Common problem in the cnc machining process (2)
author: YITECH
2024-11-25
06. Surface roughness
Reasons:
1) Unreasonable cutting parameters and rough surfaces of the workpiece.
2) Dull cutting edge of the tool.
3) Tool clamping is too long, and the tool edge length is too long.
4) Poor chip evacuation, air blowing, and oil flushing.
5) Programming tool path (consider using contour milling whenever possible).
6) The workpiece has burrs.
Improvements:
1) Cutting parameters, tolerances, and residual amounts should be set reasonably, as well as speed and feed rate.
2) The tool should be checked regularly and replaced regularly by operators.
3) When clamping the tool, the operator should clamp it as short as possible, and the clearance of the tool edge should not be too long.
4) For flat cutters, R cutters, and round nose cutters, the cutting parameters, speed and feed rate settings should be reasonable.
5) The appearance of burrs on the workpiece is directly related to the machine tool, cutting tool, and tool path. Therefore, we need to understand the performance of the machine tool and adjust the tool path to remove burrs on the edge.
07. Tool breakage
1) Feed rate is too fast - slow down to an appropriate feed rate.
2) Feed rate is too fast at the beginning of cutting - slow down the feed rate at the beginning of cutting.
3) Loose clamping (tool) - clamp the tool.
4) Loose clamping (workpiece) - clamp the workpiece.
5) Insufficient rigidity (tool) - use the shortest allowable tool, clamp the shank deeper, and try contour milling.
6) The cutting edge of the tool is too sharp - change the brittle cutting edge angle and use a one-time edge.
7) Insufficient rigidity of the machine tool and shank - use a machine tool and shank with better rigidity.
08. Wear
1) The machine speed is too fast - slow down, and use enough coolant.
2) Hardened materials - use advanced tool materials and surface treatment methods.
3) Chipping adhesion - change the feed rate, chip size, or use coolant or an air gun to clean the chips.
4) Improper feed rate (too low) - increase the feed rate and try contour milling.
5) Improper cutting angle - change to an appropriate cutting angle.
6) The primary back angle of the tool is too small - change it to a larger back angle.
09. Damage
1) The feed rate is too fast - slow down the feed rate.
2) The cutting amount is too large - use a smaller cutting amount per level.
3) The blade length and overall length are too long - clamp the shank deeper and use shorter tools, try contour milling.
4) The wear is too severe - regrind early.
Reasons:
1) Unreasonable cutting parameters and rough surfaces of the workpiece.
2) Dull cutting edge of the tool.
3) Tool clamping is too long, and the tool edge length is too long.
4) Poor chip evacuation, air blowing, and oil flushing.
5) Programming tool path (consider using contour milling whenever possible).
6) The workpiece has burrs.
Improvements:
1) Cutting parameters, tolerances, and residual amounts should be set reasonably, as well as speed and feed rate.
2) The tool should be checked regularly and replaced regularly by operators.
3) When clamping the tool, the operator should clamp it as short as possible, and the clearance of the tool edge should not be too long.
4) For flat cutters, R cutters, and round nose cutters, the cutting parameters, speed and feed rate settings should be reasonable.
5) The appearance of burrs on the workpiece is directly related to the machine tool, cutting tool, and tool path. Therefore, we need to understand the performance of the machine tool and adjust the tool path to remove burrs on the edge.
07. Tool breakage
1) Feed rate is too fast - slow down to an appropriate feed rate.
2) Feed rate is too fast at the beginning of cutting - slow down the feed rate at the beginning of cutting.
3) Loose clamping (tool) - clamp the tool.
4) Loose clamping (workpiece) - clamp the workpiece.
5) Insufficient rigidity (tool) - use the shortest allowable tool, clamp the shank deeper, and try contour milling.
6) The cutting edge of the tool is too sharp - change the brittle cutting edge angle and use a one-time edge.
7) Insufficient rigidity of the machine tool and shank - use a machine tool and shank with better rigidity.
08. Wear
1) The machine speed is too fast - slow down, and use enough coolant.
2) Hardened materials - use advanced tool materials and surface treatment methods.
3) Chipping adhesion - change the feed rate, chip size, or use coolant or an air gun to clean the chips.
4) Improper feed rate (too low) - increase the feed rate and try contour milling.
5) Improper cutting angle - change to an appropriate cutting angle.
6) The primary back angle of the tool is too small - change it to a larger back angle.
09. Damage
1) The feed rate is too fast - slow down the feed rate.
2) The cutting amount is too large - use a smaller cutting amount per level.
3) The blade length and overall length are too long - clamp the shank deeper and use shorter tools, try contour milling.
4) The wear is too severe - regrind early.
10. Vibration pattern
1) The feed rate and cutting speed are too fast - adjust the feed rate and cutting speed.
2) Insufficient rigidity (machine tool and shank) - use a better machine tool and shank or change the cutting conditions.
3) The back angle is too large - change to a smaller back angle, machine edge wear (grind once with oilstone).
4) Loose clamping - clamp the workpiece.
5) Consider speed, feed rate, and cutting depth.
The interaction between speed, feed rate, and cutting depth is the most important factor in determining cutting performance. Inappropriate feed rate and speed often lead to a decrease in production, poor quality of workpieces, and large tool damage.
CNC Machining Industry: In-Depth Analysis of Future Trends and Technological Innovations
Common problem points and improvement methods in the CNC machining process
Related Article
Choosing between 316 and 316L? 316L resists weld decay better, 316 holds strength at higher heat. Both food-grade, both marine-grade. Quick, no-fluff breakdown.
316 vs 316L Stainless Steel for CNC Machining
What is stamping and when do you use it? A plain guide to sheet metal stamping, dies, and progressive tools, plus the parts it makes faster than machining.
What Is Stamping in Metal Manufacturing?
