Release time:

2021-02-20

【Summary】1. Workpiece Overcut: Reasons: 1. The spring knife, the tool strength is insufficient, too long or too small, leading to tool springing. 2. Improper operation by the operator. 3. Uneven cutting allowance. (e.g.: 0.5 on the curved surface side, 0.15 on the bottom surface) 4. Improper cutting parameters (e.g.: too large tolerances, SF set too fast, etc.). Improvements: 1. Cutting principle: as large as possible, as short as possible. 2. Add a corner cleaning program, try to keep the allowance uniform (side and bottom surface allowances should be consistent). 3. Reasonably adjust cutting parameters, round off large corners of the allowance. 4. Utilize the machine tool's SF function, the operator fine-tunes the speed to achieve the best cutting effect. 2. Centering Issues: Reasons: 1. Inaccurate manual operation by the operator. 2. Burrs around the mold. 3. The centering rod is magnetic. 4. The four sides of the mold are not vertical. Improvements: 1. Manual operation should be carefully checked repeatedly, centering should be done at the same point and height as much as possible. 2. Use an oil stone or file to remove burrs around the mold, then wipe clean with a rag, and finally confirm by hand. 3. Demagnetize the centering rod before centering the mold (ceramic centering rods or others can be used). 4. Use a level to check if the four sides of the mold are vertical (if the verticality error is large, discuss the plan with the fitter). 3. Tool Alignment Issues: Reasons: 1. Inaccurate manual operation by the operator. 2. Incorrect tool clamping. 3. Incorrect blade on the flying knife (the flying knife itself has a certain error). 4. There is an error between the R knife and the flat bottom knife and flying knife. Improvements: 1. Manual operation should be carefully checked repeatedly, and tool alignment should be done at the same point as much as possible. 2. Clean the tool before clamping with an air gun or wipe with a rag. 3. Measure the tool rod and use one blade when measuring the light bottom surface on the flying knife. 4. Create a separate tool alignment program to avoid errors between R knife, flat knife, and flying knife. 4. Machine Collision - Programming: Reasons: 1. Insufficient safety height or not set (when rapid feed G00, the tool or chuck collides with the workpiece). 2. The tool on the program sheet is incorrect compared to the actual program tool. 3. The tool length (blade length) on the program sheet is incorrect compared to the actual machining depth. 4. The depth Z-axis data on the program sheet is incorrect compared to the actual Z-axis data. 5. Incorrect coordinate settings during programming. Improvements: 1. Accurately measure the height of the workpiece to ensure the safety height is above the workpiece. 2. The tool on the program sheet must match the actual program tool (try to use automatic program sheets or images for program sheets). 3. Measure the actual machining depth on the workpiece and clearly write the tool length and blade length on the program sheet (generally, the tool clamping length should be 2-3MM above the workpiece, and the blade length should avoid a gap of 0.5-1.0MM). 4. Write down the actual Z-axis data on the workpiece clearly on the program sheet. (This operation is generally manual and should be checked repeatedly). 5. Machine Collision - Operator: Reasons: 1. Incorrect depth Z-axis tool alignment. 2. Incorrect centering and operation data (e.g.: single-sided data collection without entering the tool radius, etc.). 3. Wrong tool used (e.g.: using D10 tool to process with D4 tool). 4. Wrong program path (e.g.: A7.NC running A9.NC). 5. Incorrect direction of the handwheel during manual operation. 6. Incorrect direction pressed during manual rapid feed (e.g.: pressing -X instead of +X). Improvements: 1. Pay attention to where the depth Z-axis tool alignment is done (bottom surface, top surface, analysis surface, etc.). 2. Check the centering and operation data repeatedly after completion. 3. When clamping the tool, check repeatedly against the program sheet and program before clamping. 4. Programs should be run in order, one by one. 5. When using manual operation, the operator should enhance their proficiency in operating the machine tool. 6. When moving manually, first raise the Z-axis above the workpiece before moving. 6. Curved Surface Precision: Reasons: 1. Unreasonable cutting parameters, rough surface of the workpiece. 2. The tool edge is not sharp. 3. The tool clamping is too long, and the blade gap is too long. 4. Poor chip removal, blowing, and oiling. 5. Programming cutting method (consider using a continuous milling approach as much as possible). 6. The workpiece has burrs. Improvements: 1. Cutting parameters, tolerances, allowances, and speed feed settings must be reasonable. 2. The tool should be checked periodically by the operator and replaced as needed. 3. When clamping the tool, the operator should try to clamp it short, and the blade gap should not be too long. 4. For flat knives, R knives, and round nose knives, the downward cutting speed feed settings should be reasonable. 5. The presence of burrs on the workpiece is directly related to our machine tool, tools, and cutting methods. Therefore, we need to understand the performance of the machine tool and make up for the edges with burrs.

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