Винты для обработки станков с ЧПУ: Master Precision для промышленного крепежа

cnc hobbing

В Промышленное производство, why do 98% of high-quality screw producers rely on CNC machine tool processing screws instead of traditional manual lathes? The answer lies in CNC’s ability to solve critical pain points—like inconsistent thread dimensions, slow production cycles, and high scrap rates—that plague manual methods. This article breaks down the full workflow, ключевые параметры, выбор инструмента, Контроль качества, and real-world applications of CNC screw processing, helping you achieve uniform, эффективный, and cost-effective screw production.

What Is CNC Machine Tool Processing Screws?

Винты для обработки станков с ЧПУ is an automated manufacturing process that uses Computer Numerical Control (Сжигание) lathes or machining centers to produce screws—critical fasteners used in machinery, Электроника, и строительство. Unlike manual processing (where operators manually adjust tool positions and cutting speeds), CNC systems follow pre-programmed G-code and M-code to control every step: from shaping the screw’s outer diameter to cutting precise threads.

Think of it as a “digital craftsman” for screws: it executes repetitive tasks with micron-level accuracy, ensuring every screw matches design specs (НАПРИМЕР., нить шаг, head shape) perfectly—even for high-volume production runs of 10,000+ единицы.

Full Workflow of CNC Machine Tool Processing Screws

CNC screw processing follows a linear, error-proof sequence—each step builds on the last to avoid defects. Below is the detailed workflow with actionable tips:

  1. Материал подготовка
  • Цель: Select raw materials that match the screw’s strength and corrosion resistance needs.
  • Общие материалы:
  • Углеродистая сталь (for general-purpose screws, НАПРИМЕР., ОТ 933 болты).
  • Нержавеющая сталь (304/316, for corrosion-resistant screws in medical/ marine applications).
  • Титановый сплав (for high-strength screws in aerospace).
  • Форма: Use metal bar stock (diameter 3mm–50mm) or wire—bar stock is ideal for thick screws, while wire suits thin, small screws.
  • Кончик: Dry materials at 80°C for 2 hours if stored in humid environments—moisture causes surface rust during machining.
  1. Зажим & Позиционирование
  • Процесс: Secure the raw material to the CNC lathe’s spindle chuck or collet.
  • Accuracy Requirement: Use a dial indicator to check runout (radial deviation) < 0.01mm—excess runout leads to uneven thread depth.
  • Solution for Long Materials: For bar stock longer than 300mm, use a tailstock center to support the free end (prevents bending during rotation).
  1. Выбор инструмента

The right tool determines thread quality and tool life. Use this table to match tools to screw types:

Screw FeatureRecommended Tool TypeКлючевое преимущество
Outer circle turningCarbide turning inserts (CCMT 09T304)Устойчивость к износу; handles cutting speeds up to 200 м/мин для стали.
Thread cutting (external)Indexable threading inserts (16IR 1.5 Iso)Quick tool change; uniform thread profile (60° included angle for metric screws).
Screw head shapingВысокоскоростная сталь (HSS) Конец мельницыSharp cutting edge; ideal for shaping hexagon or pan heads.
  1. Программирование с ЧПУ
  • Core Codes:
  • G76: Thread cutting cycle (sets pitch, глубина, and number of passes).
  • G01: Linear interpolation (moves tool to thread start position).
  • M03: Spindle rotation (clockwise for right-hand threads).
  • Example Program Snippet for M5×0.8mm Screw:
G00 X7 Z5; (Position tool above material)G76 P020060 Q0.005 R0.01; (Set thread quality: 2 passes, 60° angle, 0.005mm minimum cut)G76 X4.2 Z-15 P0.583 Q0.3 F0.8; (Cut thread: minor diameter 4.2mm, length 15mm, pitch 0.8mm)
  • Tool for Complex Screws: Use CAD/CAM software (НАПРИМЕР., Мастеркам) to generate programs for screws with non-standard threads (НАПРИМЕР., trapezoidal threads for lead screws).
  1. Симуляция & Trial Machining
  • Симуляция: Use the CNC system’s virtual simulation function to check for tool collisions (НАПРИМЕР., tool hitting chuck) or overcuts (excessive material removal).
  • Trial Run: Machine 1–2 test screws first. Осмотреть:
  • Thread pitch (use a thread gauge).
  • Внешний диаметр (use a micrometer).
  • Head flatness (use a surface plate and feeler gauge).
  • Корректирование: If thread depth is 0.05mm too shallow, increase the “P” value in G76 by 0.05mm.
  1. Formal Machining
  • Параметры резки: Optimize based on material (См. Таблицу ниже):
МатериалСкорость резки (м/мой)Скорость корма (мм/rev)Depth of Cut per Pass (мм)
Углеродистая сталь (45#)150–1800.15–0,20.2–0,3
Нержавеющая сталь (304)80–1200.1–0,150.15–0.25
Титановый сплав (TI-6AL-4V)50–800.08–0.120.1–0,2
  • Мониторинг: Listen for abnormal noises (НАПРИМЕР., squealing = tool wear) — replace tools if wear exceeds 0.1mm.
  1. Качественная проверка
  • Ключевые метрики & Инструменты:
  • Thread pitch: Thread plug gauge (for internal threads) or ring gauge (for external threads).
  • Точность размеров: Координировать измерительную машину (ШМ) — tolerance ±0.02mm for critical screws.
  • Шероховатость поверхности: Profilometer — Ra < 1.6 μm for visible screws; Раствор < 0.8 μm for precision machinery screws.
  • Sampling Rate: Осмотреть 5% of screws for small batches (100–500 единиц); 1% Для больших партий (10,000+ единицы).
  1. После лечения
  • Выслушивание: Use a nylon brush or tumbler (10 минуты) to remove burrs on thread roots (prevents hand injury during assembly).
  • Поверхностная обработка:
  • Цинковое покрытие (for carbon steel screws — improves corrosion resistance).
  • Пассивация (for stainless steel — enhances surface oxide layer).
  • Термическая обработка: For high-strength screws, quench and temper at 850°C (увеличивает прочность на растяжение до 800 MPA+).

