At present, CNC flame and plasma cutting machines have been widely popularized in China's industrial enterprises. The CNC cutting machines produced by domestic CNC cutting machine manufacturers have gradually matured and stabilized in terms of machine tool design and manufacturing level. However, in the case of the same hardware structure and manufacturing level of CNC cutting machine, due to the lack of CNC cutting software technology, the CNC cutting machine generally has the problems of low cutting production efficiency and serious waste of steel and consumables during the use process. several aspects:
1. The numerical control system is unstable: when users purchase the CNC cutting machine to select the CNC system, they blindly pursue the high configuration of the civil computer, select the Windows system, the high-frequency CPU and the large hard disk, ignoring the stability of the industrial CNC system. Due to the high main frequency CPU and large hard disk power, the heat is high, especially in the summer, the internal heating and overheating of the CNC system, the CNC system and the cutting machine can not work normally, and the industrial fan is used to wind-cool the numerical control system. In addition, the high-frequency CPU must be equipped with a fan, and the fan is easy to wear, the life is limited, and the CPU and the motherboard are easily damaged. The vibration of the hard disk damages the track and is susceptible to viruses, which may cause instability of the numerical control system, resulting in stagnant cutting production.
2. No nesting software is used: When purchasing CNC cutting machine, there is no purchase of optimized nesting software, just use CAD software and NC conversion software to draw and NC cut files, or call the parts library in CNC system, in CNC system Manually programming the DXF or NC file on the DXF or NC file, the partial cutting, so that the CNC cutting machine is waiting for the idle state of the programming nest most of the time, greatly reducing the production efficiency of the CNC cutting machine, and at the same time, due to the partial cutting of the steel plate, a large number of The residual material in the corners or the remaining steel leads to a serious waste of steel.
3. Automatic cutting is not possible: There is no automatic cutting process and cutting parameter database on the CNC system. The cutting workers can only adjust and control the piercing process, cutting speed and corner acceleration and deceleration by hand through experience and eye observation. And automatic cutting, the production efficiency of CNC cutting machine can not be effectively played.
4. Single-piece cutting and hot-cutting deformation: each part must be pre-heated and perforated and cut one by one. It does not use high-efficiency cutting methods such as co-edge, edge-to-edge, bridge-cutting, etc., which is not only prone to thermal cutting deformation, but also flame preheating. Perforation time-consuming consumables, low cutting efficiency, and serious waste of plasma cutting nozzle.
5. Cutting quality problems: such as the part cutting point over burning scar, the corner of the part is over-burned, the cutting surface is excessively inclined, the circular part is deformed or not closed when cutting the circular part, the cutting large part has serious error, the cutting deformation is not closed, etc. Serious cutting quality problems.
The following introduces the new CNC cutting concept and technical method, through the CNC cutting software technology, realize the "full-time cutting, automatic cutting, high-efficiency cutting, high-quality cutting and high nesting rate cutting of CNC cutting machine !"
Full time cutting:
Traditional cutting method: use CAD drawing software and NC conversion software to draw DXF parts drawing into NC file, then carry out manual nesting programming on CNC system, or call parts in CNC system parts library, and set on CNC system. Material programming, so that most of the CNC cutting machine (more than 50%) time is waiting for the idle state of the CNC system for nesting programming, CNC cutting machine can not do full-time cutting, cutting efficiency is greatly reduced (more than 50%).
Full-time cutting method: FastCAM Company advocates and promotes full-time cutting production methods. Using FastCAM optimized nesting programming software on the computer to complete the whole board nesting, residual board nesting and efficient cutting nesting programming, CNC cutting machine only accepts the CNC cutting program provided by the nesting software, so that the CNC cutting machine is used all the time. Cutting. Change the traditional programming nesting on the CNC system, so that the CNC cutting machine idles waiting for the cutting production mode of the programming nesting, effectively improving the cutting efficiency of the CNC cutting machine.
