16mm lead Japan THK C3 level lead screw.

· THK C3 level: positioning error 0.008mm

· HIWIN C5 level: positioning error 0.015mm

· Pitch detect: every meter hit 300 points

X/Y/Z three directions guideway also have particulars. 45mm wide roller linear guideway compared to ordinary ball linear guideway extra bear 30% weight. Specify Germany Rexroth brand roller linear guideway, compared to use domestic goods expensive 1.2 ten thousand yuan.

System process speed manage process part surface smooth degree. FANUC 0i-MF Plus has Type 1 and Type 5 two versions. Type 1 one time can pre-read 200 program blocks, Type 5 only can read 40, two units system price difference 1.5 ten thousand yuan.

Buy Mitsubishi M80A system need pay attention screen size. 8.4 inch is ordinary screen, 10.4 inch own bring 3D process trajectory simulate picture. Single change this piece big screen and match motherboard, factory extra spend 2800 yuan cost.

Tool magazine hold tool quantity and change tool hand material use also divide three six nine grades. Install 24 pieces tool mechanical hand, ordinary cam box use is cast iron. Change to Taiwan OKADA or GIFU brand, single set quote price 1.4 ten thousand yuan, change tool action stable at 1.8 seconds.

· Umbrella type tool magazine: change tool spend 5.5 seconds

· Tool holder universal size: BT40

· Pull stud receive force bear degree: 1000kgf

80% machine own bring 250W water pump, water pressure only 0.2MPa. Bring spindle center output water 20Bar high pressure filter water tank, need add money 8500 yuan just can install on.

Discharge iron chips machine style decide clean need how long. Ordinary caterpillar chip conveyor sell 2500 yuan, bring magnetic scraper double layer chip conveyor sell 5200 yuan. Cut cast iron time, magnetic scraper every day help you save down 2 hours sweep iron dregs effort.

Machine tool outer shell iron skin thickness and bake paint craft also have doorway. 1.5mm thick cold roll steel plate cutting time easy buzz buzz ring. Use 2.0mm thick steel plate plus electrostatic powder spray coat, single unit outer shell extra out 1800 yuan.

Guideway pump oil frequency with wear speed hook up. Every time pump 3cc machine oil volume pump easy make dirty cutting fluid. Extra spend 3500 yuan install a set pneumatic butter device, every year save down 1200 yuan buy machine oil expense.

Buy tool setter and measure probe need separately calculate money. Renishaw OMP40-2 probe need 2.4 ten thousand yuan, TS27R tool setter 8000 yuan. Install on probe after, first piece find coordinate from 15 minutes shrink short to 2 minutes.

Electric box inside install not install air conditioner temperature difference very big. Ordinary plastic fan carry not live workshop 40℃ high temperature. Spend 1200 yuan install a 300W industrial air conditioner, can take FANUC system motherboard heat stop machine probability drop down 45%.

Air source filter net manage spindle hole clean degree. Ordinary piece filter net hole is 5 micrometers. Japan SMC brand 0.01 micrometers two stage remove water filter sell 650 yuan. Install on after spindle stuck tool fault less 80%.

Machine tool pad iron material price difference can have ten times. Load bear 2 tons ordinary cast iron pad iron is not want money. Spend 480 yuan buy 6 sets load bear 5 tons anti-vibration rubber pad iron, heavy cutting time vibration pattern depth can press in 0.003mm inside.

Additional Fees

A machine LJ-855 pack good size roughly is 2.8 meters long, 2.2 meters wide, 2.4 meters high, must find 13 meters long flatbed truck to pull.

Cross province highway transport according to mileage calculate fee. From Guangdong Dongguan send goods to Jiangsu Suzhou, 1400 kilometers journey, single trip transport fee roughly in 6500 yuan to 7500 yuan up down.

Equipment arrive factory area big gate, logistics driver is not care unload goods. Buyer has to own go outside intersection call a 25 tons truck crane take machine tool unload down.

Crane master output truck one time start step price is 800 yuan. If workshop doorway too narrow need take equipment move to ground mouse trailer on one point point push enter, every extra spend one hour just need extra add 300 yuan shift fee.

