However, it is not always a wise idea to integrate different machining technologies into one machine tool. When choosing the processing technology, we should also consider the specific processing needs of the enterprise itself.
In the machining case, the goal is to find a machining method of armature shaft that can reduce turning cost, clamping cost and improve productivity. Manufacturers hope to achieve this goal by integrating turning and hobbing into special hobbing machines.
Although machine tool manufacturers are designing a machine tool that can roll bars and perform some simple turning operations, customers are faced with the demand of workpiece processing with increasingly large dimensional variables and complex geometric shapes (such as various contours and knurling), which requires increasing the number of moving shafts and tools used for turning. This new requirement will soon lead to the separation of turning and hobbing. Compared with the development of longitudinal turning and fly-cutter dry hobbing, the technical scheme of adding multiple turning axes to a bar hobbing machine is too expensive.
Flying cutter dry hobbing is developed as a "by-product" of integrated process flow. Flying cutter dry hobbing can replace centerless grinding (which is also a cost-effective machining method) and armature shaft center grinding process with high machining cost. Flying cutter dry hobbing can also eliminate the inherent shortcomings of using damping center frame when hobbing the ground armature shaft, and its processing cycle time is the shortest (almost no idle time).
If the end user distributes the machining time equally to different axes of a multi-axis machining machine tool, he may begin to seriously consider whether a compound machining machine tool integrating various technologies should be adopted. For example, when machining a large gear on a two-axis multifunctional machine tool, the process sequence is: turning the first end face → turning the second end face → hobbing → deburring the drum wheel. This process allocation method can ensure that the main motion axis rarely idles. Only by using two independent machining spindles in balance can we give full play to the advantages of cutting/hobbing center of lathe.
Process integration is not always an economical and feasible solution. In the case of machining armature shaft, it is impossible to realize an important premise of adopting compound machining machine tool: reasonable distribution of different machining processes. In the hobbing unit of compound machine tool, it is inevitable that the spindle will not idle. Because the end user can realize a short idle time of the spindle when machining the armature shaft through a single process, composite machining has become too expensive compared with a highly automated single process.
Process integration may not greatly shorten the processing cycle. When verifying the feasibility of compound processing, its main function is determined by the production time and its importance, as well as the specific logistics mode adopted by the enterprise. The advantages and disadvantages of compound machining depend on specific workpieces and specific enterprises, and it is necessary to carefully analyze and comprehensively weigh the advantages and disadvantages of single machining and multifunctional machining or compound machining.
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