How to prolong the service life of special bottom die machine for knife die?

To prolong the service life of the special bottom die machine for knife dies, it is necessary to comprehensively manage the equipment maintenance, operation specifications, environmental control and other aspects to reduce the wear of parts and avoid the accumulation of faults. The following are specific measures:

1. Daily maintenance: the core of reducing component wear and tear

Regular lubrication to reduce friction loss.

Key parts: moving parts such as guide rail, ball screw, spindle bearing and gear box are the key points of lubrication.

Guide rail: clean the dust on the surface of the guide rail with a brush before starting the machine every day, and add special guide rail oil (such as ISO VG32/46) to ensure uniform oil film coverage (to avoid guide rail strain caused by dry friction);

Ball screw: check the tightness of the screw cover every week (to prevent sawdust and dust from entering), add high-temperature grease (such as lithium grease) every two weeks, and move the shaft body manually after grease injection to make the grease evenly distributed;

Spindle: Replace the spindle lubricating oil (such as synthetic gear oil commonly used for high-speed spindles) according to the instructions, and replace it after the first use for 300 hours, and then every 1000-1500 hours to avoid bearing wear caused by oil deterioration.

Taboo: Different types of lubricating oils should not be mixed (for example, the components of guide rail oil and hydraulic oil conflict, which may lead to lubrication failure).

Cleaning and maintenance to prevent impurity damage.

Worktable and fixture: Clean up the sawdust and glue residue on the table surface after daily processing (air gun can be used to blow it clean+wet cloth can be used to wipe it), check the adsorption surface/contact surface of positioning fixture (such as sucker and backing), and repair it in time if there are scratches or deformation (to avoid uneven stress on the tool caused by workpiece positioning deviation);

Electrical system: use compressed air to purge the dust in the control cabinet every week (power-off operation), and check whether the wiring terminals are loose (especially at the wiring of spindle motor and servo motor to prevent poor contact and fever);

Cooling system: if it is a water-cooled spindle, check the coolant level every week (when it is insufficient, add special coolant, and it is forbidden to replace it with tap water to prevent scale blockage), replace the coolant once a month and clean the water tank; If it is air-cooled, clean the filter screen of the cooling fan (to avoid dust accumulation affecting heat dissipation).

Tool and spindle maintenance

Before installation of the cutter, it is necessary to clean the handle and spindle taper hole (wipe with alcohol to remove oil stains and iron filings), and ensure that the fit clearance is ≤0.01mm (excessive clearance will lead to vibration of the cutter and increase the wear of the spindle bearing);

Check the wear of cutting edge in time after the tool is used, and the tool with serious wear needs to be replaced immediately (to avoid the spindle overload caused by the increase of cutting resistance);

When the machine is shut down for a long time (more than one week), it is necessary to run the spindle with no-load for 5 minutes (low speed → high speed) to discharge the internal condensate, then disassemble the cutter and apply antirust oil in the spindle taper hole.

Second, standardize the operation: avoid man-made injury

Processing parameters are set reasonably.

Matching cutting parameters according to material characteristics (such as wood board, rubber board and density board);

For materials with higher hardness (such as multilayer board), the feed speed should be reduced (3-5m/min is recommended) and the spindle speed should be increased (4000-6000r/min);

Soft materials (such as EVA rubber sheet) can appropriately increase the feed speed, but it is necessary to ensure the smooth cutting of the tool (to avoid the spindle overload caused by "boring the tool").

It is forbidden to process beyond the range: if the maximum cutting depth of the equipment is 50mm, it is forbidden to forcibly process materials with a thickness of 60mm (which will lead to overload deformation of the Z-axis screw and guide rail).

The workpiece is firmly clamped.

Before machining, make sure that the workpiece is completely fixed (the vacuum degree of the suction cup should be ≥-0.08MPa, and the mechanical fixture should lock the nut), so as to avoid the tool collision caused by the displacement of the workpiece during machining (light edge collapse, heavy damage to the spindle);

Irregular workpieces need to be customized with special fixtures, and it is forbidden to press the workpieces by hand for processing (there are potential safety hazards and uneven stress will affect the stability of the equipment).

