“Guide to Maintenance and Common Problem Handling of CNC Machine Tool Processing”
I. Introduction
As a key equipment in modern manufacturing, CNC machine tools play an important role in improving production efficiency and ensuring processing accuracy. However, any equipment cannot do without careful maintenance during use, especially for CNC machine tool processing. Only by doing a good job in maintenance can we ensure the normal operation of CNC machine tools, extend their service life and improve production efficiency. This article will introduce in detail the maintenance methods and common problem handling measures of CNC machine tool processing to provide reference for users.
As a key equipment in modern manufacturing, CNC machine tools play an important role in improving production efficiency and ensuring processing accuracy. However, any equipment cannot do without careful maintenance during use, especially for CNC machine tool processing. Only by doing a good job in maintenance can we ensure the normal operation of CNC machine tools, extend their service life and improve production efficiency. This article will introduce in detail the maintenance methods and common problem handling measures of CNC machine tool processing to provide reference for users.
II. The Importance of Maintenance for CNC Machine Tool Processing
CNC machine tools are high-precision and high-efficiency processing equipment with complex structures and high technical content. During use, due to the influence of various factors such as processing load, environmental conditions, and operator skill levels, the performance of CNC machine tools will gradually decline and even malfunctions. Therefore, regular maintenance of CNC machine tools can timely discover and solve potential problems, ensure the normal operation of equipment, improve processing accuracy and production efficiency, reduce maintenance costs, and extend the service life of equipment.
CNC machine tools are high-precision and high-efficiency processing equipment with complex structures and high technical content. During use, due to the influence of various factors such as processing load, environmental conditions, and operator skill levels, the performance of CNC machine tools will gradually decline and even malfunctions. Therefore, regular maintenance of CNC machine tools can timely discover and solve potential problems, ensure the normal operation of equipment, improve processing accuracy and production efficiency, reduce maintenance costs, and extend the service life of equipment.
III. Maintenance Methods for CNC Machine Tool Processing
Daily inspection
Daily inspection is mainly carried out according to the normal operation of each system of the CNC automatic machine tool. The main maintenance and inspection items include:
(1) Hydraulic system: Check whether the hydraulic oil level is normal, whether there is leakage in the hydraulic pipeline, and whether the working pressure of the hydraulic pump is stable.
(2) Spindle lubrication system: Check whether the spindle lubricating oil level is normal, whether the lubrication pipeline is unobstructed, and whether the lubrication pump is working normally.
(3) Guide rail lubrication system: Check whether the guide rail lubricating oil level is normal, whether the lubrication pipeline is unobstructed, and whether the lubrication pump is working normally.
(4) Cooling system: Check whether the coolant level is normal, whether the cooling pipeline is unobstructed, whether the cooling pump is working normally, and whether the cooling fan is running well.
(5) Pneumatic system: Check whether the air pressure is normal, whether there is leakage in the air path, and whether the pneumatic components are working normally.
Weekly inspection
Weekly inspection items include CNC automatic machine tool parts, spindle lubrication system, etc. Also, iron filings on CNC machine tool parts should be removed and debris should be cleaned. The specific contents are as follows:
(1) Check whether there is looseness, wear or damage in various parts of the CNC machine tool. If there is a problem, tighten, replace or repair it in time.
(2) Check whether the filter of the spindle lubrication system is blocked. If it is blocked, clean or replace it in time.
(3) Remove iron filings and debris on CNC machine tool parts to keep the equipment clean.
(4) Check whether the operation parts such as the display screen, keyboard and mouse of the CNC system are normal. If there is a problem, repair or replace it in time.
Monthly inspection
It is mainly to inspect the power supply and air dryer. Under normal circumstances, the rated voltage of the power supply is 180V – 220V and the frequency is 50Hz. If there is an abnormality, measure and adjust it. The air dryer should be disassembled once a month and then cleaned and assembled. The specific contents are as follows:
(1) Check whether the voltage and frequency of the power supply are normal. If there is an abnormality, adjust it in time.
(2) Check whether the air dryer is working normally. If there is an abnormality, repair or replace it in time.
(3) Clean the filter of the air dryer to ensure the dryness of the air.
(4) Check whether the battery of the CNC system is normal. If there is an abnormality, replace it in time.
Quarterly inspection
After three months, the inspection and maintenance of CNC machine tools should focus on three aspects: the bed of CNC automatic machine tools, hydraulic system and spindle lubrication system, including the accuracy of CNC machine tools and hydraulic system and lubrication system. The specific contents are as follows:
(1) Check whether the accuracy of the bed of CNC automatic machine tools meets the requirements. If there is a deviation, adjust it in time.
(2) Check whether the working pressure and flow of the hydraulic system are normal, and whether there is leakage, wear or damage of hydraulic components. If there is a problem, repair or replace it in time.
(3) Check whether the spindle lubrication system is working normally and whether the quality of lubricating oil meets the requirements. If there is a problem, replace or add it in time.
(4) Check whether the parameters of the CNC system are correct. If there is an abnormality, adjust it in time.
