Vertical- milling machines CNC metal differ vertical position spindle that moves up and down. They allow to carry out a complex of operations for roughing, semi-finishing and finishing of metals, wood and other materials. With their help, you can easily produce parts of various shapes in small, medium and large series.
The CNC vertical milling machine consists of a movable cross part, a vertically moving headstock and a stationary column.
Some models are distinguished by the fact that they have a console that provides movement of the cross table from top to bottom. By the direction of movement of the shaft and the console, you can determine the types of cutters used and the specialization of the machine as a whole. Additional equipment of milling and processing centers with rotary tables with the addition of 1-2 controlled axes is done in order to expand the technological capabilities of this equipment.
CNC vertical milling machines for metal are of great interest to medium and large production shops, because they allow as soon as possible to process the surfaces of large quantities of products of a sufficiently complex profile. A vertical milling machine with DRO makes it possible to sharpen, drill, countersink horizontal and vertical surfaces of parts, among which are:
- gears;
- molds of different sizes;
- stamped blanks; spiral figures;
- corners and grooves of various sizes.
Taps and cutters are used for threading. The presence of a system for quick automatic tool change allows you to consistently perform all kinds of transitions on the vertical milling center. The necessary tooling is located in the drum or chain magazine, as well as in the turret.
CNC vertical milling machine for metal: advantages
CNC control allows you to simplify and speed up operations associated with the processing of complex parts. From the operator of a vertical milling machine with DRO, you only need to select and configure the necessary program, set the processing coordinates, and the machine will do the main process. Only minor intervention is required to set up the workpiece and control the processes.
CNC vertical milling machines for metal are widely used in many Moscow and Russian machine-building industries.
In the event of malfunctions due to accidents, manual control can be carried out. For the manufacture of stationary parts and tables of the machine, cast iron of the highest degree of rigidity and resistance to vibration is used. In this case, the workpiece is fed into the cutting area automatically.
Milling equipment is a whole class of devices that are used for processing flat surfaces, cutting slots and teeth, creating profiles and drilling holes. With the help of such equipment, you can perform work on wood or polymer material, as well as for various metals.
The installation of the cutter is carried out at a certain angle, and vertical milling machines are widely used in manufacturing for processing automotive parts, furniture assembly items, building products and other items. Such devices are distinguished by the convenience of design, performance and versatility of use.
The device and purpose of the vertical milling machine
Structurally, vertical milling machines are divided into two categories:
- Console machines. They are equipped with a working surface, which is rigidly fixed on the body and can move along the guides and vertical slide relative to the spindle.
- Machines without console. With their help, you can process large-sized workpieces, the process is performed at high speed. The structure adopts automatic guiding system, the spindle features high-speed structure and runs vertically.
Vertical milling machine for metal
Milling metal work implies high strength in the side of the drilling, therefore, machines designed for such actions are distinguished by carbide parts and high electric drive power.
The basis is a frame that receives load-bearing loads; in a vertical projection, a spindle is located on the axis. Also, metalworking machines in most cases have a console, workpiece clamps and a feed box for the speed of moving the part. Some models do not have a console, a number of machines are equipped with CNC: they usually cost more.
Vertical milling machine for wood
For the processing of wooden blanks, special machines can be used, which are compact, good performance, low price and functionality.
In such devices, the spindle is mounted vertically, in some models it has a movable structure for tilting the workpiece. Replacement of a mill is carried out without the special tool. Most woodworking machines have an electric motor and require a 220 or 380 V mains connection.
Modern models may differ in the speed of milling, the maximum size of the workpiece, the quality of the processing of the wooden surface. Wood saws can also be used when working with plastic, polyamide, plastic and other light materials.
CNC vertical milling machines
Many models are equipped with a CNC - a mechanism that makes it possible to control the main processes in real time and provides the most accurate and convenient control.
Such machines have the following advantages:
- relatively small dimensions;
- high quality processing, excellent accuracy;
- productivity, the possibility of high-speed processing of materials;
- ease of setup;
- unpretentiousness in service.
