The core technologies of precision machining in Dalian are mainly reflected in the following key areas, which together support high-precision and high-efficiency part manufacturing:

1、 High precision machine tools and numerical control systems

Precision Design and Manufacturing of Machine Tools

The structural rigidity, guide rail accuracy (such as static pressure guide rail and air floating guide rail), and spindle rotation accuracy (high-precision bearing technology) of machine tools are the foundation, and it is necessary to optimize the structure through finite element analysis to reduce thermal deformation and vibration.

Typical technologies: Liquid static pressure spindle (accuracy up to 0.1 μ m level), closed-loop control system with nanometer level grating scale feedback.

Progressiveness of Numerical Control System (CNC)

High resolution interpolation techniques (such as nanoscale interpolation), feedforward control, and error compensation algorithms (thermal deformation compensation, screw pitch error compensation) ensure the accuracy of motion trajectories.

Multi axis linkage control (such as five axis linkage) to achieve complex surface machining requires the use of tool radius compensation and head/turntable error correction techniques.

2、 Precision cutting tool technology

Tool materials and coatings

Superhard materials (diamond, cubic boron nitride CBN) are used for processing high hardness materials; Hard alloy coated cutting tools (such as TiAlN and DLC coatings) enhance wear resistance and surface quality.

Fine processing of tool edges (such as nanoscale polishing) reduces cutting stress concentration and lowers surface roughness during machining.

Tool structure design

For micro machining (such as micro holes with a diameter<0.1mm), integral hard alloy or diamond micro milling cutters are used, combined with high-precision tool holders (such as HSK-E32 tool holders, with a runout of ≤ 2 μ m).

The positioning accuracy of rotatable cutting tools (such as high-precision tool seat interfaces) and blade wear detection technology (such as acoustic emission monitoring) ensure machining consistency.

3、 Advanced processing techniques and methods

Micro lubrication and low-temperature processing

Minimum Quantity Lubrication (MQL) combined with vegetable oil-based lubricants to reduce cutting heat and tool wear; Low temperature processing (such as liquid nitrogen cooling) is used for difficult to process materials such as titanium alloys and high-temperature alloys to improve surface integrity.

Composite processing technology

Integrated milling grinding polishing process (such as five axis linked grinding machine) reduces clamping errors; The combination of electrical discharge machining (EDM) and ultrasonic vibration machining is used for complex cavity machining of hard materials.

Precision Grinding and Grinding

Ultra precision grinding machines (such as FANUC ROBNano α - Ni from Japan) use elastic spindles and online measurement to achieve mirror grinding (Ra<0.01 μ m); Magnetorheological polishing (MRF) and ion beam polishing (IBP) are used for nanoscale surface processing of optical components.

4、 Detection and error compensation technology

Online measurement and closed-loop control

During the processing, real-time monitoring of dimensional and positional errors is carried out using laser interferometers and coordinate measuring machines (CMM), which are fed back to the numerical control system for dynamic compensation (such as real-time correction of thermal deformation).

Error modeling and compensation

Establish a machine tool error model based on multi-body system theory (including geometric error, thermal error, load deformation error), and predict and compensate for comprehensive errors through software algorithms such as neural networks and genetic algorithms.

Surface quality inspection

White light interferometer and atomic force microscope (AFM) are used for measuring nanoscale surface roughness; X-ray diffraction (XRD) analysis of residual stress on the machined surface to avoid later deformation of the parts.

5、 Process Planning and Simulation Technology

Digital Process Design

Based on Model Based Definition (MBD) technology, the 3D model is integrated with process information, and the tool path is optimized through CAM software (such as UG NX, Mastercam) to reduce void cutting and cutting load fluctuations.

machining process simulation

Using finite element analysis (such as Deform, AdvantEdge) to simulate the cutting process, predict cutting force, temperature field distribution, and tool wear, optimize cutting parameters (spindle speed, feed rate, cutting depth), and avoid machining defects (such as chatter, chipping).

Green process planning

Adopting dry cutting, biodegradable cutting fluids, and tool life management systems (such as RFID tool identification) to reduce energy consumption and environmental pollution, in line with the trend of sustainable manufacturing.

6、 Intelligent Manufacturing and Automation Technology

Intelligent tool management system

Real time monitoring of tool wear through sensors (such as sudden changes in cutting force and abnormal vibration signals), automatic triggering of tool change instructions, and combined with a tool life database to achieve predictive maintenance.

Flexible Manufacturing Unit (FMC) and Automated Production Line

Robots automatically load and unload materials, multiple machine tools are networked for collaborative processing, and an adaptive control system (such as automatically adjusting cutting parameters based on material hardness) is used to improve the accuracy, consistency, and efficiency of batch processing of complex parts.

Digital twin technology

Establish a virtual mapping model for the machining process, monitor the deviation between the physical machine tool and the virtual model in real time, optimize process parameters, provide early warning of equipment failures, and achieve transparency and intelligence in the precision machining process.

The core technology of precision machining is based on high-precision machine tool hardware, supported by advanced numerical control systems and tool technology. Through process optimization, online detection, and intelligent control, a closed-loop system is formed, ultimately achieving stable manufacturing of parts with micrometer (μ m) to nanometer (nm) precision. The future trend will focus more on the integration of multiple technologies (such as the combination of AI and processing technology), green manufacturing, and processing capabilities under special conditions (such as ultra-high temperature and ultra-low temperature environments).