Start-stop and operation specification

Start-up sequence: first turn on the power supply → turn on the air source (if any) → start the control system → preheat the spindle (run at low speed for 3-5 minutes, especially in winter, to avoid bearing damage due to cold start);

Shutdown sequence: the spindle stops → the control system is turned off → the air source is turned off → the power supply is turned off, and direct power off is prohibited (to prevent the system parameters from being lost or the servo motor from overshoot);

In case of abnormal sound, vibration or alarm during operation, press the "Emergency Stop Button" immediately, and then restart after checking the causes (such as tool jamming and foreign objects on the guide rail). It is forbidden to run with faults.

Third, environmental control: reduce the influence of external factors

Optimize the working environment

Temperature and humidity: keep the workshop temperature at 15-25℃ (excessive temperature difference will easily lead to thermal expansion and cold contraction of machine tool parts, which will affect accuracy and life), and the humidity will be 50%-60% (too high humidity will easily make electrical components get wet and rust, too low will increase dust);

Dustproof and shockproof: install a dust cover above the equipment (especially when processing materials with more sawdust), and stay away from the seismic source (such as punching machine and air compressor). If necessary, lay a shockproof pad at the bottom of the equipment (to reduce ground vibration transmission);

Power supply stability: install a voltage regulator (voltage fluctuation ≤ 5%) to avoid burning the servo motor or control system due to sudden voltage rise and fall (especially in unstable areas of power grid).

Long-term shutdown protection

When the machine stops for more than one month:

Clean up the impurities inside and outside the equipment, apply antirust oil to the guide rail, screw rod and other parts, and cover them with plastic film;

Desiccant is placed in the control cabinet (to prevent electrical components from getting wet);

Disconnect the main power supply and unplug the plug to avoid standby current loss of components;

Before re-use: remove the rust-proof layer, check the lubrication state of all components, and run the machine empty for 30 minutes to confirm that there is no abnormality before processing.

Fourth, regular maintenance: find potential problems in advance.

Monthly inspection

Check whether the anchor bolt is loose (if the levelness error exceeds 0.1mm/m, it needs to be leveled again);

Test the sensitivity of limit switch (when manually triggered, the shaft movement should stop immediately, otherwise the switch needs to be replaced);

Check whether the pneumatic components (such as cylinders and air pipes) are leaking, and replace the aged air pipes.

Quarterly/semi-annual maintenance

Check the radial runout of the spindle by professionals (the error should be ≤0.01mm, and the bearing should be replaced if it exceeds the tolerance);

Check the operating temperature of the servo motor (normally it should be ≤60℃, and overheating may be caused by bearing wear or driver failure);

Calibrate the positioning accuracy of each axis (detected by dial indicator, compensated by control system parameters when the error exceeds the limit).

Easily worn parts should be replaced in time.

Parts to be replaced regularly: guide guard (impurities will be introduced when it cracks due to aging), cutting fluid filter, suction cup gasket (air leakage affects adsorption force), spindle belt (if it is belt drive, it will easily slip after wear);

Original parts should be used when replacing accessories (if the accuracy of non-original bearings is insufficient, the life of the spindle will be shortened).

Five, personnel management: enhance the awareness of operation and maintenance.

Operators must be trained and qualified before taking up their posts (familiar with equipment performance, parameter setting and emergency treatment);

Establish equipment maintenance ledger, record daily lubrication, cleaning and troubleshooting (easy to trace the root cause of the problem);

Organize technical personnel to communicate regularly and share maintenance experience (for example, optimize the replacement cycle according to the tool wear law of specific material processing).

Through the above measures, the abnormal loss of the special bottom die machine for knife dies can be effectively reduced, and the service life of the equipment can usually be extended by more than 30% (the conventional service life is 5-8 years, and the proper maintenance can reach more than 10 years). The core principle is: "prevention first, timely treatment"-avoid minor problems from turning into major failures through daily detail management, and dynamically adjust the maintenance strategy according to the running status of equipment.