Half-year inspection
After half a year, the hydraulic system, spindle lubrication system and X-axis of CNC machine tools should be inspected. If there is a problem, new oil should be replaced and then cleaning work should be carried out. The specific contents are as follows:
(1) Replace the lubricating oil of the hydraulic system and spindle lubrication system, and clean the oil tank and filter.
(2) Check whether the transmission mechanism of the X-axis is normal, and whether there is wear or damage to the lead screw and guide rail. If there is a problem, repair or replace it in time.
(3) Check whether the hardware and software of the CNC system are normal. If there is a problem, repair or upgrade it in time.
Daily inspection
Daily inspection is mainly carried out according to the normal operation of each system of the CNC automatic machine tool. The main maintenance and inspection items include:
(1) Hydraulic system: Check whether the hydraulic oil level is normal, whether there is leakage in the hydraulic pipeline, and whether the working pressure of the hydraulic pump is stable.
(2) Spindle lubrication system: Check whether the spindle lubricating oil level is normal, whether the lubrication pipeline is unobstructed, and whether the lubrication pump is working normally.
(3) Guide rail lubrication system: Check whether the guide rail lubricating oil level is normal, whether the lubrication pipeline is unobstructed, and whether the lubrication pump is working normally.
(4) Cooling system: Check whether the coolant level is normal, whether the cooling pipeline is unobstructed, whether the cooling pump is working normally, and whether the cooling fan is running well.
(5) Pneumatic system: Check whether the air pressure is normal, whether there is leakage in the air path, and whether the pneumatic components are working normally.
Weekly inspection
Weekly inspection items include CNC automatic machine tool parts, spindle lubrication system, etc. Also, iron filings on CNC machine tool parts should be removed and debris should be cleaned. The specific contents are as follows:
(1) Check whether there is looseness, wear or damage in various parts of the CNC machine tool. If there is a problem, tighten, replace or repair it in time.
(2) Check whether the filter of the spindle lubrication system is blocked. If it is blocked, clean or replace it in time.
(3) Remove iron filings and debris on CNC machine tool parts to keep the equipment clean.
(4) Check whether the operation parts such as the display screen, keyboard and mouse of the CNC system are normal. If there is a problem, repair or replace it in time.
Monthly inspection
It is mainly to inspect the power supply and air dryer. Under normal circumstances, the rated voltage of the power supply is 180V – 220V and the frequency is 50Hz. If there is an abnormality, measure and adjust it. The air dryer should be disassembled once a month and then cleaned and assembled. The specific contents are as follows:
(1) Check whether the voltage and frequency of the power supply are normal. If there is an abnormality, adjust it in time.
(2) Check whether the air dryer is working normally. If there is an abnormality, repair or replace it in time.
(3) Clean the filter of the air dryer to ensure the dryness of the air.
(4) Check whether the battery of the CNC system is normal. If there is an abnormality, replace it in time.
Quarterly inspection
After three months, the inspection and maintenance of CNC machine tools should focus on three aspects: the bed of CNC automatic machine tools, hydraulic system and spindle lubrication system, including the accuracy of CNC machine tools and hydraulic system and lubrication system. The specific contents are as follows:
(1) Check whether the accuracy of the bed of CNC automatic machine tools meets the requirements. If there is a deviation, adjust it in time.
(2) Check whether the working pressure and flow of the hydraulic system are normal, and whether there is leakage, wear or damage of hydraulic components. If there is a problem, repair or replace it in time.
(3) Check whether the spindle lubrication system is working normally and whether the quality of lubricating oil meets the requirements. If there is a problem, replace or add it in time.
(4) Check whether the parameters of the CNC system are correct. If there is an abnormality, adjust it in time.
Half-year inspection
After half a year, the hydraulic system, spindle lubrication system and X-axis of CNC machine tools should be inspected. If there is a problem, new oil should be replaced and then cleaning work should be carried out. The specific contents are as follows:
(1) Replace the lubricating oil of the hydraulic system and spindle lubrication system, and clean the oil tank and filter.
(2) Check whether the transmission mechanism of the X-axis is normal, and whether there is wear or damage to the lead screw and guide rail. If there is a problem, repair or replace it in time.
(3) Check whether the hardware and software of the CNC system are normal. If there is a problem, repair or upgrade it in time.
IV. Common Problems and Handling Methods of CNC Machine Tool Processing
Abnormal pressure
Mainly manifested as too high or too low pressure. The handling methods are as follows:
(1) Set according to the specified pressure: Check whether the pressure setting value is correct. If necessary, readjust the pressure setting value.
(2) Disassemble and clean: If the abnormal pressure is caused by blockage or damage of hydraulic components, the hydraulic components need to be disassembled for cleaning or replacement.
(3) Replace with a normal pressure gauge: If the pressure gauge is damaged or inaccurate, it will lead to abnormal pressure display. At this time, a normal pressure gauge needs to be replaced.
(4) Check in turn according to each system: Abnormal pressure may be caused by problems in the hydraulic system, pneumatic system or other systems. Therefore, it is necessary to check in turn according to each system to find out the problem and deal with it.
