CNC machine tool as an indispensable core equipment in modern manufacturing industry, its processing accuracy directly determines the quality and performance of the product. With the continuous progress of industrial technology and the rapid development of manufacturing industry, the requirements for machining accuracy of CNC machine tools are becoming higher and higher. Therefore, in-depth study of various factors affecting the machining accuracy of CNC machine tools, and actively explore and practice effective methods to improve the machining accuracy of CNC machine tools, for improving the overall level and competitiveness of the manufacturing industry is of extremely important significance.
1 Factors affecting the machining accuracy of CNC machine tools
1.1 Error factor
In the machining process of CNC machine tool, affected by the tool Angle, measurement scale and other reasons, there may be various errors, which lead to the reduction of precision of CNC machine tool. When using CNC machine tools for processing, the level counting should be controlled according to its specific accuracy requirements. For example, some machine tools have relatively low processing accuracy requirements, and the level count can be controlled below 0.04mm/1000mm, while for some machine tools with high accuracy requirements, the level count should be controlled to 0.02mm/1000mm. Therefore, choosing the correct tool size and Angle is a key link to ensure the machining accuracy of the machine tool and ensure the accurate completion of the processing task. If the tool size and Angle selection is not accurate, it will not only affect the machining accuracy of the parts, but also lead to serious errors. In addition, practice shows that the thermal deformation in the machining process of CNC machine tools is also an important reason for the machining error of machine tools, and the error may even reach 40% to 70%. With the continuous development of CNC machine tool technology, in order to ensure the precision of CNC machining, more and more CNC systems begin to use motor sliding ball to adjust the tool. In the case of long-term continuous rotation of the ball, the gap inside the bearing will continue to increase, and then the parts of the CNC machine tool will gradually deviate from the forward and reverse under the external action. In addition, due to the different mechanical force Angle, the accuracy and overall performance will also be affected by the difference in force during rotation, which will affect the machining accuracy and quality of the parts.
1.2 Servo factor
In the actual operation process, the machining accuracy of CNC machine tools may also be affected by various other factors, such as the servo control system. In the whole CNC machine tool system, the servo control system can effectively control the running state of the CNC machine tool, ensure the stable operation of the CNC machine tool, reduce the error during the operation process, and improve the machining accuracy and quality of the machine tool. As the main source of running power of CNC machine tool system, the performance of servo control system directly affects the machining accuracy of machine tool. The precision, response speed and stability of servo system are the key factors affecting the machining accuracy of CNC machine tools. If the accuracy of the servo system is not high enough, it will not be able to ensure the precise positioning and motion trajectory of the machine tool, thus affecting the machining accuracy. The slow response speed will lead to the hysteresis of the machine tool in the processing process, affecting the processing efficiency and accuracy. Poor stability will lead to irregular fluctuations in the processing process, affecting the processing quality. Therefore, in the use of CNC machine tools for parts processing, in order to achieve accurate control of the servo system, the operator needs to use the servo system to effectively control the ball screw, so as not to affect the machining accuracy of parts due to unnecessary errors.
2 Solutions
2.1 Error compensation
In the process of CNC machine tool processing will inevitably appear a variety of deviations. In order to ensure the machining accuracy of CNC machine tools, various deviation problems can be solved by error compensation technology. CNC machine tool operators in the processing process, should be based on the actual situation of the CNC machine tool system and parts processing needs, the CNC system paid Settings, to minimize the reduction of processing accuracy caused by error factors. Error compensation technology includes two ways: software compensation and hardware compensation. The software compensation is mainly through the compensation algorithm in the numerical control system, the application of programming technology, the accurate positioning of the parameter unit, the real-time calculation and correction of the motion error of the machine tool, so as to control the reverse clearance and achieve reasonable compensation. For example, by establishing the error model, the thermal deformation of the machine tool, tool wear and other errors can be compensated. Hardware compensation mainly refers to the reasonable adjustment of machine tool hardware to reduce errors. For example, by adjusting the preload force of the ball screw, the error caused by mechanical clearance can be effectively reduced. In addition, CNC machine tool operators can also install high-precision sensors and feedback systems, real-time monitoring of the operating status of the machine tool, timely detection and adjustment of deviations, so as to improve processing accuracy.