Factory building ground thickness manage machine open move time shake not shake. Factory side give construction drawing on mark clear, place machine concrete layer must towards down dig at least 300 millimeters deep.

Find construction team newly beat foundation, dig pit, tie 12 number thread steel bar, pour C30 label cement, one machine position civil work material and manual fee in 4000 yuan early.

Cement pour finish cannot immediately put machine, need wait on 15 to 20 days curing period. Have people for rush delivery date ahead of time enter field, foundation not dry thorough happen settlement, machine tool level degree run drift 0.05 millimeters.

Buy machine give cable wire usually only 5 meters long. Workshop main power electric box if distance far, has to own go hardware store pull a root 3x16+1x10 square national standard red copper cable, one meter need sell 45 yuan.

Machine tool spindle loose tight tool all rely compressed air push against. Single buy one unit exhaust volume 0.6 cubic meters, gas storage tank volume 150 liters screw type air compressor, match on cold dryer, this set air source pack price need 6800 yuan.

Factory inside voltage not stable still has to equip a 15KVA three phase dry type transformer. Buy one unit bring pure copper coil stabilize voltage transformer cabinet, purchase expense will extra out 2200 yuan.

This unit transformer every month even if only empty turn standby, also will consume away roughly 40 degrees electricity, according to industrial use electricity 1.2 yuan one degree calculate, also is a sum run not drop expense.

Gather complete table inside this set open work kit, finance just has to again approve down 7030 yuan budget. This still not calculate on various shape milling cutters.

Bump on process stainless steel this kind hard material, still has to prepare on 5 boxes tungsten steel milling blade. One box 10 pieces pack Hitachi or Mitsubishi blade, buy down need spend away roughly 1400 yuan.

Factory home install master ascend door is not not want money. Contract inside writing free collect debug fee, but master buy high speed rail ticket and stay hotel money has to buyer output.

· Master ascend door hit level, install protection cover, trial cut out a qualified part, most fast need toss 2 days.

· Night give master arrange express hotel, plus every day 150 yuan business trip meal allowance.

· This one trip human feeling and travel spend fundamentally in 1200 yuan up down.

· Boss require master extra stay 3 days teach factory inside apprentice memorize code, every day need according to rule stuff 300 yuan hard work fee.

Quote sheet on number still have include tax and not include tax difference amount. Sales quote a 14 ten thousand naked price, that is not want invoice private account trade number.

Walk public account issue 13% value added tax special invoice, sell price will towards up float 8% to 10%. Issue invoice price will become 15.2 ten thousand, extra out 1.2 ten thousand yuan cash flow press in tax amount inside.

Computer on draw picture program software need dig out money buy. Install a set genuine Mastercam 2024 three axis milling module, agent quote price in 3.5 ten thousand yuan.

Small processing shop in order to save money will go find people in computer on install a set decipher version UG software. Spend 80 bucks find a understand trade college student install on just can read drawing output program.

Machine open move after every day all at towards outside dig out money. Water tank inside fill full 200 liters add water dilute cutting fluid, summer workshop temperature high, every separate 40 days just will stink grow green hair.

Invite environment protect company dispatch pump feces truck come pull away this 200 liters waste fluid treat. According to every ton 3000 yuan danger waste treat fee calculate, single time clean need dig out 600 yuan.

Spindle on belt one year half to two years just will lengthen slip. Change three roots Japan Mitsuboshi brand tooth type belt, link manual bring material need give repair worker settle drop 850 yuan.

Electric box behind heat dissipate sponge net every month all is oil mud block dead. Spend 25 yuan buy one roll 2 meters long dustproof cotton own cut a piece change on, can save down two three thousand bucks motherboard over heat repair fee.

After-sales Promise

Outer shell cast iron part and sheet metal literal word guarantee period is 1 year. FANUC or Mitsubishi electric box motherboard and servo amplifier, machine tool factory take goods time own bring 2 years to 3 years quality guarantee period.

