In modern manufacturing, horizontal machining centers are important equipment for precision machining, and their machining accuracy directly affects the quality and production efficiency of products. However, in actual production, the problem of poor machining precision of horizontal machining centers often occurs, which not only increases production costs but may also have adverse effects on the product's performance. This article will explore the reasons, influencing factors, and corresponding solutions for the poor machining precision of horizontal machining centers from multiple perspectives.
1、 Analysis of the Reasons for Poor Precision in Horizontal Machining Centers
1. Insufficient rigidity of the equipment
The rigidity of horizontal machining centers is one of the key factors affecting machining accuracy. The insufficient rigidity of the equipment is mainly reflected in two aspects: the rigidity of the machine tool structure and the rigidity of the transmission system. The insufficient rigidity of the machine tool structure may be caused by loose inserts on the sliding plate, unstable spindle support system, and other reasons, resulting in vibration during the machining process, which in turn affects the machining accuracy. Insufficient rigidity of the transmission system may be caused by wear and tear of transmission components, excessive clearance, or improper assembly, leading to the accumulation of errors in the transmission chain and ultimately reflected on the machined parts.
2. Insufficient rigidity of cutting tools and workpieces
The rigidity and installation accuracy of cutting tools directly affect the cutting stability and machining accuracy during the machining process. If the rigidity of the cutting tool is insufficient or installed improperly, it is easy to generate vibration and displacement during the cutting process, resulting in an increase in surface roughness and a decrease in machining accuracy. Similarly, insufficient rigidity of the workpiece can also affect machining accuracy due to deformation caused by cutting forces. This problem is particularly prominent when processing workpieces with poor rigidity such as slender shafts and thin-walled parts.
3. Unreasonable cutting parameter settings
Cutting parameters include cutting speed, feed rate, cutting depth, etc. The reasonable setting of these parameters is crucial for ensuring machining accuracy. If the cutting parameters are not set reasonably, such as too fast cutting speed, excessive feed rate, etc., it will exacerbate tool wear and workpiece deformation, thereby affecting machining accuracy. In addition, not adding cutting fluid during low-speed cutting can also lead to an increase in cutting heat, further exacerbating workpiece deformation and surface roughness deterioration.
4. Systematic errors and human factors
The machining accuracy of horizontal machining centers is also affected by systematic errors and human factors. Systematic errors include manufacturing errors, assembly errors, servo system errors, etc. of the machine tool itself, which will gradually accumulate and affect machining accuracy over long-term use. Human factors are mainly reflected in the programming of machining programs, the selection and installation of cutting tools, the clamping and positioning of workpieces, and any negligence in any link may lead to a decrease in machining accuracy.
2、 The influence of machining precision difference on horizontal machining center
Poor precision in horizontal machining centers not only leads to substandard product quality, increased scrap and repair rates, but also affects the production efficiency and economic benefits of enterprises. Specifically, poor machining precision may have the following impacts:
1. * * Decreased product quality * *: Failure to meet processing accuracy standards will directly affect the product's performance and lifespan, reducing customer satisfaction and market competitiveness.
2. * * Increased production costs * *: The increase in scrap and repair rates will increase the production costs of enterprises, including waste of raw materials, labor, energy, and other aspects.
3. * * Decreased production efficiency * *: Frequent equipment adjustments, tool changes, and workpiece rework can interrupt the production process and reduce overall production efficiency.
4. Damage to Corporate Image: Frequent product quality issues can damage a company's brand image and reputation, affecting its long-term development.
3、 Strategies for improving the machining accuracy of horizontal machining centers
To address the issue of poor machining precision in horizontal machining centers, efforts can be made to improve machining accuracy from the following aspects:
1. Strengthen equipment maintenance and management
Regularly maintain the horizontal machining center, check and adjust key parameters such as the rigidity of the machine tool, clearance and accuracy of the transmission system. At the same time, establish a comprehensive equipment management system to ensure that the equipment operates in its optimal state.
2. Optimize cutting parameters and tool selection
Reasonably set cutting parameters based on the characteristics of the processing material and workpiece, such as cutting speed, feed rate, cutting depth, etc., to reduce the impact of cutting force and cutting heat on the workpiece. At the same time, select suitable cutting tools for processing materials and requirements, and ensure that the rigidity and installation accuracy of the tools meet the requirements.
3. Strengthen personnel training and management
Strengthen the training and management of operators, improve their professional quality and operational skills. Through regular training, skill assessment, and on-site guidance, ensure that operators can proficiently master the operation methods and processing techniques of horizontal machining centers, and reduce the impact of human factors on machining accuracy.
4. Implement online monitoring and compensation technology
Adopting advanced online monitoring technology to monitor real-time changes in various parameters during the machining process, such as cutting force, vibration, temperature, etc., and adjusting machining parameters and compensating for errors in a timely manner based on monitoring results. At the same time, utilizing advanced numerical control systems to precisely control machine tools can further improve machining accuracy.
5. Introduce intelligent manufacturing technology
With the development and application of intelligent manufacturing technology, more and more enterprises are beginning to introduce intelligent manufacturing technology into production practice. By introducing intelligent manufacturing technologies such as smart robots, automated production lines, etc., the intelligent and automated control of the production process can be achieved, improving machining accuracy and production efficiency. Meanwhile, intelligent manufacturing technology can also achieve real-time collection, analysis, and processing of production data, providing strong support for enterprise production decisions.
In summary, the problem of poor machining precision in horizontal machining centers is a complex and important issue. By strengthening equipment maintenance and management, optimizing cutting parameters and tool selection, enhancing personnel training and management, implementing online monitoring and compensation technology, and introducing intelligent manufacturing technology, the machining accuracy and production efficiency of horizontal machining centers can be effectively improved, creating greater economic and social benefits for enterprises.