2.2 Servo Compensation
In the CNC machine tool system, the servo control system plays a crucial role and plays a key role. Once the servo control system fails, it will not only affect the machining efficiency of CNC machine tools, but also seriously affect the machining accuracy of CNC machine tools. In order to ensure the stability and accuracy of the servo system, it is necessary to perform regular maintenance and calibration of the servo system. CNC machine tool maintenance personnel should check whether the connection between the servo motor and the drive is firm, ensure that there are no loose or damaged parts, and regularly check the parameter setting of the servo system to ensure that it matches the operation requirements of the machine tool. In addition, maintenance personnel can also adjust the control parameters to ensure the response speed and stability of the servo system, such as adjusting the PID parameters, to achieve the best control effect. In some cases, hardware components of the servo system may need to be replaced or upgraded to improve its performance. For example, the use of higher precision encoders can improve the accuracy of position detection, thus improving the machining accuracy. Finally, for the maintenance of the servo system, a complete maintenance plan should be established, including regular inspection, cleaning and lubrication, to ensure the long-term stable operation of the servo system.
3 CNC machine tool processing accuracy guarantee measures
3.1 Strengthen staff awareness and improve team quality
In the process of CNC machine tool processing, in order to ensure that the processing accuracy meets the expected standards, enterprises should actively take a series of measures to strengthen the management and training of CNC machine tool operators and maintenance personnel, in order to continuously improve their professional skills and operational levels, and thus ensure the efficient and accurate operation of the machine tool. On the one hand, enterprises can organize systematic training courses on a regular basis, so that operators and maintenance personnel can timely grasp the latest CNC machine tool technology, processing technology and error compensation methods, to help them more deeply understand the performance of the machine tool, improve the accuracy and efficiency of the operation. On the other hand, enterprises should encourage technical exchanges and experience sharing among employees, so that employees can master various abilities to solve practical problems existing in the process of CNC machine tool processing by analyzing actual cases, so as to promote the dissemination of professional knowledge, but also to stimulate employees' innovative thinking, so that they can better control processing errors in daily work. Ensure the stability of CNC machining accuracy. In order to further stimulate the enthusiasm of employees, enterprises should also establish a sound incentive mechanism to encourage employees to actively participate in CNC machine tool processing technology improvement and innovation activities, and promote employees to pay more attention to the control of processing accuracy under the drive of providing rewards and recognition. Among them, the incentive mechanism can include bonuses, promotion opportunities, recognition and other forms to better meet the needs of different employees and motivate them to make continuous progress.
3.2 Improve the processing technology and optimize the processing program
In the process of CNC machine tool processing, in order to further improve the processing accuracy, on the basis of strengthening the awareness of personnel and improving the quality of the team, it is also crucial to improve the processing technology and optimize the processing procedures. The continuous improvement of the processing technology of CNC machine tools can effectively reduce the errors in the processing process and improve the processing quality of parts. On the one hand, enterprises should constantly update and optimize the processing process, scientific planning tool selection, cutting parameters setting and the use of coolant. For example, enterprises should choose tools suitable for specific materials and processing requirements according to the machining needs of CNC machine tools, so as to minimize tool wear, extend the service life of the tool, and improve the finish of the machining surface; Reasonable setting of parameters such as cutting speed, feed rate and cutting depth can effectively avoid machine overload and tool fracture, and ensure the stability of the machining process and the machining accuracy of parts. On the other hand, optimize the processor. The precise control of machine tool movement can be realized by writing and adjusting numerical control program according to the requirement of machine tool technician. When writing the program, technicians should give full consideration to the dynamic characteristics of the machine tool, avoid the operation that may lead to the vibration and processing error of the machine tool, and make full use of the advanced programming functions provided by the modern numerical control system, such as subroutines, macroprograms and cycles, simplify the program structure, improve programming efficiency, reduce human error, and thus improve the processing accuracy. In addition, enterprises should also pay attention to the real-time monitoring and feedback during the processing of CNC machine tools, and through the installation of high-precision sensors and feedback systems, real-time monitoring of the operating status and processing quality of the machine tools, timely detection and adjustment of deviations, so as to effectively avoid the processing error caused by the abnormal state of the machine tool. At the same time, attention should also be paid to the application of modern information technology such as the Internet of Things and big data analysis in the machining process of CNC machine tools to achieve an in-depth analysis of the processing process, find potential problems, and take measures in advance to ensure the stability of processing accuracy.
3.3 Determine cutting parameters and improve cutting environment
In the machining process of CNC machine tool, the reasonable selection of cutting parameters will directly affect the machining accuracy of CNC machine tool. Reasonable cutting parameters can effectively reduce the thermal deformation and tool wear in the process of CNC machine tool, so as to improve the machining accuracy. Enterprises should scientifically select parameters such as cutting speed, feed rate and cutting depth according to machine tool performance and material properties. For example, for some materials with higher hardness, in order to reduce tool wear and extend tool life, the cutting speed should be appropriately reduced. At the same time, the feed rate and cutting depth should also be reasonably controlled, so as to effectively avoid the stability and processing accuracy of CNC machine tools due to tool exercise or machine overload. In addition to the reasonable selection of cutting parameters, improving the cutting environment is also an important measure to improve the machining accuracy of CNC machine tools. In the machining process of CNC machine tools, a good cutting environment can effectively reduce the thermal deformation and vibration in the machining process, thereby improving the machining accuracy. In order to achieve this effect, the rational use of cutting fluid should be ensured. The cutting fluid can not only reduce the cutting temperature, but also reduce the friction between the tool and the workpiece, and improve the finish of the machined surface; At the same time, improve the cooling system of the machine tool to ensure the uniform distribution and effective cooling of the cutting fluid, which can further improve the machining accuracy; Regular inspection and maintenance of machine guide rails and sliding parts to ensure that they are well lubricated and reduce thermal deformation and wear due to friction.
