Innovative Five-axis Laser Processing Technology: Enabling Ultra-hard Tool Manufacturing with Natural Marble Base and Full Closed-loop System
In the field of precision tool processing,the fifth-generation five-axis laser processing equipment has redefined thestandards for ultra-hard material processing through the innovative integrationof natural marble substrates and intelligent control systems. This equipment,specially designed for PCD/CBD tools, has successfully broken through the dualbottlenecks of efficiency and precision in traditional processing methods. Ithas now become the upgrade choice for 3C electronic tool and automotive toolmanufacturers.
Core Technology Innovation
I. Ultra-Stable Structural Platform
The main frame is made of a whole piece ofnatural marble processed. With a thermal expansion coefficient of <0.002mm/m³ and a hardness value of >80HRC, a rigid platform with avibration attenuation rate of 92% is constructed. Compared with traditionalsteel structures, the deformation caused by temperature fluctuations is reducedby 67%, providing physical support for micro-micron-level processing.
II. Full-Closed-loop Motion System
• Linear axis equipped with linear motor +ball bearing guide rail combination, achieving a fast-moving speed of 120m/minwith a resolution of 0.1μm
• Dual rotational axes configured withdirect drive torque motor, with angular positioning accuracy of ±2 arc seconds
• Five-axis linkage equipped withHEIDENHAIN grating ruler, forming full-closed-loop feedback control. Thismotion system enables the equipment to maintain a roughness Ra < 0.05μm at the cutting edge when processing φ0.2mmmicro milling cutters.
III. Intelligent Processing Ecosystem
1. Online Monitoring Module: Integrating a12MP industrial camera and contact probe, it can obtain the tool profile datain the processing process in real time and automatically compensate for pathdeviations.
2. Smart Turntable System: Dual-armhigh-precision turntable supports continuous rotation of ±270°, and is combined with vacuum suctionfixtures to achieve unmanned processing.
3. Process Database: Supports directlyparsing and generating processing paths from CAD models.
Industry Application Breakthrough
This equipment has achieved a breakthroughin full-scale coverage processing from φ0.1mm microdrill bits to φ50mm face milling cutters. In theautomotive industry, it has successfully increased the processing efficiency ofPCD tools by 3.2 times compared to traditional EDM. The specific manifestationsare as follows:
• During the rough machining stage: Thelaser ablation rate reaches 15mm³/min, which is 5 timesfaster than wire cutting
• In the finishing processing stage:Through the independently developed pulse modulation technology, the edgecollapse is controlled within <2μm
• In composite processing: All 12 processesincluding roughing of helical grooves, contour finishing, and edge blunting canbe completed in a single setup. •
Technical Extension Advantages
• The adaptive processing system can handledifferent grades of materials (including De Beers CTM302, Element Six CBN100,etc.)
• The configured dust removal andpurification device ensures that the concentration of processing dust is lessthan 0.1mg/m³
• The equipped process simulation softwarecan predict more than 90% of processing defects
As the culmination of the fifth-generationlaser processing technology, this equipment can achieve surface integrity anddimensional consistency that surpass traditional processes for both themicro-cutting tools of smart phones and the huge milling blades of new energyvehicles. Click here to learn how to achieve a leap in tool processing qualitythrough equipment upgrades.