Buy sell both sides easy at system guarantee repair time on pull tear. Part contract sheet take whole machine guarantee repair unified write become 1 year, take system extra out 1 year guarantee repair period wipe flat. 18th month drive burn destroy, buy side has to according to original price 7500 yuan extra plus 600 yuan manual fee own expense buy one change on.

Spindle guarantee repair separate calculate a sum separate account. Factory home give belt spindle open out free guarantee repair condition is 10000 hours or is 12 months inside, with first arrive time calculate. Operator hit wrong code take milling cutter hit smash at spindle on, spindle taper hole deflection exceed 0.01 millimeters, repair spindle money not belong factory home output.

“Operate mistake happen hit machine lose accuracy, spindle return factory change bearing 4500 yuan fee by buy side settle clear, repair come back delay 6 days time full amount own negative.”

Stop machine one day bill very easy take calculator knock out. Receive outside send order processing shop, one machine one hour output 80 yuan to 120 yuan processing fee. Stop machine 24 hours, one day less 2000 yuan flow water, deliver goods late face 500 yuan start step exceed time fine.

Oral promise call call arrive, fall to paper surface on look time effect require. Province inside buyer get 24 hours inside repair worker ascend door word slip. Cross province send goods separate far, paper surface on take ascend door time put wide to 48 hours, remote area write clear 72 hours inside arrive field.

· Report repair after 2 hours inside, factory inside after-sales dial telephone communicate troubleshoot fault.

· Telephone inside teach press down 3 reset codes no react, customer service back stage generate 1 piece dispatch worker sheet.

· Repair worker sit high speed rail bring 5 kilos tool bag ascend door, single trip high speed rail ticket reimburse 150 yuan.

Change burn bad 24V power line not collect consume material money. Have several small factories after-sales return receipt sheet leave tail money opening, require buy side according to every kilometer 1.5 yuan unit price pay repair car gasoline fee.

Take new accessory speed look sell side at local have not have rent warehouse. Z axis hold brake motor burn, local warehouse prepare new piece, repair worker ride electric bicycle half hour take piece install on, whole factory delay half day time.

Surround three provinces not rent down 500 square meters above spare part turnover warehouse, repair machine piece all rely Guangdong Dongguan factory area send SF Express. Mail one 15 kilos heavy servo motor walk aviation piece collect 120 yuan, buy side dry stare eye wait on 2 days just get express piece.

“Buy side need verify sell side at Jiangsu, Zhejiang, Shanghai region set not set spare part turnover warehouse, warehouse inside has to regular prepare FANUC drive module and HIWIN guideway slider.”

Machine every day run full half year, lead screw inside steel ball appear 0.005 millimeters wear. Big factory after-sales sheet inside write clear full 6 months give 1 time maintain. Repair worker carry two buckets 18 liters pack clean agent ascend door, work 4 hours take water tank bottom 20 centimeters thick iron mud shovel out.

Work full one year half machine tool, three axis drop tool position happen run drift. Repair worker take come a set 25 ten thousand yuan Renishaw XL-80 laser interferometer, frame at worktable on give three axis newly hit one pass laser.

· X axis walk full stroke 800 millimeters distance, every separate 20 millimeters shoot one time laser point.

· Computer calculate out actual walk 799.98 millimeters, difference amount is 0.02 millimeters.

· Repair worker take 0.02 millimeters compensate parameter knock enter control panel complete align.

Buy side find outside measure company ascend door hit one time laser, market on quote price sheet according to axis collect money, hit finish XYZ three axis need pay 2500 yuan to 3000 yuan labor fee.

Control spindle and tool magazine action PLC program will update version. Leave factory time delay time less set 0.2 seconds, tool magazine grab tool appear stuck. Repair worker take a 16GB U disk insert at electric box interface on, spend 5 minutes copy enter 30MB big small patch package take fault clear drop.

Full 1 year whole machine guarantee repair period arrive period, repair worker enter factory bright mark price collect output field fee. Own expense repair machine manual fee according to day settle, Yangtze River Delta this side repair quote price at every day 400 yuan to 600 yuan up down float.