Models and specifications of vertical milling machines
When choosing equipment, first of all, it is necessary to pay attention to the design, power, dimensions and additional working options of the machine. On the modern market you can find vertical milling devices of various types, including in the small and medium price segment. Vertical milling machines are produced by both domestic and foreign companies.
Machine 6r10
The 6p10 machine is a universal type milling machine, which is equipped with a swivel head and is suitable for small-scale and single production of parts. The model is distinguished by a low noise level in operation, good wear resistance of rubbing elements, and optimal accuracy indicators. The finished surface of the workpiece after processing corresponds to the roughness index V6.
Machine 6r11
In appearance, the 6r11E machine refers to cantilever structures. It is used for processing steel billets, cast iron, various types of metals, as well as hard plastics. The equipment allows you to give the workpiece a surface with a roughness up to V5, can work at different speeds at the right angle. Good power and a competent drive system ensures high performance results.
Machine 6r12
Model 6p12 is used for processing metal and cast iron blanks mainly with the help of end and face mills, creating grooves, flat edges, frames and corners. The machine is suitable for creating curved parts, processing non-standard shaped surfaces. The device is characterized by high power and rigidity, due to which high-speed steel cutters can also be used.
Machine 6r13
The 6p13 device also has a cantilever structure, is equipped with a copier for working with non-standard workpieces and a swivel spindle head. The model is suitable for the production of piece copies and small-scale production of products. Finished parts conform to accuracy class H.
Machine 6t12
Model 6t12 has a powerful electric motor, a large area of the working surface, can work in manual, inching and automatic mode. On such equipment, almost any kind of materials and workpieces can be processed.
Machine VM 127
Machine BM 127 is used to work with metal and steel parts, as well as cast iron elements. The equipment is used both in the environment of private craftsmen and professional workshops; it allows processing planes, grooves, gear, slotted products. The work cycle can be automatic or semi-automatic.
Machine 6m13p
The machine 6m13p belongs to the category of electrical devices of increased accuracy, it can work with a high-speed cutter of high rigidity. The equipment is used for small and large-scale production, allows you to process parts by drilling and milling, create gear rings and wheels.
Machine 6n11
Equipment 6n11 has a working surface of 25 by 100 cm, is equipped with a 4.5 kW main drive motor, and is used for processing non-ferrous and ferrous metals.
Distinctive features of the machine 6n11:
- high accuracy;
- performance;
- ease of maintenance.
Machine FSS 400
FSS 400 machines are suitable for individual and serial use. With their help, you can carry out along and counter milling, automatically lower the part and ensure high quality results. The control of such a machine is possible from a special pendant control.
Machine FSS 450 mr
FSS 450 mr devices manufactured in Belarus are suitable for working with cutters of various shapes and purposes. They can be used to process steel, alloys and pure metals, cast iron. Most often, such machines are used in small-scale and medium-scale production.
Where and at what price to buy a vertical milling machine?
You can buy such equipment on the Internet or from direct suppliers. The cost is formed depending on the brand, functionality and purpose. So, vertical milling devices for wood cost 50-90 thousand, for metal - up to 200-250 thousand, and universal models cost up to 300 thousand rubles.
Manufacturers and suppliers of vertical milling equipment
The most popular machines on the market are HAAS, Hannsa, SMD, TAKISAWA, DMTG, Triumph, as well as Simbirsk equipment. Companies such as Abamet, kmt-stanki.ru or VseInstrumenty.ru offer favorable conditions for bulk purchases and cooperate with workshops in various cities and regions of the country.
Modern vertical milling machines are demonstrated at the annual exhibition "".
A traditional type vertical milling machine or a CNC machining center are among professionals considered indispensable equipment for processing complex-profile parts.
1
In the described installations for metal, the spindle has a vertical arrangement, the feed in them is carried out along three axes, and the design and operation of the drive are almost the same as in vertical drilling units.
