Machining training Q&A.
What should I do if the workpiece is overcut?
Causes: Tool ejection, improper operation, uneven cutting allowance, inappropriate parameters.
Solution: Select the tool "as large as possible, not too small, as short as possible, not too long." Add a corner cleanup program, adjust the cutting parameters, and use SF to fine-tune the speed.
What should I do if centering is inaccurate?
Causes: Manual error, mold burrs, magnetized centering rod, mold not perpendicular.
Solution: Repeatedly check manual operation, remove burrs, demagnetize the centering rod, and calibrate to check perpendicularity.
What should I do if there is a tool setting problem?
Causes: Manual error, incorrect clamping, incorrect fly cutter blade, and tool-to-tool error.
Solution: Repeatedly check manual operation, clean the tool, measure the tool rod, and create a separate tool setting program.
What should I do if the program crashes?
Causes: Insufficient safety height, incorrect tool programming, incorrect depth programming, incorrect Z-axis reading, and incorrect coordinate settings.
Solution: Accurately measure the workpiece height, compare the tool with the program sheet, clearly write the tool length and blade length, and repeatedly check the Z-axis reading.
What should I do if an operator crashes the machine while operating it?
Causes: Z-axis tool setting error, incorrect centering collision count, using the wrong tool, incorrect program, or turning the handwheel in the wrong direction.
Improvements: Pay attention to tool setting position, repeatedly check centering collision counts, verify tool alignment with program, and execute programs in order to improve operator proficiency.
How should I address insufficient surface accuracy?
Causes: Improper cutting parameters, blunt tool edges, excessive clamping length, and poor chip removal.
Improvements: Set cutting parameters appropriately, regularly check and replace tools, keep tool clamps as short as possible, and set feed speed appropriately.
What should I do if the cutting edge is chipped?
Causes: Feeding too fast, loose clamping, or insufficient rigidity.
Improvements: Reduce feed speed, clamp the tool and workpiece tightly, use shorter tools, clamp deeper, change the cutting edge angle, and use a rigid machine tool and toolholder.
What should I do if the wear is too severe?
Causes: Excessive machine speed, hardened material, and chip adhesion.
Improvement: Slow down the speed, add coolant, use high-quality tools, change the feed rate to clean chips, and adjust the cutting angle and backlash angle.
What to do if damage occurs?
Cause: Feed too fast, excessive cutting depth, excessive blade length and overall length.
Improvement: Slow down the feed rate, use a smaller cutting depth, clamp the tool deeper into the shank, and re-grind the tool initially.
What to do if chatter marks are too obvious?
Cause: Feed and cutting speed are too fast, and rigidity is insufficient.
Improvement: Adjust the speed, use the machine tool and toolholder properly, change the backlash angle, clamp the workpiece, and set the speed and feed rate appropriately.
Note: Speed, feed rate, and cutting depth are key to cutting performance. Choose appropriate cutting conditions based on material properties.
