1. Pre-Machining Preparation
① Design Drawings: Use CAD software to construct 3D models or 2D drawings, clearly defining dimensions, tolerances, and other essential specifications.
② Material Matching: Select materials from metals, plastics, wood, etc., considering strength requirements and machining feasibility. For example, aluminum alloys are commonly used as the base material for precision parts.
③ Tool Configuration: Select carbide end mills or coated drills based on the cutting task. The tip radius and chip flute design directly affect the surface finish.
④ CAM Programming: Generate G-code using software, setting parameters such as cutting speed (800-1500 rpm), feed rate (0.1-0.3 mm/tooth), etc., to generate the optimal toolpath.
2. Machining Execution Flow
① Workpiece Fixing: Use vacuum chucks or hydraulic vises to ensure positioning accuracy ≤0.02 mm, eliminating machining vibration sources.
② Automatic Tool Setting: Use a laser tool setter to calibrate the tool's Z-axis zero point, controlling the error within ±0.005 mm.
③ Layered Cutting: A 0.5mm allowance is left during rough machining, and the spindle power is maintained at 80% load; during finishing, PCD tools are switched for mirror cutting, achieving an Ra value of 0.8μm.
④ Online Inspection: A probe system is installed to monitor dimensional deviations in real time; complex curved surfaces are inspected using a coordinate measuring machine (CMM).
3. Post-Processing
① Edge Treatment: Micron-level burrs are removed using a magnetic polishing machine; internal cavities and channels are deburred using electrolytic deburring.
② Strengthening Treatment: Anodizing (15-25μm) or PVD coating is selected based on the service environment; aerospace titanium parts require an additional shot peening process.
③ Cleaning and Packaging: After ultrasonic cleaning, the parts are vacuum-sealed with vapor phase rust-preventive paper; precision components must be stored in a constant temperature and humidity environment.