Economic Benefits: The biggest economic benefit brought by “full-time cutting†is to improve the production efficiency of CNC cutting machine, and to improve the cutting production capacity of the original CNC cutting machine into the cutting production capacity of two or even three CNC cutting machines. .
Figure 1: Full-board cutting for full-time cutting
Figure 2: Residual sheet nesting for full-time cutting
Automatic cutting:
Traditional cutting method: relying on the cutting experience of the cutting worker, manual operation through the close cooperation of the hand and the eye, adjusting and controlling the preheating, perforation, cutting, idle and normal cutting acceleration and deceleration and corner acceleration and deceleration of the CNC cutting process, etc. .
The real problem: the company can't guarantee that every cutting worker has rich cutting experience and good operational skills, and can't guarantee that the working attitude and physical condition of each cutting worker are always in the best or good state, so it can't be maintained. Or to ensure the cutting efficiency and cutting quality of CNC cutting machine. Only by writing rich cutting experience and cutting process into the numerical control system, workers can use the automatic cutting method to eliminate the interference of human factors to ensure the cutting efficiency and cutting quality of the CNC cutting machine.
Automatic cutting method: FastCAM company advocates and promotes automatic cutting production methods. FastCAM's FastCNC CNC system for flame and plasma CNC cutting provides users with a complete automatic perforation and automatic cutting process. By calling the plate cutting parameter library and automatic cutting logic, the automatic cutting function key is used to realize automatic cutting, including automatic Automatic acceleration and deceleration of perforation, idle and cutting speed, and automatic acceleration and deceleration of corner and arc cutting. The biggest advantage of the automatic cutting method is that the perfect cutting process and rich cutting experience are integrated in the numerical control system, which effectively compensates for the lack of experience of the cutting workers and the fluctuation of physical strength and emotion, and can effectively improve and ensure the cutting efficiency of the CNC cutting machine. And cutting quality.
Figure 3: Automatic cutting process database
Figure 4: Automatic cutting plate parameter database
It is particularly worth pointing out that the flame plate perforation technology is difficult and the cutting process is complicated. FastCNC numerical control system provides the unique automatic flame-punching cutting logic database of the thick plate and the automatic intelligent judgment function of the blind hole. It can realize the automatic perforation of the perforation of the flame thick plate, automatically determine the blind hole of the open hole, realize the edge cutting, effectively reduce and avoid the flame. The number of slab perforations.
Efficient cutting:
Traditional cutting method: Whether it is flame cutting or plasma cutting, the main reason for low cutting efficiency is that each part must be preheated and perforated, and must be cut one by one. Flame cutting preheating perforation time-consuming consumables, cutting efficiency is low, plasma cutting cutting nozzle The waste is wasted.
Efficient cutting methods: FastCAM promotes and promotes efficient cutting production methods. FastCAM optimized nesting software provides high-efficiency cutting method programming methods such as co-edge, continuous cutting, borrowing, bridging, etc. on the basis of the whole board nesting and residual board nesting, effectively reducing preheating perforation, reducing repeated cutting and preventing heat. Cutting deformation, which effectively improves cutting efficiency, saves steel and consumables, especially saves plasma supplies.
At the same time, the FastCNC numerical control system provides a part nesting graphic library and a blind hole automatic judgment and edge cutting function for efficient cutting, saving drawing programming time, realizing the whole board nesting and co-edge and continuous cutting, effectively reducing Preheating the perforation, changing the traditional one-by-one part cutting, the cutting method of each part perforation, effectively improving the cutting efficiency.
Figure 5: Flame efficient cutting, using the common edge technology,
 Figure 6: High-efficiency plasma cutting, using bridging and cutting technology, the whole plate is cut only three times!
Economic Benefits: High-efficiency cutting production can reduce the number of perforations by 70-80%, saving 50% of cutting nozzles and consumables every year.