ЧПУ против. Traditional Screw Processing: Критическое сравнение

Why switch to CNC? The table below highlights the gap in efficiency and quality:

АспектCNC Machine Tool ProcessingTraditional Manual Lathe
Скорость производства30–50 screws per hour (M5 size).8–12 screws per hour (M5 size).
Thread AccuracyPitch tolerance ±0.005mm; 99.5% последовательность.Pitch tolerance ±0.05mm; 85% последовательность.
Скорость лома<1% (simulation + trial run reduce errors).8–12% (operator error, износ инструмента).
Labor Requirement1 operator manages 2–3 CNC lathes.1 operator per lathe (full-time supervision).

Real-World Application Case: Aerospace Screw Manufacturing

  • Испытание: An aerospace firm needed titanium alloy screws (M8×1.25mm) с:
  • Tensile strength > 900 МПА.
  • Thread tolerance class 4h (strict for aircraft engine mounting).
  • Corrosion resistance to jet fuel.
  • CNC Solution:
  1. Материал: Titanium alloy Ti-6Al-4V bar stock (diameter 10mm).
  2. Инструменты: Carbide threading inserts (16IR 1.25 Iso) with TiAlN coating (resists high heat).
  3. Параметры: Скорость резки 60 м/мой, feed rate 0.1mm/rev, 8 thread passes.
  4. После лечения: Пассивация + термическая обработка (900° C гашение).
  • Результат:
  • Скорость лома выпала с 15% (традиционный) к 0.8%.
  • Production time per 1000 screws cut from 83 часы до 20 часы.
  • All screws passed aerospace industry testing (ASTM F568M standard).

Перспектива Yigu Technology

В Yigu Technology, Мы видим CNC machine tool processing screws as the foundation of reliable industrial fastening. Our CNC lathes (YG-2000 series) are optimized for screw production: they have auto-tool change systems (cut tool change time by 60%) and real-time thread quality monitoring (alerts for pitch deviations > 0.003мм). We’ve helped automotive clients cut screw production costs by 35% and aerospace firms achieve 4h thread tolerance consistently. As demand for micro-screws (М1–М3) grows, we’re integrating high-precision spindles (runout < 0.005мм) to support next-gen electronics manufacturing.

Часто задаваемые вопросы

  1. Q.: What’s the minimum screw size CNC machines can process?

А: Our standard CNC lathes handle screws as small as M1×0.25mm (diameter 1mm, pitch 0.25mm). For micro-screws (M0.5×0.1mm), we offer custom machines with ultra-fine collets (0.5мм диаметр) and high-frequency spindles (40,000 Rpm).

  1. Q.: How to reduce tool wear when processing stainless steel screws?

А: Use tools with TiAlN or diamond coatings (increase wear resistance by 2x). Также, apply cutting fluid (water-soluble for 304 сталь) to reduce friction—fluid flow rate should be > 5 L/мин.

  1. Q.: Can CNC process both metric and imperial screws?

А: Да! Our CNC systems support both metric (Iso) and imperial (UNC/UNF) thread standards. Just input the thread pitch (НАПРИМЕР., 0.8mm for metric M5, 0.0315” for imperial #10-32) in the G76 cycle—no hardware changes needed.

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