1. Improvement of operator skills
Professional training and learning
Attending professional CNC processing technology training courses is the basis for improving operator skills. These courses can be provided by machine tool manufacturers, industry training institutions or vocational schools. The training content includes the basics of CNC programming (such as learning G codes and M codes), machine tool operation safety specifications, and the principles and applications of different types of processing technologies (milling, turning, drilling, etc.).
Encourage operators to learn CAD/CAM software in depth. For example, learn the advanced functions of Mastercam software, such as complex surface modeling, tool path optimization algorithms, etc. By mastering these software, operators can program and simulate parts more efficiently and discover potential processing problems in advance.
Experience accumulation and communication
Operators should focus on experience accumulation in their daily work. After each processing task is completed, record the processing parameters, tool selection, problems and solutions in detail. For example, when processing a part of a new material, record the processing effect under different cutting speeds and feed speeds for reference when processing similar parts in the future.
Actively participate in industry technical exchange activities, such as technical seminars, machine tool exhibitions, etc. During these activities, operators can share experiences with peers and learn about the latest CNC machining technologies and application cases. At the same time, they can communicate with the technicians of the machine tool manufacturer to obtain suggestions on optimizing the performance of the machine tool.
2. Optimize the machining process
Cutting parameter optimization
In-depth study of the impact of cutting parameters (cutting speed, feed speed, cutting depth) on machining quality and efficiency. Through experimental and theoretical analysis, determine the optimal cutting parameters for different metal materials and tool combinations. For example, when machining stainless steel materials, according to the material and diameter of the tool, it is determined through experiments that the appropriate cutting speed range is 80-120m/min, the feed speed is 0.1-0.2mm/r, and the cutting depth is between 1-2mm, which can obtain better machining surface quality and higher machining efficiency.
Adaptive control technology is used to dynamically adjust cutting parameters. Some advanced CNC machine tools are equipped with an adaptive control system that can automatically adjust the cutting speed and feed speed according to real-time feedback information such as cutting force and tool wear during machining. This can fully utilize the performance of the machine tool and tool while ensuring machining quality.
Tool path planning
Use CAD/CAM software for efficient tool path planning. During programming, minimize idle travel to make the tool's movement path the shortest and most reasonable during processing. For example, when milling complex cavities, use circular cutting or spiral feed to avoid the impact of vertical tool feed and improve processing efficiency.
Consider the impact of the tool's cutting-in and cutting-out methods on processing quality. Reasonable cutting-in and cutting-out methods can reduce tool wear and the roughness of the processed surface. For example, when turning an outer circle, use arc cutting-in and cutting-out methods to avoid tool marks on the workpiece surface.
3. Tool management and selection
Tool selection optimization
Select appropriate tool materials and tool types according to the processing material and part shape. For example, when processing alloy steel with higher hardness, carbide tools or ceramic tools are preferred; for the processing of complex curved surfaces, ball-end milling cutters can better fit the curved surface shape.
Pay attention to the research and development and application of new tools. If coated tools are used, their surface coatings (such as TiN, TiAlN coatings, etc.) can improve the hardness, wear resistance and oxidation resistance of the tool. Understand the applicable scope of different coated tools, and choose them reasonably to significantly extend the tool life and improve processing efficiency.
Tool wear monitoring and replacement
Establish an effective tool wear monitoring system. Indirect monitoring methods can be used, such as monitoring cutting force, cutting power, vibration signals, etc. to determine the degree of tool wear. For example, when the cutting force suddenly increases or the vibration intensifies, it may mean that the tool has been severely worn.
Establish reasonable tool replacement standards. Determine the service life and replacement cycle of the tool according to the processing accuracy requirements and tool wear monitoring results. Replace worn tools in time to avoid excessive tool wear leading to reduced processing quality or damage to the machine tool.
4. Machine tool maintenance and upgrade
Regular machine tool maintenance
Perform regular maintenance in strict accordance with the recommendations of the machine tool manufacturer. Including cleaning the machine tool, checking the lubrication system, tightening the connecting bolts of each component, etc. For example, after work every day, clean the chips and oil on the machine tool workbench and guide rails, check and replenish lubricating oil regularly (such as once a month) to ensure good lubrication of all moving parts of the machine tool.
Perform regular precision inspection and adjustment of key components of the machine tool (such as spindles, ball screws, linear guides, etc.). For example, use a laser interferometer to check the positioning accuracy and repeat positioning accuracy of the machine tool every six months, and make timely adjustments and compensation when the accuracy drops to ensure the processing accuracy of the machine tool.
Machine tool upgrade and transformation
Pay attention to the development of machine tool technology and upgrade and transform existing machine tools in a timely manner. The CNC system can be upgraded to obtain more powerful programming functions and higher computing speeds. For example, upgrading the old CNC system to a new CNC system with high-speed and high-precision machining functions can achieve more complex machining algorithms and faster interpolation operations.
Transform the mechanical part of the machine tool, such as adding automatic loading and unloading devices, replacing high-precision spindles, etc. This can improve the automation level and processing performance of the machine tool and adapt to the ever-increasing processing requirements.
Sejow can provide OEM/ODM Wiring Harness ，Cnc Machining Parts based on your requirements. Wiring harness, also known as Cable Harness, CNC machining parts are assembly of Cnc Milling Service which transmit signals or electrical power. In the future, Sejow will continue to uphold the business philosophy of "integrity, responsibility, and innovation", provide customers with better products and services, and work together to create a better tomorrow. Consultation hotline: 0755-29426119.
Sejow (Shenzhen) Industrial Co., Ltd.
