4. Prepare all tools according to programming instructions
According to the tool data in the programming operation guide, replace the tool to be processed and let the tool contact the height measuring device placed on the datum surface. When the red measurement light is on, set the relative coordinate value of the point to zero. The device is turned on. Move the tool to a safe position, manually move the tool down 50mm, and set the relative coordinate value of the point to zero again. This point is the Z-axis zero position.
Record the machine tool coordinate Z value of this point in one of G54~G59. In this way, the zero adjustment of the X, Y, and Z axes of the workpiece is completed. Double check the data again for correctness.
Single-sided touch counting is to touch one side of the X-axis and Y-axis of the workpiece according to the above method, and offset the relative coordinate values of the X-axis and Y-axis of the point. The radius of the touch head is the zero position of the X-axis and Y-axis. The mechanical coordinates of the X and Y axes are marked in one of G54~G59. Double check the data again for correctness.
Check the correctness of the zero point, move the X and Y axes to the side suspension of the workpiece, and visually check the correctness of the zero point according to the size of the workpiece.
Copy the program file to the computer according to the file path in the programming operation guide.
5. Setting of processing parameters
Spindle speed setting during processing: N=1000×V/(3.14×D)
N: Spindle speed (rpm/min)
V: cutting speed (m/min)
D: Tool diameter (mm)
Processing feed speed setting: F=N×M×Fn
F: Feed speed (mm/min)
M: Number of cutting edges
Fn: Cutting amount of tool (mm/rev)
Setting of cutting amount per tool: Fn=Z×Fz
Z: Number of blades of the tool
Fz: Cutting amount of each edge of the tool (mm/rev)
6. Start processing
At the beginning of each program, you must carefully check that the tool used is the one specified in the programming guide. When starting processing, the feed speed should be adjusted to the minimum, single block execution, rapid positioning, knife drop, and feed should be concentrated. Your hand should be on the stop button. If something goes wrong, stop immediately. Pay attention to the direction of tool movement to ensure safe feeding. knife, then slowly increase the feed speed to the appropriate level while adding coolant or cold air to the tool and workpiece.
Do not leave the control panel too far during rough machining. If there is any abnormality, stop the machine immediately for inspection.
Pull the gauge again after roughing to make sure the workpiece is not loose. If so, it must be recalibrated and touched.
During the processing process, the processing parameters are continuously optimized to achieve the best processing effect.
Since this process is a critical process, after the workpiece is processed, its main dimensions should be measured to see if it matches the drawing requirements. If a problem occurs, immediately notify the team leader or programmer to check and solve it. It can be removed after passing the self-inspection. It must be sent to an inspector for special inspection.
Processing type: Hole processing: Before drilling on the machining center, you must first use a center drill for positioning, then use a drill bit 0.5 to 2 mm smaller than the drawing size, and finally use a suitable drill bit for finishing.
Reaming processing: When reaming the workpiece, you must first use a center drill to position it, then use a drill bit 0.5 to 0.3mm smaller than the drawing size to drill, and finally use a reamer to ream. When reaming, pay attention to controlling the spindle speed. Within 70~180rpm/min.
Boring processing: When boring the workpiece, first use a center drill to position it, then use a drill bit 1~2mm smaller than the drawing to drill, and then use a rough boring tool (or milling cutter) to process until only about 0.3mm is left on one side. Measure, and finally use the pre-adjusted fine boring tool for fine boring. The last fine boring allowance should not be less than 0.1mm.
Direct numerical control (DNC) operation: Before DNC CNC machining, the workpiece should be clamped, zero position set, and parameters set. Open the processing program to be transferred in the computer for inspection, then let the computer enter the DNC state and enter the correct file name of the processing program. Press the TAPE key and program start key on the machine tool, and the word LSK will flash on the machine tool controller. Press the Enter keyboard on the computer to perform DNC data transmission processing.
7. Content and scope of employee self-examination
Processing personnel must read the contents of the process card clearly before processing, clearly know the location, shape, and size of the workpiece to be processed, and know the processing content of the next process.
Before the workpiece is clamped, the dimensions of the blank should be measured to see if it meets the drawing requirements. When clamping the workpiece, you must carefully check whether its placement is consistent with the programming operating instructions.
After rough machining is completed, self-inspection should be carried out in time to adjust the erroneous data in time. The content of self-inspection is mainly the position and size of the processing part. For example: whether the workpiece is loose; whether the workpiece is correctly centered; whether the dimensions of the processed parts to the reference edge (reference point) meet the requirements of the drawing; the position dimensions between the processed parts. After checking the position and size, the rough cut shape should be measured (except for arcs).
Finishing is performed after roughing self-inspection. After processing is completed, workers should conduct self-inspections on the shape and size of the workpiece: check the basic length and width dimensions of the workpiece on the vertical plane; measure the basic point size marked on the drawing at the inclined surface processing part.
After the workers complete the self-inspection of the workpiece and confirm that it meets the drawings and process requirements, the workpiece can be removed and sent to the inspector for special inspection.