The vertical milling machine uses different types of cutters to process metal workpieces. Most often, shaped, angular, cylindrical and end tools are used.
The console milling machine for metal works at a high level of quality with the following products:
- gear wheels;
- planes (vertical and horizontal);
- all kinds of products made of cast iron, different grades of steel alloys, non-ferrous metals;
- any types of molds and models of stamps;
- frames and grooves;
- keyways.
And a modern CNC cantilever machining center makes it possible to work with more "serious" structures that cannot be made by other metalworking methods (stamping, casting, cutting, and so on).
Standard technological process on milling units used at domestic enterprises (for example, or), includes three stages:
- procurement;
- directly milling;
- finishing.
The last of these steps is usually done manually. Finishing parts after milling them on machines is considered the most time-consuming procedure, which significantly increases the cost of processing products. There is only one way to reduce costs - by providing high-quality processing of workpieces of simple and complex shapes.
This quality can be guaranteed by an efficient and reliable milling machine (CNC machining center or traditional vertical machine). Console milling equipment of our days is recommended for small-scale and serial production of complex parts, since in this case the production process is fully justified from an economic point of view.
The consoleless machine (see photo) differs from the console machine in that its cross table is mounted on a bed fixed type. At the same time, its surface makes movements exclusively in the transverse or longitudinal direction. A cantilever vertical unit is often unable to mill heavy and large products, but cantilever machines can handle them without problems. In addition, feeds for machines without a console are made by motors, in which the choice of the number of revolutions (gears) is stepless.
2
The vertical milling machine, due to its sufficient rigidity and high power of the drives installed on it, makes it possible to work with a carbide-type tool. The layout of the units described in the article and shown in the photo, the kinematic scheme of their work are the same for most Russian and foreign machines.
The feed and speed boxes, which determine the number of machine gears, are located in the frame, in which the spindle head is also installed. It rotates in a vertical plane, and the spindle axis can be turned in relation to the plane of the table to perform work operations at the required angle.
The working table is characterized by movement (longitudinal) along the slide guides. The process of spindle rotation is the main movement of the console milling machine. The skids of the unit move (in the transverse direction) along the cantilever rails. The console also moves a given distance in the vertical direction along the guides of the bed.
The described kinematic scheme of movement of different units of aggregates for milling allows you to choose one of three directions for feeding the workpieces to be processed. And with the help of a gearbox and gears, you can select the modes of milling products.
The fixing of parts on conventional console-milling machine equipment is carried out by means of various special and universal devices (ordinary machine vices, squares, clamps, prisms, etc.). The CNC machining center (see photo), of course, has a more complex design, and the kinematic scheme of movement, feeding and fastening of workpieces in it has a number of differences. But we will talk about these modern units below.
3
Dividing heads are of great importance for the operation of the machines under consideration. Console and non-cantilever milling unit with a vertical spindle for metal will not be able to do their job without these devices. Such heads are necessary for turning (performed periodically) milled products to the desired angle, as well as for their constant movement (in fact, rotation) during helical grooving.
The design of the dividing head is simple, it has the following elements:
- rotary drum;
- frame;
- spindle with center.
The spindle has a special thread that allows you to install a leash or a cam chuck on it. The spindle rotation scheme is also simple - a single-thread worm engages with a toothed worm wheel, this design is driven by a control lever (handle).
We won't give detailed description gearboxes of vertical milling equipment, talk about the features of feeding workpieces on different machines and transmitting movement to them, since they can be different for each installation. The main thing here is that all these boxes, providing the necessary feeds and gears, guarantee the efficiency of the milling work.
4
Both a "fancy" CNC machining center (machine) and a conventional metal milling machine use certain cutters to process workpieces of various types. Horizontal planes, for example, are processed with a face tool, which is characterized by smooth operation in any mode from the speeds and gears selected using the gearbox, as well as rigid fixation in the spindle assembly.
