Application of the hottest 5-axis inspection in th

2022-08-12
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Application of 5-axis inspection in mold manufacturing process

in the mold manufacturing process, can the use of 5-axis inspection bring the same benefits in terms of measurement speed and accuracy

when measuring parts with various characteristics (such as components in the transmission system and complex hyperboloid parts, including wings, turbine blades and other parts), the use of 5-axis measuring head and probe measurement system can bring unexpected measurement results. For example, when measuring an aircraft engine part, the time it takes has been reduced from the original 46min to 4.5min, while the time required to detect the 12 valve seats and cylinder head guide holes of the car has been reduced from the original 30min to less than 3min. After seeing these test results, many mold manufacturers raised such a question: can the adoption of 5-axis test bring the same benefits to their company in terms of test speed and accuracy

the meaning of rapid detection

in order to answer this question, it is very important to first understand how to achieve rapid detection in actual production operations. The main limitation of using the ordinary 3-axis scanning measurement method is that in non Cartesian orbit measurement, any attempt to quickly move the large mass coordinate measuring machine (CMM) may lead to inertial errors due to acceleration and deceleration. Therefore, the only way to maintain the measurement accuracy is to reduce the detection speed

1. Advantages of 5-axis inspection

in 5-axis inspection, the key to saving time is to be able to overcome the above limitations. This technology uses a synchronized measuring head, and allows the measuring machine to move during the scanning process, allowing the measuring probe to move rapidly with the change of part geometry, so as not to bring dynamic errors. Therefore, in this case, CMM can move at a constant speed and measure at the same time without affecting the accuracy of measurement

the second advantage of using 5-axis detection is that its measurement accuracy is improved due to the use of a tip sensing measurement probe. Most mold manufacturers are familiar with the method of 5-axis machining, and also understand the benefits of using shorter tools

because the 5-axis machining machine tool can lower the machining head to the position of the part, and then make the tool aim at the direction of the workpiece surface, it is possible to achieve the above goals. In 3-axis machining, a longer tool must be used to reach the surface of the workpiece, so its measurement accuracy is low. Using the same method, the measurement of 5-axis inspection is very close to the surface of the part. This means that a shorter measuring probe can be used here, so the inspection accuracy obtained is relatively high

2. Application software

since the latest scanning technology needs to be adopted here, the successful application of 5-axis detection also requires the use of appropriate detection software/programs to support the use of new probes and verify that various geometric shapes required in the manufacturing process of major CMM coordinate measuring machines serve the construction and free shape of a national green and environmental friendly society (Figure)

the inspection program supporting probe detection is used to verify the geometry and free shape in the manufacturing process of major CMM coordinate measuring machines

over the years, we have gained quite rich experience in the production of mobile measuring arm systems. Therefore, the development of CMM 5-axis inspection has drawn a lot of valuable experience. Because the measuring arm has sensitive flexibility, and the measuring probe can constantly change their direction, these measuring devices can carry out multi axis detection, and the software supporting its inspection needs to be able to process the measured values detected by the probe. Similarly, the use of laser scanners on these measuring arms also requires appropriate software to process a large amount of data generated. This kind of measurement system can use 5-axis detection to process a large amount of measurement data obtained by CMM coordinate measuring machine

the development of the 5-axis inspection program also uses the relevant technology originally used to support 5-axis machining. At the same time, a similar program is also used to drive the 5-axis movement. Because the validated 5-axis simulation technology and anti-collision detection technology can be combined in the processing system, this new inspection software also draws a lot of experience from here. Similarly, computer models can also be used to simulate the machining process, so that a large number of universal CMM coordinate measuring machines have been developed to monitor the operation of the whole system, not just the probe movement around the parts. All this enables it to conduct a comprehensive inspection before running on the CMM, and conduct offline testing on the computer. Therefore, users can be sure that the inspection program will be able to operate safely and effectively, and there will be no collision between the technical talents of the national first-class experimental machine, resulting in the damage of the probe and parts

application of mold

whether the mold manufacturer can make great efforts is beyond the industry's premonition. Like complex aerospace and automotive parts manufacturers, it will depend on the size and complexity of the mold to obtain the same benefits from the 5-axis inspection method. For manufacturing large molds, especially mold manufacturers with deep cavities, more accurate measurement results can be obtained by using the 5-axis detection method because they can use shorter tip sensing probes. For small and simple mold manufacturers, the use of 3-axis CMM coordinate measuring machine can provide a more perfect and appropriate inspection report. However, with the different application fields, great changes may also occur. Therefore, at least 5-axis measurement technology should be investigated to determine whether it is possible to increase its measurement speed

for mold manufacturers who manufacture parts with complex design, and those enterprises that need special precision machining for the surface, using the 5-axis measurement system can obtain more measurement values, and its measurement speed is faster, so as to complete a more comprehensive inspection report for their customers. This inspection method is also particularly important for manufacturers who produce large molds and composite components, such as wind turbine generators or truck cockpits and baffles

overall inspection of molds

for enterprises that need to produce parts with undercut, adopting such a measurement tool also has a great advantage. Because the 3-axis CMM can only measure a single component in the mold, it cannot reach the undercut area for measurement after the whole mold is assembled. The 5-axis method can reach any measuring part of the mold, which is conducive to the company providing customers with a more comprehensive inspection report

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