Oil pump does not spray oil
There are many reasons for the oil pump not spraying oil. The handling methods are as follows:
(1) Low liquid level in the fuel tank: Check whether the liquid level in the fuel tank is normal. If the liquid level is too low, add an appropriate amount of oil.
(2) Reverse rotation of the oil pump: Check whether the rotation direction of the oil pump is correct. If it is reversed, adjust the wiring of the oil pump.
(3) Too low speed: Check whether the speed of the oil pump is normal. If the speed is too low, check whether the motor is working normally or adjust the transmission ratio of the oil pump.
(4) Too high oil viscosity: Check whether the viscosity of the oil meets the requirements. If the viscosity is too high, replace the oil with appropriate viscosity.
(5) Low oil temperature: If the oil temperature is too low, it will lead to an increase in oil viscosity and affect the work of the oil pump. At this time, the problem can be solved by heating the oil or waiting for the oil temperature to rise.
(6) Filter blockage: Check whether the filter is blocked. If it is blocked, clean or replace the filter.
(7) Excessive volume of suction pipe piping: Check whether the volume of suction pipe piping is too large. If it is too large, it will cause difficulty in oil suction of the oil pump. At this time, the volume of suction pipe piping can be reduced or the oil suction capacity of the oil pump can be increased.
(8) Air inhalation at the oil inlet: Check whether there is air inhalation at the oil inlet. If there is, the air needs to be eliminated. The problem can be solved by checking whether the seal is intact and tightening the oil inlet joint.
(9) There are damaged parts on the shaft and rotor: Check whether there are damaged parts on the shaft and rotor of the oil pump. If there are, the oil pump needs to be replaced.
Abnormal pressure
Mainly manifested as too high or too low pressure. The handling methods are as follows:
(1) Set according to the specified pressure: Check whether the pressure setting value is correct. If necessary, readjust the pressure setting value.
(2) Disassemble and clean: If the abnormal pressure is caused by blockage or damage of hydraulic components, the hydraulic components need to be disassembled for cleaning or replacement.
(3) Replace with a normal pressure gauge: If the pressure gauge is damaged or inaccurate, it will lead to abnormal pressure display. At this time, a normal pressure gauge needs to be replaced.
(4) Check in turn according to each system: Abnormal pressure may be caused by problems in the hydraulic system, pneumatic system or other systems. Therefore, it is necessary to check in turn according to each system to find out the problem and deal with it.
Oil pump does not spray oil
There are many reasons for the oil pump not spraying oil. The handling methods are as follows:
(1) Low liquid level in the fuel tank: Check whether the liquid level in the fuel tank is normal. If the liquid level is too low, add an appropriate amount of oil.
(2) Reverse rotation of the oil pump: Check whether the rotation direction of the oil pump is correct. If it is reversed, adjust the wiring of the oil pump.
(3) Too low speed: Check whether the speed of the oil pump is normal. If the speed is too low, check whether the motor is working normally or adjust the transmission ratio of the oil pump.
(4) Too high oil viscosity: Check whether the viscosity of the oil meets the requirements. If the viscosity is too high, replace the oil with appropriate viscosity.
(5) Low oil temperature: If the oil temperature is too low, it will lead to an increase in oil viscosity and affect the work of the oil pump. At this time, the problem can be solved by heating the oil or waiting for the oil temperature to rise.
(6) Filter blockage: Check whether the filter is blocked. If it is blocked, clean or replace the filter.
(7) Excessive volume of suction pipe piping: Check whether the volume of suction pipe piping is too large. If it is too large, it will cause difficulty in oil suction of the oil pump. At this time, the volume of suction pipe piping can be reduced or the oil suction capacity of the oil pump can be increased.
(8) Air inhalation at the oil inlet: Check whether there is air inhalation at the oil inlet. If there is, the air needs to be eliminated. The problem can be solved by checking whether the seal is intact and tightening the oil inlet joint.
(9) There are damaged parts on the shaft and rotor: Check whether there are damaged parts on the shaft and rotor of the oil pump. If there are, the oil pump needs to be replaced.
V. Summary
Maintenance and handling of common problems of CNC machine tool processing are the key to ensuring the normal operation of equipment. Through regular maintenance, potential problems can be discovered and solved in time, the service life of equipment can be extended, and production efficiency can be improved. When handling common problems, it is necessary to analyze according to the specific situation, find out the root cause of the problem and take corresponding handling measures. At the same time, operators also need to have a certain level of skill and maintenance knowledge, and operate strictly in accordance with operating procedures to ensure the normal operation of CNC machine tools.
Maintenance and handling of common problems of CNC machine tool processing are the key to ensuring the normal operation of equipment. Through regular maintenance, potential problems can be discovered and solved in time, the service life of equipment can be extended, and production efficiency can be improved. When handling common problems, it is necessary to analyze according to the specific situation, find out the root cause of the problem and take corresponding handling measures. At the same time, operators also need to have a certain level of skill and maintenance knowledge, and operate strictly in accordance with operating procedures to ensure the normal operation of CNC machine tools.