Inclined planes are machined with end and end mills, while vertical ones are usually milled with an end tool. It is also used for processing various ledges. The vertical milling machine also allows you to mill various grooves with high quality:
- end mills - keyway closed and rectangular grooves;
- single-angle - "dovetail".
Toothed cylindrical wheels are processed with special finger cutters.
Today, CNC vertical milling cantilever center is often used for milling complex profile surfaces. But also standard equipment makes it possible to work with such blanks, which include different kinds sections - concave, convex, rectilinear. In this case, it is important to correctly draw up a diagram and an equation to obtain a product with a complex surface with given roughness indicators.
The specified equation for machining cylindrical convex and concave surfaces takes into account the radius of the cutter used and the surface being machined, as well as:
- feed amount;
- high-rise scallop, which is formed during milling;
- angle of rotation of the axis of the working tool.
Note that the most significant influence on the level of product roughness is exerted by the angle of rotation of the cutter and the amount of feed. The remaining indicators have little effect on the quality of surface treatment.
5
The traditional vertical milling machine is different from CNC machines. program management the level of automation for controlling the speed of the working tool and the movement of the working surface during milling. In companies engaged in serial production products with a curved complex surface, not a simple machine is always used, but a modern machine (machining center) for CNC metal.
The presented photos show that such equipment has a relatively compact size. This allows you to use almost any machining center as part of an existing production line. The machine integrates into it without any problems and performs its tasks.
Console milling machines with CNC for metal can have the same number of gears as standard installations, their design (boxes, units, mechanisms, and so on) is identical to that of conventional machines. But at the same time, they are always more automated and require minimal human intervention in their work.
The machining center, which allows you to perform milling work on metal, has a spindle located on its own slide. Due to this, the working device moves around its axis and vertically. The number of gears the machine can have is different, its gearboxes provide different feed rates. The center, as a rule, allows solving multiple metalworking tasks (threading, countersinking, facing, reaming, and others).
The clamping table of such CNC machines is in most cases horizontal, and the spindle is, of course, vertical. The movement of the table along the X and Y axes occurs along the bed (along its guides), but in the vertical direction it moves through the movement of the headstock (it is called the spindle head). There is also such an arrangement of centers, in which the movement of the table along all axes becomes possible due to the movement of the specified headstock.
On machines with numerical control, the change of cutters is carried out in just a fraction of a second, their gearboxes and feeds are designed to ensure high-speed milling complex products, and the machine itself is engaged in the choice of the necessary gears. All these features determine the demand for CNC centers, on which a number of various work operations are carried out with one processing cycle.
Let us single out one more advantage of machines with program control. It lies in the fact that the unit is easy to equip with additional equipment. It is allowed to mount more efficient gearboxes, additional units and special devices, which significantly expand technical capabilities vertical milling machine.
The 6t12 machine is a unit for performing vertical milling work, which has been produced on the territory of the Gorky Combine since the mid-80s of the last century. The design of the 6t12 machine strongly resembles the products of the P line, but the main difference lies in greater uniformity.
Main technical indicators and advantages
Despite the fact that the presented model has been produced in Russia for more than 30 years, this does not prevent the machine from still creating good competition with more modern models. There are several reasons for this.
So, for example, the minimum deviation of the location of the treated surface and its shape is explained by the fact that the bearing elements have a higher rigidity. Also, scraper guides with a compatible profile are used to increase rigidity.
The spindle bearings used by the vertical milling machine are equipped with paired angular contact and double row roller bearings, which are characterized by increased load capacity. This contributes to the performance of power cutting with high quality processing. If stock lubrication is used and the structural elements themselves are at the correct tension, bearing life will be longer than the amount of time before an overhaul. To determine the class of bearings, you must familiarize yourself with the technical data sheet.
