What should I do if the size of CNC machining is unstable? Do it like this!

1. Inaccurate Workpiece Dimensions and Poor Surface Finish

Cause of the Issue:

1) The cutting tool is damaged or not sharp.
2) The machine tool experiences vibration or is unevenly placed.
3) Mechanical crawling occurs due to worn guide rails or loose ball screws.
4) Improper machining techniques are used.

Solution (with comparison):

1) If the tool is dull or damaged, re-grind it or replace it with a sharper one.
2) Adjust the machineâ€™s level, ensure a solid foundation, and fix any instability to reduce vibration.
3) Check for wear on the carriage guide rails and ball screws. Regular maintenance, including cleaning and lubrication, can help prevent crawling.
4) Use an appropriate coolant for the material being machined. If possible, increase the spindle speed to improve surface finish and accuracy.

2. Tapered Workpiece Size

Cause of the Issue:

1) The machine tool is not leveled properly, leading to uneven placement.
2) When turning a long shaft, the workpiece is hard, causing the tool to dig in.
3) The tailstock center is not aligned with the spindle.

Solution:

1) Level the machine tool and ensure it is placed on a solid, stable foundation.
2) Select an appropriate cutting process and feed rate to avoid excessive tool pressure.
3) Adjust the tailstock to align it with the spindle center.

3. Inconsistent Workpiece Size Despite Normal Driver Phase Lamp

Cause of the Issue:

1) Pallets running at high speed cause wear on the screw and bearings.
2) Tool holder positioning accuracy drifts over time.
3) The main spindle may be worn, causing size changes during high-speed operation.

Solution (with comparison):

1) Use a dial gauge to check the repeat positioning accuracy of the carriage. Adjust screw clearance or replace the bearing if necessary.
2) Check the tool holderâ€™s repeatability using a dial indicator. Adjust or replace as needed.
3) Inspect the spindle for runout and replace the bearing if it is worn out.

4. Workpiece Size Varies by a Few Millimeters or Axial Changes

Cause of the Issue:

1) Rapid positioning speed is too fast, causing the drive to lose synchronization.
2) Long-term friction causes tightness in the lead screw and bearings.
3) Tool holder is too loose after tool change.
4) Program errors cause improper tool cancellation.
5) Incorrect system settings like electronic gear ratio or step angle.

Solution (with comparison):

1) Adjust G0 speed, acceleration, and deceleration time to match the motorâ€™s rated frequency.
2) Re-adjust the machine after wear has occurred, ensuring proper clearance between the screw and bearing.
3) Check the tool holderâ€™s reversal time and internal components for wear or looseness.
4) Correct the program to ensure accurate processing according to the drawing specifications.
5) Verify system parameters, especially the electronic gear ratio and step angle, and adjust if necessary.

5. Poor Arc Machining Effect and Misaligned Dimensions

Cause of the Issue:

1) Vibration frequencies overlap, causing resonance.
2) Improper machining technique.
3) Feed rate is too high, leading to stepping out of sync.
4) Excessive backlash or tightness in the lead screw.
5) Worn timing belt.

Solution:

1) Identify and adjust the source of resonance to avoid frequency overlap.
2) Optimize the machining process based on the material properties.
3) For stepper motors, avoid setting the feed rate too high.
4) Ensure the machine is securely installed, and check for wear or looseness in the carriage or tool holder.
5) Replace the worn timing belt to restore smooth motion.

6. Occasional Dimensional Deviation in Mass Production

Cause of the Issue:

1) Dimensional changes occur without parameter adjustments.
2) After re-aligning the tool, the dimensions become accurate again.

Solution:

1) Carefully inspect the fixture and operator technique to ensure consistent clamping. Improve the tooling design to minimize human error.
2) Reduce external interference by isolating strong electric cables from signal lines, adding capacitors, and using shielded cables. Ensure proper grounding to prevent electrical noise from affecting the system.

7. One Part of the Workpiece Has Dimensional Changes, Others Are Accurate

Cause of the Issue:

Whether the block program parameters are set correctly and whether the programming format meets the standard requirements.

Solution:

When thread machining results in incorrect pitch, check the encoder configuration and spindle speed. Ensure the number of encoder pulses matches the system settings. For arc blocks, verify that the arc path is correct and that there are no special relationships between circles.