Figure 7: Parts nesting and cutting graphics library
Figure 8: Wireless remote control
Wireless remote control technology directly improves the efficiency of CNC cutting production
FastCNC numerical control system provides a unique and convenient wireless remote control, which effectively improves the operation efficiency of steel plate correction, cutting point positioning, changing cutting nozzle, cutting and corner acceleration and deceleration, avoiding operators in steel plates, cutting guns and CNC Running back and forth between the systems, one can easily control the operation of the cutting machine. Compared with touch screen technology, the wireless touch technology is to improve or replace the keyboard operation, but it is limited to the numerical control system, and the wireless remote control technology not only improves and replaces the operation of the keyboard, but also gets rid of the limitation of the numerical control system, directly in the cutting machine. And the operation on the steel, effectively improve the operation efficiency of the cutting process such as steel plate correction, cutting point positioning perforation, cutting acceleration and deceleration, changing the cutting nozzle, etc., to avoid the workers going back and forth, effectively improving the cutting efficiency.
High quality cutting:
Several common CNC cutting quality problems:
1. After using the CNC cutting machine for a period of time, the rack and pinion wear causes a back gap, which causes the cutting parts to not close and the machine to shake up and down, which seriously affects the cutting quality and the service life of the machine.
2. There are widespread cutting quality problems such as corner over-burning and excessively curved cutting surfaces in plasma cutting.
3. In the plasma cutting, the quality problem of the burnt point of the cut-off point is common, especially in the cutting of stainless steel, it is difficult to repair due to over-burning scar, which causes processing difficulties and waste of steel.
4. When cutting large-sized parts, cutting errors occur, resulting in the parts not being cut and causing waste. Or when cutting a part consisting of a large number of small entities, quality problems such as up and down shaking, non-closing, deformation, etc. of the CNC cutting machine occur, resulting in reduced cutting quality and shortened machine life.
5. When the CNC cutting machine cuts round or curved parts, the cutting is not closed, or the circle or arc is severely deformed.
High quality cutting process:
The FastCNC CNC system provides a complete system of cutting technology to ensure high-quality cutting of CNC cutting machines.
1. Provide automatic compensation and cutting process for rack and pinion clearance, effectively solve the problem of cutting quality in back gap and prolong the service life of cutting machine.
2. Provide the setting and cutting process of corner and arc automatic acceleration and deceleration under different plate thickness and different cutting modes, effectively solve the problem of corner overburning and arc cutting face tilting.
3. Provide a variety of methods for introducing lead line compensation to effectively solve the quality problem of scarring at the point of overcutting. According to the needs of welding or machining, the user can choose to introduce a small amount of over-burning, leaving a small tail, or an approximately smooth cutting point.
4. Provide the pre-processing function of the CNC program, and fit the small line segment compression in the DXF arc to a smooth curve, so that the CNC cutting machine can cut smoothly, effectively avoiding the up and down shaking of the machine tool and improving the cutting quality.
5. Provide linear interpolation operation and circular interpolation operation to ensure that the circular part is not deformed.
High nesting rate cutting:
The traditional cutting method: reading the DXF or NC file of the part on the numerical control system or calling the parts in the CNC system parts library, using the manual or matrix method to carry out nesting and programming on the numerical control system, and then performing localization on the numerical control cutting machine. Cutting. The usual result of manual nesting and partial cutting is that a large area of ​​irregular steel remains in the middle of the steel sheet, and accurate nesting and cutting can no longer be performed, resulting in a large amount of surplus steel and steel waste.
High nesting rate cutting method: FastCAM company advocates and promotes high nesting rate cutting production mode. Using FastCAM optimization nesting software, the whole board nesting and residual material board nesting, and then the whole board cutting and residual material board cutting, effectively avoiding the generation and waste of the residual material of the steel plate, so that the remaining steel plate can be fully reused.
In short, in the case of the machine tool structure, hardware configuration and manufacturing level of the CNC cutting machine are almost the same or similar, it is completely possible to achieve "full-time cutting, automatic" through software technology, especially supporting FastCAM optimized nesting software and FastCNC numerical control system. Cutting, high-efficiency cutting, high-quality cutting and high nesting rate cutting, further improve the cutting efficiency and cutting quality of CNC cutting machine, and effectively save steel and consumables.
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