In the screw pair, the backlash is eliminated with the help of a specially provided movable nut, which is included in the axial clearance control mechanism. Bimetallic materials are used in the production of all running nuts. Parts subject to more accelerated wear at friction points are produced using steel with a surface HDTV hardening. Gears are strengthened in exactly the same way of heat treatment. As a result, the equipment works for a long period of time without the need for service. And when it does come time to do it, the cost of spare parts will be minimal.
The composition of a centralized efficient lubrication system includes two groups. The first includes lubrication for the mechanisms in the console, and the second - the oil supply system for the mechanisms that are located in the frame. Each of them, respectively, provides a separate power supply from its own plunger-type pump.
If the machine 6t12 1 is used every day in two shifts, the overhaul cycle will be at least 11 years. But to achieve such indicators is possible only on the condition that the user complies with the operational requirements and mainly mills steel.
Increased drive power reserve, a wide range of speeds and feeds, minimal system compliance - all this contributes to the high-performance processing of metal blanks, which include plates made of STM or materials of increased strength.
Achieving additional time savings becomes possible thanks to the electromechanical method of fixing the tool. The table itself moves in automatic cycles. The revolutions are switched without sequential passage of steps.
Components
Considering the main characteristics, the basic design advantages of this model of equipment are the presence of the following components:
- a device for slowing down the feed rate (the machine uses a proportional scheme);
- a mechanism to protect the operator and others from getting metal chips;
- an electromagnetic type clutch that effectively brakes the spindle assembly in a horizontal plane;
- clutch to protect the electric motor of the main feed from overload;
- a device that allows you to adjust the gap in the screw pair (when performing feed in the longitudinal direction).
It is also worth noting that the fixation of working tools on this machine is carried out according to a mechanized principle. Thus, the manufacturer was able to achieve a significant reduction in the time required to process the metal workpiece.
Location of components
The above image shows the layout of all the components of the 6t12 machine. In total, the presented vertical machine used consists of such units and assemblies.
- Coolant pump start system.
- The system controls the direction in which the spindle rotates - right or left.
- Electric motor for table drive.
- Limb, the surface of which has a scale indicating the amount of feed.
- Mushroom for switching feed.
- Handle for moving the table in manual mode and vertical direction.
- A handle holding the sled against the console.
- A handle designed to control the operation of the longitudinal stroke of the table.
- Electric motor for spindle drive.
- Duplicate handle, including the longitudinal course of the table.
- Flywheel for moving the table in manual mode and in the transverse direction.
- Cams for turning off the system of longitudinal feed of the table in automatic mode.
- Crane for supplying coolant.
- Trigger keypad mounted on the front of the sled.
- Duplicate handle for engaging vertical or transverse gear.
- Switch for the workspace lighting system.
- Switch for the whole machine.
- Handle for selecting the spindle speed.
- Limb, the scale of which indicates the number of revolutions.
- Pointer for gearbox.
- Start button panel on the spindle box.
- Cams that automatically turn off the vertical feed of the table.
- Cams that automatically turn off the cross feed of the table.
- Handle, including vertical and transverse table feed.
Location of controls
The layout of all controls is shown in the image above. It is worth noting that the design that the equipment in question has is characterized by a convenient arrangement of buttons and other controls. This contributes to a quick transition to the required operations. Even a specialist with minimal practical experience, thanks to the comfortable placement of controls, will be able to intuitively understand the main list of functions.
How is the rotary head of the machine?
The image above shows the current drawing of the rotary head, which is used in the 6T12 machine. It is centered in an annular groove located in the neck of the frame, fixed with 4 bolts that enter into a 1-different groove of the frame flange.
The spindle consists of a two-bearing shaft, which is integrated into the sliding sleeve. Adjustment of axial play is reduced to the need to grind rings 4 and 3. Elimination of increased play in the front bearing becomes possible by tightening the nut and grinding ring 5. The owner is required to comply right order maintenance. To get rid of the radial play, which is one hundredth of a millimeter, a grinding of approximately 0.12 millimeters is required.