8. Increasing or Decreasing Dimension in Each Process

Cause of the Issue:

1) Program writing errors.
2) Unreasonable system parameter settings.
3) Incorrect configuration settings.
4) Periodic changes in mechanical transmission components.

Solution:

1) Check if the program follows the required trajectory. Use a dial indicator to monitor position accuracy during repeated runs.
2) Review system parameters to ensure they are set correctly and have not been altered.
3) Confirm that the machine tool's configuration calculations, such as pulse equivalent, are accurate.
4) Inspect the machineâ€™s transmission components for damage or irregularity. Check gears and couplings for uniform movement and regular failure patterns.

9. Slight Dimensional Difference from Actual Size

Cause of the Issue:

1) Increased screw clearance due to long-term wear causes large backlash, resulting in floating dimensions.
2) Incorrect tool selection or poor clamping leads to dimensional variation.
3) Improper selection of spindle speed, feed rate, and cutting depth.
4) Instability in machine tool placement affects accuracy.
5) CNC system issues like out-of-step or insufficient driver power.
6) Is the tool holder locked after a tool change?
7) Spindle runout or misalignment of the tailstock.
8) Backlash cannot be compensated in certain processes, leading to continuous deviation.

Solution (with comparison):

1) Adjust the screw nut to reduce backlash, or use gap compensation in the system to maintain accuracy.
2) Choose the right tool based on the workpiece material and ensure proper clamping.
3) Program the process correctly, selecting appropriate speeds and feeds based on the material type.
4) Ensure the machine is placed stably and levels are adjusted to prevent resonance.
5) Check the program and system parameters for accuracy. Verify the driverâ€™s power and pulse output.
6) Confirm the tool holder has enough time to lock after a tool change.
7) Inspect the spindle and tailstock for coaxiality and runout.
8) Use advanced programming techniques to compensate for backlash in the system.

10. Dimensional Instability Caused by the Drive

Cause of the Issue:

1) Signal loss from the driver causes it to lose synchronization.
2) Improper servo drive parameters or gain factor settings.
3) Signal interference causes the drive to lose steps.
4) High temperature environment reduces stability and may alter internal drive parameters.
5) Insufficient torque from the drive or motor.
6) Low driver current.
7) Drive damage.

Solution (corresponding to the above):

1) Determine whether the drive is a stepper or servo type. Use phase lamps or dial indicators to detect synchronization issues.
2) Adjust gain parameters according to the DA98 manual.
3) Install shielded cables and anti-interference capacitors.
4) Ensure good ventilation and cooling to maintain optimal operating temperatures.
5) Replace the drive or motor to meet the required torque needs.
6) If current is still insufficient, consider replacing the drive.
7) Send the drive to the factory for repair if it is damaged.

11. Dimensional Change Due to System Instability

Cause of the Issue:

1) System parameter settings are incorrect.
2) Unstable power supply voltage.
3) External interference causes the system to lose steps.
4) Mismatched impedance between the system and driver causes signal loss.
5) Incorrect signal transmission between the system and driver.
6) System damage or internal failure.

Solution (with comparison):

1) Check if the system settings, such as speed, acceleration, and spindle speed, are reasonable. Monitor for any changes caused by user modifications.
2) Install a voltage regulator to stabilize the power supply.
3) Ensure proper grounding and install anti-interference capacitors at the driverâ€™s pulse output contact. Larger loads can increase interference, so manage accordingly.
4) Choose the correct capacitor model to match the system requirements.
5) Check the signal connections between the system and driver for reliability and shielding. Ensure no pulse signal is lost or distorted.
6) Send the system to the factory for repair or replace the motherboard if necessary.

12. Mechanically Unstable Processing Dimensions

Cause of the Issue:

1) The stepper motor damping plate is too tight or too loose.
2) Water ingress into the motor plug causes insulation failure or motor damage.
3) The workpiece is not properly clamped.
4) The workpiece is oval-shaped.
5) Excessive screw backlash.
6) The mechanical screw is installed too tightly.

Solution (with comparison):

1) Adjust the damping plate to prevent motor resonance.
2) Replace the motor plug, protect it, or replace the motor if damaged.
3) Check the feed rate and clamping force. Avoid extending the chuck too far to prevent tool interference.
4) Inspect the spindle for runout and overhaul if necessary, replacing bearings if worn.
5) Measure the screw backlash with a dial indicator. Ensure the system compensates for any excess clearance.
6) Check for crawling or slow response in the screw mechanism.

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