CNC machining center operation instructions

I. Operation preparation
1.1 Check the oil level in the oil tank and whether the oil is deteriorated or contaminated.
1.2 Check whether the cooling pump filter is blocked.
1.3 Check whether the ball screw is lubricated enough; whether the fan is rotating; whether the motor is vibrating or heating; whether the cable is aging and cracked.
1.4 Only employees who have participated in the training and passed the examination can work on the job. No one else can operate without permission.
1.5 After each start-up or emergency stop reset of the machine tool, first return the machine tool to the reference zero position (i.e. return to zero) so that the machine tool has a reference position for its subsequent operation.
II. Operation
2.1 Clamping the workpiece
2.1.1 Before clamping the workpiece, clean all surfaces first, and do not allow oil, iron filings and dust to stick to them, and use a file (or oilstone) to remove burrs on the surface of the workpiece.
2.1.2 The equal height iron used for clamping must be ground by a grinder to make it smooth and flat. The shims and nuts must be strong and can reliably clamp the workpiece. Some small workpieces that are difficult to clamp can be clamped directly on the vise.
2.1. 3 Make sure that the machine tool workbench is clean and free of iron filings, dust, and oil.
2.1. 4 Shims are generally placed at the four corners of the workpiece. For workpieces with too large a span, shims of equal height must be placed in the middle.
2.1. 5 According to the dimensions of the drawing, use a ruler to check whether the length, width, and height of the workpiece are qualified.
2.1. 6 When clamping the workpiece, according to the clamping and placement method in the programming work manual, consider avoiding the processing area and the situation where the tool head may hit the fixture during processing.
1, 2.1. 7 After the workpiece is placed on the pad, the workpiece reference surface should be checked according to the requirements of the drawing. The error of the workpiece base angle surface reading should be less than 0.01mm, the top surface X, Y and Z vertical workpiece dimensions within 100mm should have an error less than 0.01mm, and the workpiece size above 600mm should have an error less than 0.05mm. For workpieces that have been ground on all six sides, their verticality should be checked to see if it is qualified.
2.1. 8 After the workpiece is checked, the nut must be tightened to prevent the workpiece from shifting during processing due to loose clamping.
2.1. 9 Check the table again to make sure that the error does not exceed the tolerance after clamping.
2. 2 Workpiece touch count: The clamped workpiece can be touched and counted by the touch count head to determine the reference zero position of the processing. The touch count head can be photoelectric or mechanical. There are two touch selection methods: center touch count and single-side touch count. The center touch count steps are as follows:
2.2. 1 Touch counting method: mechanical speed 450~600rpm.
2.2.2 Manually move the X axis of the worktable to make the touch counting head touch one side of the workpiece. When the touch counting head just touches the workpiece, set the relative coordinate value of this point to zero; then manually move the X axis of the worktable to make the touch counting head touch the other side of the workpiece. When the touch counting head just touches the workpiece, record the relative coordinate at this time.
2.2.3 Subtract the diameter of the touch counting head (i.e. the length of the workpiece) from its relative value to check whether the length of the workpiece meets the requirements of the drawing.
2.2.4 Divide this relative coordinate number by 2, and the resulting value is the middle value of the workpiece X axis. Then move the worktable to the middle value on the X axis, set the relative coordinate value of the X axis of this point to zero, and this point is the zero position on the X axis of the workpiece.
2.2. 5 Carefully record the mechanical coordinate value of the zero position on the X axis of the workpiece in one of G54~G59, and let the machine tool determine the zero position on the X axis of the workpiece. Carefully check the correctness of the data again.
2.2.6 The steps for setting the zero position of the Y axis of the workpiece are the same as those for the X axis.
2.3 Prepare all tools according to the programming operation manual.
2.4 According to the tool data in the programming operation manual, replace the tool to be processed, let the tool touch the reference surface, and set the relative coordinate value of this point to zero.
2.5 Move the tool to a safe place, manually move the tool down 50mm, and set the relative coordinate value of this point to zero again. This point is the zero position of the Z axis.
2.6 Record the mechanical coordinate Z value of this point in one of G54~G59. This completes the zero position setting of the X, Y, and Z axes of the workpiece. Carefully check the correctness of the data again.
2.7 For single-side contact counting, touch one side of the workpiece X and Y axis according to the above method. The relative coordinate value of the X and Y axis at this point is offset by the radius of the contact counting head, which is the zero position of the X and Y axis. Finally, mark the mechanical coordinate of the X and Y axis in one of G54~G59. Check the correctness of the data again.
2.8 Check the correctness of the zero point, move the X and Y axes to the side of the workpiece, and visually check the correctness of its zero point according to the size of the workpiece.
2.9 Copy the program file to the computer according to the file path of the programming work manual.
2.10 Start processing:
2.10. 1 At the beginning of each program, you must carefully check whether the tool used is the tool specified in the programming manual. When starting processing, adjust the feed speed to the minimum, execute in a single section, and concentrate when positioning quickly, dropping the tool, and feeding the tool. Keep your hand on the stop button. If there is a problem, stop immediately. Pay attention to the direction of tool movement to ensure safe feeding, and then slowly increase the feed speed to a suitable level. At the same time, add coolant or cold air to the tool and workpiece.
