Beijing JINGDIAO In-machine Measurement and
Intelligent Modification Technology
Beijing JINGDIAO In-machine Measurement and Intelligent Modification Technology
How to achieve the micron-level accuracy machining stably and efficiently? The first is to select a high-accuracy high-performance CNC machine, the second is to eliminate all deviations to the most available extent that would affect the machining accuracy.
Just as the JINGDIAO high-accuracy high-speed 5-axis machining centers, we buy it and acquire the high dynamic-performance and low-vibration machine tools.
But how to measure and compensate the deviations precisely and quickly is still a big challenge.
First of all, let’s look through the deviations impacting the process accuracy:
Workpiece origin deviation, workpiece raw allowance and in-process allowance, etc.
Tool dimensional deviation, tool profile deviation, tool wear, etc.
Axial center deviation of rotary table of 5-axis machine caused by changes of ambient temperature, machining depth deviation caused by spindle growth, etc.
Workpiece Orgin Deviation
Tool Size Deviation
Spindle Growth
Workpiece Orgin Deviation
Tool Size Deviation
Spindle Growth
In view of the above deviations, although users adopt a variety of advanced detection means to measure and compensate it, such as In-machine probe supported by MDI (manual data input) function, the In-machine laser tool calibrator, off-line CMM, and etc., but the out-of-tolerance problems often happen in micron-level processing.
The reason is that the current measuring and compensating solutions are so simple and wholly reliant on manual operations, such as manual alignment by dial indicator, manual probing points definition and data input by MDI functions.
For instance, for the complexed 3D shaped workpiece, it is almost impossible to find the accurate work origin by In-machine probing based on MDI.
The IMIM technology developed by Beijing JINGDIAO solves this problem thoroughly.
Beijing JINGDIAO IMIM Technology
What is the IMIM? In-machine Measurement and Intelligent Modification.
The measurement and compensation of all available deviations are programmed in CAM software, for example, probing points distribution, probing direction definition, compensation mode, etc.
Combine the measuring and compensation programs and NC programs into one and output to NC control system of JINGDIAO machine tools.
The above mix programs drive machine tools to complete In-machine measurement and compensation to the available deviations automatically and efficiently.
The final products’ accuracy can be inspected by IMIM, and result display on the controller screen for operator’s reference.
The following figure illustrates the whole process.
The IMIM system of Beijing JINGDIAO has the following characteristics:
Taking the extended instruction set G100 of JINGDIAO CNC system as the application interface, 424 G100 instructions are provided to achieve 409 measurement functions.
These functions and instructions include: sensor calibration, measurement sampling, data management, deviation calculation, CAM calculation, compensation calculation and so on.
The deviation calculation mode has obtained the authoritative certification of International Standards Organization PTB.
The final machining results are displayed in the form of measurement deviation cloud map and data list.
PTB Certification
Report on CNC System
Report on CAM Software
PTB Certification
Report on CNC System
Report on CAM Software
The IMIM system can measure and compensate the following deviations:
Workpiece clamping position, clamping attitude, surface margin, size and shape and position tolerance between the blank and the process (including: flatness, parallelism, inclination, perpendicularity, position, roundness, cylindricity, concentricity, coaxiality, etc.), 3D curve deformation compensation, 3D surface deformation compensation, virtual point detection compensation, detection element evaluation report output, cloud image display, etc.
Machining tool diameter, length deviation detection compensation, tool 3D contour deviation detection compensation, tool runout detection, tool wear detection.
5-axis machine tool rotating axis center detection and compensation, spindle growth detection and compensation, etc.
Surface Allowance Measurement
Tool Profile Measurement
Rotation Axis Center Measurement
Surface Allowance Measurement
Tool Profile Measurement
Rotation Axis Center Measurement
GRU400T Beijing JINGDIAO precision 5-axis high-speed machining center, configured with IMIM system, can stably and efficiently achieve ±2.5µm 5-axis special accuracy in simultaneous machining.
Application
As shown in Figures below, this is an insert block of die casting mold of an automobile engine cylinder. The brown and blue features have been processed by a 3-axis machine tool first. Due to the negative angle and 9:1 length-diameter ratio of cutting tools, the gray portion needs to be processed on a 5-axis machine tool, like GRU400T.
3D Model
Raw Workpiece from 3-axis machine
3D Model
Raw Workpiece from 3-axis machine
Because of the complex and irregular shape of the raw workpiece, it is almost impossible to define the accurate work origin by manual dial indicator or In-machine probing based on MDI.
With the support of the IMIM, GRU400T automatically and efficiently completed the above processing. The specific methods are as follows:
Firstly, the measuring programs were written and edited in JINGDIAO CAM software -- SurfMill 9.5, as shown in the figure below:
Detection points were placed on the top blue surface of the workpiece to measure and compensate the deviation Δz in Z-axis direction, the angle deviation Δa in A-axis direction and Δb in B-axis direction;
Detection points were placed on green feature on the side of the workpiece to measure and compensate the deviation Δc in C-axis direction;
Detection points were placed on the yellow surface in the middle cavity to measure and compensate the deviation Δx and Δy in the X-axis and Y-axis direction.
Secondly, the mix programs including measure and compensation programs were automatically executed on the GRU400T. The CNC system of GRU400T automatically calculates the origin deviation △X, △Y, △Z, and the rotation deviation △a, △b, △c around the X, Y and Z axes. These data are saved in the G54.4 (P1) of the CNC system to complete the position compensation of the workpiece, as shown in the figure below:
Measurement in JINGDIAO Machine —— JDGRU400T
Measurement in JINGDIAO Machine —— JDGRU400T
Origin Deviation in G54.4 (P1)
Measurement in JINGDIAO Machine —— JDGRU400T
Measurement in JINGDIAO Machine —— JDGRU400T
Origin Deviation in G54.4 (P1)
Finally, execute the machining program, after machining, the completed workpiece was detected directly on the machine. The 3D contour accuracy was displayed on the controller screen, the result was 3.2μm -- 6.4μm.
Report on CNC System
Report on CNC System
As a result of this processing, not only the tolerances in shape and surface are safely maintained, but also each individually manufactured insert can be used in any die casting mold. The quality of the end product is very uniform and service replacement is extremely easy and fast.
Vote for IMIM
