What are the main parts of the cutting auxiliary system of the die precision engraving machine?

The cutting auxiliary system of the die precision engraving machine is a key component to ensure machining accuracy, tool life and equipment stability, which mainly includes cutting fluid system, cooling system, chip removal system, pneumatic system (some equipment) and other modules. The following are the specific components, functions and technical points of each system:

First, the cutting fluid system

1. System composition

Liquid storage unit:

Stainless steel or engineering plastic water tank (capacity is usually 20-100L, depending on equipment specifications), and some high-end models are equipped with liquid level sensors and temperature monitoring devices.

Cycle unit:

Centrifugal pump (flow rate 10-30L/min, lift ≥10m), filtering device (paper filter element, magnetic separator or line gap filter, filtering accuracy 5-20μm).

Injection unit:

Adjustable nozzle (0.5-2mm in diameter, supporting multi-angle rotation) and shunt valve (switching between internal cooling and external cooling of spindle).

2. Core functions

Cooling tool: reduce the temperature of the cutting area (300-500℃ when processing carbon steel) to avoid overheating and wear of the tool.

Lubricating the cutting surface: reduce the friction between the tool and the workpiece (the friction coefficient can be reduced by 30%-50%) and improve the surface smoothness (the Ra value is reduced from 1.6μm to below 0.8μm).

Scouring chips: remove metal chips in the machining area in time to prevent chip accumulation from affecting machining accuracy.

Second, the spindle cooling system

1. System type and composition

Water cooling system (most common):

Circulating water tank (capacity 5-15L), cooling pump (flow rate 5-10L/min), heat exchanger (plate or tube, heat exchange area 0.5-1m2), temperature controller (control water temperature at 20-25℃ with fluctuation ≤ 1℃).

Oil cooling system (high power spindle):

Oil cooler (refrigerating capacity is 2-5kW), heat-conducting oil (viscosity is 32-46cSt), and pressure sensor (monitoring oil circuit pressure is 0.3-0.5MPa).

2. Technical points

The water cooling system needs deionized water or special coolant (to prevent the pipeline from being blocked by scale deposition), and it should be replaced once a month. When the scale thickness exceeds 0.5mm, it should be cleaned with citric acid solution.

The heat transfer oil of oil cooling system is recommended to be replaced once every six months. If the oil quality is black or the impurity content exceeds 0.05%, it should be replaced immediately.

Third, the chip removal system

1. System classification and structure

Dry chip removal (applicable to non-ferrous metals such as aluminum and copper);

Negative pressure dust suction device: fan (air volume 500-1000 m/h), dust removal filter element (filtering accuracy ≤5μm), pipeline (diameter 50-100mm), which is matched with the side suction port of workbench or the dust suction cover of spindle.

Wet chip removal (suitable for steel processing);

A chain plate chip cleaner (width 100-300mm, speed 0.5-1m/min) and a spiral chip cleaner (diameter 50-80mm, pitch 100-150mm) are installed in the groove at the bottom of the workbench.

2. Design points

The elbow angle of the dust suction pipeline should be ≥ 120 to avoid chip accumulation; Wet chip removal machine should regularly clean the entanglements on the chain (such as aluminium scrap ball) to prevent sticking.

The gap between the chip discharge port and the workbench should be ≥50mm to ensure that the chips fall smoothly and avoid accumulation in the processing area.

Four, pneumatic system (optional configuration)

1. System composition

Air source processing unit: air compressor (displacement 0.3-0.6m/min), triple parts (filter, pressure reducing valve, oil mist device, output pressure 0.4-0.6MPa).

Execution unit: pneumatic fixture, spindle blowing device (air pressure is 0.3MPa, which is used to blow clean the surface debris of tools and workpieces), and pneumatic tool changing mechanism of tool magazine.

2. Application scenarios

Tool cleaning: after machining, use high-pressure gas (0.5MPa) to blow off the debris in the handle and spindle taper hole to ensure the accuracy of tool change.

Workpiece Fixation: Pneumatic fixture can quickly clamp thin-walled workpieces (such as die plates) to avoid mechanical clamping deformation.

Five, the linkage control of cutting auxiliary system

1. Electrical linkage logic

The cutting fluid pump is interlocked with the spindle motor: the cutting fluid is automatically turned on after the spindle is started, and turned off after the spindle stops for 30 seconds (to prevent the cutting fluid from splashing when idling).

Linkage between chip removal machine and cutting fluid system: When the liquid level in the water tank exceeds the upper limit, the chip removal machine will automatically start to discharge excess liquid (to prevent overflow).

2. Intelligent monitoring function

Some high-end equipment is equipped with cutting fluid concentration detector (monitoring emulsion concentration in real time, and giving an alarm when the deviation exceeds 1%) and flow sensor (detecting cooling water flow rate, and stopping to protect the spindle when it is lower than the set value).

VI. Typical Faults and Solutions

Possible causes of fault phenomena and solutions

Insufficient cutting fluid injection, worn impeller of water pump, clogged filter, replacement of water pump, cleaning or replacement of filter element.

The spindle temperature is too high, the cooling water flow rate is low, and the heat exchanger is fouled. Check the pump pressure and clean the heat exchanger with citric acid.

Chip removal machine stuck chip winding chain, motor overload cleaning winding, adjusting inverter overload protection parameters.

Insufficient clamping force of pneumatic fixture, too low air pressure and aging of cylinder sealing ring. Check air supply pressure and replace sealing ring.

summary

Each module of the cutting aid system ensures the high precision and stability of the cutting die engraving process through the synergistic effect of "cooling-lubrication-chip removal-pneumatic". In practical application, it is necessary to optimize the system parameters (such as cutting fluid concentration, cooling water temperature and chip removal air volume) according to the processing materials (such as carbon steel, aluminum alloy and acrylic) and tool types (such as cemented carbide knives and PCD knives), and maintain them regularly to avoid the deterioration of machining accuracy caused by the failure of auxiliary systems (such as the cutting edge of the tool die is cracked and the surface roughness exceeds the standard).