2.10. 2 Do not be too far away from the control panel during rough processing. If there is any abnormality, stop the machine for inspection in time.
2.10. 3 After roughing, pull the table again to make sure that the workpiece is not loose. If there is, it must be recalibrated and touched.
2.10. 4 Continuously optimize the processing parameters during the processing to achieve the best processing effect.
2.10. 5 Because this process is a key process, after the workpiece is processed, its main dimension values should be measured to see if they are consistent with the drawing requirements. If there is any problem, immediately notify the shift leader or programmer to check and solve it. It can only be removed after passing the self-inspection, and must be sent to the inspector for special inspection.
2.10. 6 Clean the machine tool table in time after the workpiece is removed.
III. Content and scope of worker self-inspection:
3. 1 Before processing, the processor must read the process card content clearly, clearly know the part, shape, and dimensions of the workpiece to be processed, and know the content of the next process.
3. 2 Before clamping the workpiece, the blank size should be measured to see if it meets the requirements of the drawing. When clamping the workpiece, it must be carefully checked whether its placement is consistent with the programming work instruction.
3. 3. After the rough processing is completed, self-inspection should be carried out in time so that the erroneous data can be adjusted in time. The self-inspection content mainly includes the position and size of the processing part. Such as:
(1). Whether the workpiece is loose;
(2). Whether the workpiece is correctly centered;
(3). Whether the size from the processing part to the reference edge (reference point) meets the requirements of the drawing;
(4). The position and size of the processing parts. After checking the position and size, the rough processing shape ruler should be measured (except for arcs)
3. 4. Fine processing can only be carried out after rough processing self-inspection. After finishing, workers should check the shape and size of the processed parts
Self-check: Check the basic length and width of the processed parts on the vertical surface; measure the base point size marked on the drawing for the processed parts on the inclined surface.
3. 5 After the worker completes the self-check of the workpiece and confirms that it is in line with the drawing and process requirements, the workpiece can be removed for inspection for special inspection.
4. Causes of error, special attention, and corrective measures list:
4.1 Failure to check the length, width, and height of the workpiece. Before going on the machine, the length, width, and height of the workpiece must be carefully checked to see if they are in line with the drawing. Use methods such as rulers and touch counts to check their correctness
4.2 Workpiece placement direction According to the requirements of the programming work instruction, determine the placement direction of the workpiece by comparing it with the workpiece and the drawing. Carefully check the direction of the workpiece, and then operate according to the placement instructions
4. 3. Collision offset. Collision method, check after collision, check input data. After collision, move the spindle to the edge of the workpiece according to the length and width of the workpiece to check the correctness of the collision; check the correctness after entering the data
4.4. Wrong tool used. Carefully check whether the installed tool is consistent with the instruction manual. When executing the first sentence of the program, the tool used must be confirmed
4.5. The tool broke during roughing, resulting in overcutting of the workpiece and scrapping of the tool. Do not be too far away from the control panel during roughing. Stop the machine for inspection in time if there is any abnormal phenomenon
4.6. Workpiece shift after roughing. Make sure it is tight when clamping. Re-draw the table and collision after roughing
4.7. Workpiece size is less than the number. Check the tool used; notify the programming inspection program. For important positions, ensure that new tools are used for processing; modify or add programs
4.8. Wrong file name entered. Before processing, the file name corresponding to the tool used in the program must be carefully checked. Carefully check the correctness of the entered file name.
5. Common mistakes and precautions:
5.1 Wrong workpiece selection, especially the AB plate is selected in reverse.
5.2 The drilling position is wrong. Some drilling positions must be drilled strictly according to the specified position.
5.3 The front and back sides are wrong. Place according to the specified requirements or the guide pin hole position.
5.4 The left and right are reversed. The AB plate cannot be matched.
5.5 The clamping is not tight or the position is wrong.
5.6 The minute data is read wrong, and the data is calculated wrong. The offset number does not record the tool diameter or the diameter is wrong.
5.7 The program name is wrong.
5.8 The blade is not changed in the middle.
5.9 The tool is not re-calibrated after the tool is changed.
5.10 The machine tool is not checked for quality after completion.
6. Operation steps:
6. 1 Accept the task, listen carefully, and write down the key points and precautions. Be sure to ask if you are not clear.
6. 2 Do the preparation work such as drilling and cleaning.
6. 3 Keep the machine clean and load the workpiece.
6. 4 Check the center, tighten the workpiece, and make necessary records.
6. 5 Set the tool and make necessary records.
6. 6 Enter the program, start the machine, and start cutting slowly.
6. 7 Carefully observe the operation of the machine.
6. 8 Change the tool and align it.
6. 9 Check the quality and remove the machine.
VII. Programming steps:
7. 1 Check the graphics and make appropriate processing on the graphics.
7. 2 Conceive the processing ideas according to the tool and working conditions.
7. 3 Program and write the program sheet.
7. 4 Inspection, comprehensive inspection is essential.
7. 5 Make necessary communication with the operator, and use written language as much as possible.
8. Machine tool operation process:
Power on the machine tool - turn on the key switch - enter the control system - turn on "Emergency Stop" - press "Machine Tool Work" - operate the machine tool - stop the machine tool - press "Machine Tool Lock" - press "Emergency Stop" - exit the control system - shut down the computer - turn off the key switch - power off the machine tool.