The spindle rotates through a pair of cylindrical and bevel wheels that are mounted in the head. The gears and bearings mounted in the swivel head are lubricated by a pump in the frame. bearings responsible for correct work mechanism of movement of the sleeve and rotation of the spindle - by injection.
Kinematic scheme
The main task kinematic scheme is that the owner understands how the main elements of the equipment interact and contact each other. The callouts include the number of gear teeth. The main movement is made possible by a flanged electric motor through a flexible coupling. The number of revolutions can be changed by moving three gear blocks along special splined shafts.
The feeds are driven by a flanged electric motor mounted in the console. Thanks to two three-ring blocks and a moving gear wheel, 18 different feeds are available, which are transmitted to the console via a ball safety clutch.
Obtaining accelerated movements becomes possible when the high-speed clutches are turned on, which rotates thanks to the intermediate gears from the electric feed motor. The main element of the entire design of the machine is the bed, on which the rest of the mechanisms and components are fixed. It is rigidly attached to the base with a set of pins.
Wiring diagram
A scan of the drawing of the electrical circuit is given in the figure above. The equipment is optimized for operation in a three-phase network with a voltage of 380 volts with alternating current with a frequency of 50 Hz. The control circuit operates under a voltage of 110 volts with alternating current. In the control circuits, the current is constant, they operate at a voltage of 65 volts. To service local lighting, a voltage of 24 volts is supplied.
Exploitation
To increase the efficiency of operation, each machine is equipped with a set of auxiliary circuits - bearings, slings, lubrication, kinematics, and so on. The rest of the guide includes electrical equipment. Here is a schematic diagram of the connection of electrical appliances, as well as a set of specifications for the selection of spare parts.
Based on the statistical data obtained during the long-term production of the machine, the manufacturer has compiled a list of wearing parts. For them, a separate drawing of each element is provided. Thanks to the unification, it becomes possible to use spare parts from other series of 6T machines, including 6T13.
Safety
As part of the work, it is necessary to adhere to general requirements safety technology. Each specialist must check the following working bodies:
- grounding;
- compliance of the voltage in the network with the one used by the machine;
- checking the brake, signal and push-button device for serviceability;
- checking the correct functioning of the blocking device;
- checking the health of the lubrication and cooling system;
- checking the condition of each hard stop that limits the movement of the calipers.
If any of the above elements is in poor technical condition, starting the electric motor is unacceptable. An initial diagnosis is required with further troubleshooting.
Vertical milling machines is one of the most common types of industrial machine tools. According to their design, mechanisms are divided into two types, console and non-console. Every kind is different technological capabilities, is made taking into account a certain technological orientation. The main task that is set for these mechanisms is to perform metalworking works of a wide profile. Considering the design features of this technique, it is possible to perform complex work with details in the horizontal and vertical planes, to bore the inner surfaces, to produce shaped surfaces. Milling machines with a vertical console are designed for processing products and workpieces with various kinds of cutting tools. As the main equipment on the machines, shaped, end and end mills are used. Technically, vertical milling devices allow drilling, marking and countersinking of workpieces.
Machine features
In some models that are used in production, there is no console as the main structural element. The case for vertical machines is equipped with a massive base, has increased strength and stability. The main components and assemblies are given additional rigidity, with the help of which high accuracy of processing is achieved when performing serial work. The head is also a gearbox, freely moving vertically in a certain range. Axial movement of the head is carried out together with the cartridge and sleeve. The versatility of machines of this design lies in the wide possibilities of changing the position of the head, the presence of additional equipment.
Performance production process, the quality of the performance of the terms of reference depends on the power of the electric motor and functionality. Desktop equipment, semi-professional industrial mechanisms, a number of other models are designed for different operating conditions. In each case, the device is ready to demonstrate its advantages, has necessary resource and technical parameters.
The presented samples are designed for factory use, used for work in repair shops. Each product meets the necessary safety standards, has sufficiently high accuracy parameters. Specifications presented machines meet high technological standards. Each model has the required electrical protection class.