Why Do Various Error Problems Occur In CNC Machining? How To Solve It?

Why do various error problems occur in CNC machining? How to solve it?

How to solve the problem of large and small heads in processed parts

During the CNC machining process, many factories have encountered the problem of tapered workpieces, which is called the oversize head phenomenon. This situation will directly interfere with the matching performance of the parts and the final assembly effect, leading to disagreements during customer acceptance.

The main reason for this problem is that the equipment is not installed in a horizontal state, and the base is one high and one low, which will cause the cutting path of the tool to deviate. In addition, when cutting hard materials, cutting the knife too deep will also aggravate the taper situation. The solution is to use a level to recalibrate the equipment and select an appropriate feed amount to avoid tool collision.

The surface finish of the part is not ideal

Occasionally, the dimensional measurement of precision parts is completely accurate, but the surface roughness does not meet the requirements, which causes many operators to be quite distressed. Surface quality will have a direct impact on the wear resistance and service life of parts, and customers are becoming increasingly demanding on smoothness.

Reasons for poor finish include machine tool resonance caused by excessive tool wear and crawling caused by unstable equipment installation. It is recommended to replace or polish the cutting tools regularly to ensure a stable foundation of the equipment, and to carry out daily maintenance and lubrication in accordance with regulations.

The drive is OK but the size is off

In some cases, the driver phase indicator shows a completely normal display state, but the dimensions of the parts being processed exhibit abnormal fluctuations. This situation is extremely confusing, and operators often immediately wonder if there is a problem with the program or measurement method.

In fact, this is usually caused by severe wear of the spindle bearing. Under high-speed rotation, the bearing clearance will gradually increase, which will have a direct impact on the machining accuracy. Use a dial indicator to check the repeatability of the pallet, adjust the screw clearance, and replace worn bearings in a timely manner.

The curvature processing effect is not ideal

When processing arc parts, it often happens that the arc is not circular. When processing curved surface parts, it often happens that the dimensions do not reach the specified position. This type of problem is particularly common in precision mold processing. This type of problem is particularly common in the processing of complex structural parts, which greatly affects the overall quality of the product.

The main reason is the common quality problems in CNC machining. Common quality problems in CNC machining. Why do various error problems occur in CNC machining? How to solve it? , the superposition of vibration frequencies leads to the occurrence of resonance, or the synchronous belt wears and becomes loose, resulting in lost steps. At this time, it is necessary to optimize the processing parameters, moderately reduce the operating speed of the stepper motor, and replace the worn transmission belt to eliminate the impact of resonance.

How to troubleshoot large dimensional errors

When processing a part, if its size differs by a few millimeters compared to the theoretical value, or if the size in a certain direction changes significantly, this means that the problem is serious. Such errors are usually not caused by a single factor, but are the final result formed by the superposition of multiple links.

When positioning quickly, if the speed is set too high, it will cause a lag in the response of the driver. After a long period of continuous operation, the mechanical tow bar and bearings will suffer from excessive wear. If the tool holder is not locked firmly, or there is an error in programming, these situations may cause the above-mentioned problems. For this, it is necessary to investigate one by one and adjust each parameter.

Accidental errors occur frequently in mass production

After reaching the mass production stage, some factories will notice that certain product sizes will show random fluctuations, sometimes good and sometimes bad, which is simply difficult to predict. This kind of accidental error, a common quality problem in CNC machining , is really the most troublesome. This is because it is not as easy to locate and correct as a systematic error.

The main causes are negligence in manual operation and lack of fixture reliability. Electromagnetic interference may also affect the stability of the CNC system. It is recommended to increase anti-interference capacitors, use shielded wires, etc., and at the same time check whether the grounding is solid and reliable.

Did this article help you? What accuracy-related problems have you encountered during CNC machining? You are welcome to share and interact in the comment area!