How to achieve high-precision control of multi-segment diameter and depth in Metal Cutting Machine tools

High-precision control solution for multi-stage variable diameter processing of metal cutting machine tools: step-by-step instructions + real-time correction, with precision reaching IT5 level

When processing complex structures such as stepped shafts and blind holes, machine tools are prone to dimensional deviations due to tool wear and thermal deformation. The following solutions can achieve precise control of multi-stage diameter and depth:

1. Compound programming and safety margin

Using G76/G83 compound cycle instructions, set multi-stage diameter (φ10-φ100mm) and depth (10-800mm) parameters at one time, and automatically generate transition fillets (R0.1-R1mm) and chamfers (C0.5-C2mm);

Preset tool compensation values (diameter +0.01mm, depth -0.005mm) during programming to leave margins for subsequent automatic corrections.

2. Online detection and dynamic compensation

The integrated contact probe can automatically detect the diameter every 5mm depth of processing. When the error exceeds ±0.005mm, the system will immediately correct the next tool compensation amount;

During deep hole processing, the chip removal fluid pressure sensor monitors the flow rate. When the flow rate changes by ≥15%, the spindle will be triggered to stop suddenly to prevent the tool from breaking and causing the size to be out of control.

3. Thermal error pre-reduction

The spindle is equipped with an infrared temperature measurement module to compensate for the diameter deviation caused by thermal expansion in real time (compensation accuracy 0.003mm/℃);

Perform 5 minutes of dry run preheating before processing to stabilize the temperature of the metal cutting machine tool before starting, and the first piece size fluctuation is reduced by 60%.

Measured data: In the processing of a hydraulic valve body, 5 sections of variable diameter holes within the full length of 300mm are processed, with a diameter tolerance of IT5 (φ25±0.008mm), depth consistency ≤0.01mm, and a first piece pass rate of more than 95%.