What matters should be paid attention to in the use of the precision engraving machine with knife die?

In the process of use, the precision engraving machine of knife die should be strictly controlled from the aspects of equipment start-up, operation specification, maintenance and so on to ensure the machining accuracy, equipment life and operation safety. The following are specific considerations:

First, the preparation before the start of the equipment

Environmental inspection

Ensure that the working environment temperature is 15-30℃ and the humidity does not exceed 60%, and avoid high temperature, humidity or excessive dust, so as not to affect the equipment accuracy and the service life of electronic components.

The equipment should be placed on a level and stable foundation to avoid vibration (such as being far away from stamping equipment and large motors, etc.), and shockproof foot pads should be installed if necessary.

Power supply and grounding

Connect a stable three-phase power supply (voltage fluctuation does not exceed 10%), and equip it with a special regulated power supply or UPS to prevent sudden voltage change from damaging the control system.

Equipment must be reliably grounded (grounding resistance ≤4Ω) to avoid electrostatic interference or leakage risk.

Mechanical parts inspection

Check whether the transmission parts such as spindle, guide rail and lead screw are well lubricated (apply lubricating oil or grease as required in the manual) to avoid wear caused by dry friction.

Make sure that the fixing screws of the tool rest and workbench are not loose, and the tool is firmly installed (the tool handle is closely attached to the spindle taper hole, and the nut tightening torque is moderate).

Second, the specification requirements in the process of operation

Program and parameter setting

When programming, it is necessary to strictly check the tool path trajectory to avoid the tool colliding with the workbench or fixture (simulation of machining process of simulation software can be used first).

Select the appropriate cutting parameters according to the die materials (such as tungsten steel, high speed steel, copper and aluminum, etc.):

Spindle speed: When machining steel parts with cemented carbide tools, the speed is usually 8000-24000rpm；; Processing aluminum parts can be increased to 20000-30000rpm.

Feed speed: 500-1500mm/min for rough machining and 100-500mm/min for finish machining, so as to avoid cutting edge breakage or workpiece deformation caused by too fast feed.

Cutting depth: the single cutting depth shall not exceed 1/3 of the tool diameter (for example, φ3mm tool, the cutting depth shall be ≤1mm), and it shall be processed in layers to ensure the accuracy.

Tool installation and replacement

Before installing the cutter, clean cloth should be used to wipe the inner hole of the handle and spindle to avoid impurities affecting the coaxiality (coaxiality error should be < ＜0.01mm).

After replacing the tool, it is necessary to perform tool alignment operation (tool alignment instrument or manual edge touching) and set the correct workpiece coordinate system (G54-G59) to prevent machining scrap caused by coordinate deviation.

Processing monitoring

Observe the spindle load in real time during machining (the current value should be within 60%-80% of the rated value). If the load rises abnormally, it is necessary to immediately suspend the inspection of tool wear or workpiece clamping.

Monitor the running sound of the equipment. If there is abnormal vibration or abnormal sound (such as spindle howling and guide rail jamming), stop the machine immediately for investigation to avoid component damage.

For long-term processing (such as more than 4 hours), it is necessary to check whether the workpiece clamping is loose and whether there is chip accumulation on the workbench every 1-2 hours (chip accumulation will affect the processing accuracy and need to be cleaned with compressed air in time).

III. Safe Operation and Protection

personal security

Protective glasses must be worn during operation to prevent chips from splashing and hurting eyes; Long hair should be tied up, and it is forbidden to wear loose clothes or jewelry.

When the equipment is running, it is forbidden to touch the tool, workpiece or transmission parts by hand. If you need to adjust the workpiece, you must stop the machine first and ensure that the spindle stops rotating completely.

Equipment protection

Ensure that protective covers (such as spindle protective cover and workbench protective fence) are installed in place, and close the protective door during processing to avoid chips or coolant splashing.

The cooling fluid should be of a type suitable for the tool die material (such as emulsion for processing steel parts and semi-synthetic cutting fluid for processing aluminum parts) and replaced regularly (usually every 2-4 weeks) to prevent the liquid from deteriorating and corroding the equipment.

Fourth, the maintenance and maintenance after processing

Equipment cleaning

After machining, use a brush or compressed air to remove the chips and oil stains on the workbench, guide rail and lead screw, so as to prevent the guide rail from being scratched or the lead screw from being worn due to the residual chips.

Wipe the spindle end face and the tool handle, and apply antirust oil (which should be protected for a long time) to prevent rust from affecting the installation accuracy next time.

Component inspection and lubrication

Check the wear of guide rail and lead screw (such as whether there are scratches and rust on the surface), and add lubricating oil according to the instructions (the linear guide rail should be filled every 8 hours and the ball screw should be filled every 24 hours).

Check the belt tension (press the belt with your fingers, the deflection should be within 5-10mm), and adjust the motor position if it is too loose or too tight.

Electrical system maintenance

Regularly clean the dust in the electric cabinet (once every quarter), and check whether the terminal is loose and whether the contactor contacts are oxidized (wipe with alcohol).

Back up CNC system parameters (such as PLC program and servo parameters) to prevent data loss caused by system failure.

Five, common faults and emergency treatment

Tool edge collapse/excessive wear;

The reasons may be that the cutting parameters are improper (too high speed or too fast feed), and the tool material does not match the workpiece (such as machining cemented carbide with high speed steel tool), so it is necessary to re-select the tool and adjust the parameters.

Machining dimension out of tolerance:

Check whether the workpiece is deformed during clamping, tool wear and screw pitch error (it can be adjusted by reverse clearance compensation function, and the compensation value is usually ≤0.02mm).

Equipment alarm shutdown:

Check the alarm code of numerical control system (such as "servo overload" and "limit switch trigger"), and troubleshoot according to the instructions (such as lifting the limit and checking the wiring of servo motor). If it cannot be solved, contact professional maintenance personnel.

summary

The core of the use of the precision engraving machine for die cutter lies in "precise control" and "standard maintenance". Every link from environment, parameters, operation to maintenance needs to be strictly implemented to ensure the high precision of die cutter processing (such as tolerance control within ±0.01mm) and the long-term stable operation of the equipment. If complex die processing (such as multi-curved surface and deep cavity structure) is involved, it is suggested to carry out trial processing in small batches and verify the process parameters before mass production.