On this basis, in order to further improve the processing accuracy of CNC machine tools, enterprises should also pay attention to the performance improvement of the machine tool itself, and carry out regular inspection and maintenance of the machine tool to ensure that the mechanical structure and electrical system of the machine tool are in the best state. For example, regular cleaning and lubrication of key components such as guide rails and lead screws can effectively reduce wear and improve motion accuracy; Regularly check the electrical system of the machine tool to ensure that all cables are firmly connected and there is no aging or damage, so as to effectively avoid processing errors caused by electrical faults.
3.4 Reasonable selection of tools to improve machining accuracy
In the machining process of CNC machine tools, the choice of tools also has an important impact on the machining accuracy. Choosing the right tool can significantly improve machining efficiency and machining quality, reduce tool wear, extend tool life, and thus improve the overall machining accuracy. On the one hand, enterprises should choose the appropriate tool materials and geometric parameters according to the type of processing materials, hardness, toughness and processing requirements. For example, for processing materials with high hardness, cemented carbide or ceramic tools should be selected to improve the wear resistance and cutting performance of the tools. The geometric parameters such as the front Angle, back Angle and spiral Angle of the tool should also be reasonably optimized according to the processing conditions to reduce the cutting force and cutting heat and improve the finish of the machining surface. On the other hand, enterprises should regularly check and maintain the tool to ensure that the tool is in the best condition. Worn tools should be replaced in time to avoid machining errors caused by tool wear. In addition, the use of advanced tool management system can effectively track the use of the tool, predict the tool life, so as to reasonably arrange the replacement and maintenance of the tool. In addition, focus on tool innovation and improvement. With the development of material science and manufacturing technology, new tool materials and coating technology continue to emerge, and its application in CNC processing can effectively improve the performance and machining accuracy of the tool. Enterprises should pay attention to the introduction of such new tool materials and coating technologies to maintain a competitive advantage in processing accuracy.
3.5 Scientific selection of machine tools, the use of suitable equipment
In the selection of CNC machine tools, enterprises should scientifically select the appropriate equipment according to the specific needs of the processing task. Different types of CNC machine tools have their own characteristics in terms of processing accuracy, processing range and processing efficiency, so a reasonable selection of machine tools is crucial to ensure processing accuracy. Enterprises should scientifically evaluate the complexity and accuracy requirements of CNC machine tool processing tasks, and select CNC machine tools with corresponding accuracy levels and functions according to the evaluation results. For example, for parts processing requiring high precision, high precision CNC machine tools should be selected to ensure processing quality. When choosing CNC machine tools, enterprises should also give full consideration to their processing scope and flexibility, and machine tools with a wide range of processing capabilities can adapt to more kinds of processing tasks and improve equipment utilization. And with the development of technology, some new CNC machine tools are equipped with advanced functions such as high-speed machining and multi-axis linkage, which can further improve processing efficiency and accuracy. Therefore, enterprises should pay attention to the technical dynamics of the industry and introduce new CNC machine tools in a timely manner to maintain the advanced nature of processing technology. Enterprises should also pay attention to the installation and commissioning of machine tools. Ensuring that the machine tool is installed in a suitable environment and accurately adjusted can maximize the performance of the machine tool and ensure the stability of the machining accuracy. In short, the scientific selection and reasonable configuration of machine tool equipment can significantly improve the processing accuracy of CNC machine tools and meet the growing processing needs.
4 Conclusion
In short, the improvement of machining accuracy of CNC machine tools is a systematic project, which needs to be comprehensively considered and implemented from many aspects. Enterprises need to fully understand the factors affecting the machining accuracy of CNC machine tools on the basis of taking reasonable and effective solutions, and through strengthening personnel training, improving the processing technology, determining the cutting amount, reasonable selection of tools, scientific selection of machine tools and other ways to ensure the continuous improvement of CNC machine tool processing accuracy. In the fierce market competition, only by constantly pursuing excellence can we win the trust and satisfaction of customers and maintain a leading position in the field of CNC machine tool processing.
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