Basic knowledge of coordinate boring machine processing
**1. What types of coordinate boring machines can be classified according to structural features? Brief description of its processing content and accuracy range.**
A: Coordinate boring machines can be categorized into two main types based on their structural design: vertical and horizontal. The vertical type is further divided into single-column and double-column models, while the horizontal type includes vertical-bed and horizontal-bed configurations. These machines are primarily used for precision hole drilling, where high accuracy in both dimensions and positioning is essential. They are also capable of performing precise milling, scribing, and measurement tasks. The typical positioning accuracy for hole machining ranges from 0.004 to 0.01 mm, and the surface roughness of the machined surfaces is usually below Ra 0.8 μm.
**2. What are the common positioning system devices for coordinate boring machines? What are the basic components of these devices?**
A: Common positioning systems in coordinate boring machines include mechanical, optical, electromagnetic, photoelectric, and laser-based systems. These systems generally consist of three key components: a reference element (such as a scale or ruler), a signal transmission device (often using light or electrical signals), and a reading device that interprets the data. These components work together to provide accurate and repeatable positioning during machining operations.
**3. What is the positioning principle and characteristics of the precision line ruler and screen reader?**
A: The precision line ruler and screen reader operate by fixing the ruler on the workbench, which serves as a length reference. The ruler’s markings are magnified through an optical system and projected onto a screen. As the worktable moves, the image of the ruler moves accordingly, allowing the reticle on the screen to measure the exact distance traveled. This system offers high accuracy, non-contact operation, and long-term stability, making it ideal for high-precision applications.
**4. Describe the positioning principle of the induction synchronizer positioning system.**
A: The induction synchronizer works based on electromagnetic induction. It consists of a fixed scale on the machine bed and a movable slide. When the slide moves relative to the scale, induced electromotive forces are generated in the coils. These signals are processed electronically and converted into digital coordinates, which are then displayed on a screen. This system provides high precision and reliability, especially in environments where mechanical wear could affect other positioning methods.
**5. Describe the process features of boring holes on a coordinate boring machine. What effect do these process features have on the selection of the main geometric parameters of the tool?**
A: Boring holes on a coordinate boring machine requires high dimensional and positional accuracy, with fine surface finishes. To achieve this, the cutting depth and feed rate are kept small, and multiple passes are often needed. As a result, the tool geometry must be optimized—increasing the rake and relief angles, setting the main cutting edge at 90°, and adjusting the nose radius appropriately. These adjustments help maintain tool sharpness and reduce vibration, ensuring consistent and accurate results.
**6. What are the special tools for coordinate boring machines? What is its main function?**
A: Special tools for coordinate boring machines are divided into three categories: alignment tools such as dial gauges and optical positioners, clamping tools like adjustable boring bars and chucks, and scribing tools including scribers and planers. These tools assist in precise positioning, secure tool holding, and accurate marking, all of which are crucial for maintaining high-quality machining outcomes.
**7. How to use an optical positioner?**
A: After installing the optical positioner, place the angle iron on the reference plane, ensuring it aligns with the workpiece. Adjust the table so that the reticle on the angle iron matches the one on the optical positioner. Then, adjust the screen reader until the image enters a double-reticle view. By combining coarse and fine readings, you can precisely position the workpiece according to the required dimensions.
**8. When processing parts on a coordinate boring machine, what should be noted to reduce errors caused by thermal deformation?**
A: To minimize thermal deformation errors, ensure the working environment is maintained at a constant temperature (20±1°C). Pre-condition the workpiece by placing it in a controlled room for at least 8 hours before machining. Allow the machine to idle until it reaches thermal equilibrium before starting. Separate roughing, semi-finishing, and finishing operations with at least 8 hours between them. Limit cutting depth and feed rate, and avoid excessive movement around the machine to prevent temperature fluctuations.
**9. What accuracy can be achieved in the milling of precision planes on a coordinate boring machine, and what should be considered during milling?**
A: Precision milling on a coordinate boring machine can achieve a surface roughness of less than Ra 0.8 μm, flatness error of 0.004–0.012 mm, and positional accuracy up to 0.01 mm. During milling, ensure the cutting allowance is not too large (1–3 mm), keep the cutter sharp, and secure the tool in the spindle. Lock the main shaft sleeve and box to prevent movement, clamp the workpiece properly, and avoid using the precision screw for positioning during milling to prevent uneven wear.
**10. What are the main factors affecting the accuracy of hole pitch in coordinate boring machine machining, and how can they be addressed?**
A: Key factors include positioning errors, low accuracy of the precision screw, misalignment of optical lenses, poor machine geometry, low rigidity, and thermal deformation. Solutions involve selecting appropriate positioning methods, improving reference accuracy, recalibrating optical systems, repairing the machine, optimizing tool setup, and controlling temperature. Ensuring thermal stability and proper machine calibration are essential for achieving consistent and accurate results.
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