Posted on Oct. 17th, 2018, | By Will, WayKen Project Manager
Nowadays, mechanization and automation have become the mainstream of industry development. In the process of application, the machines and equipment assembled from various parts are easy to have problems due to the lack of coordination or cooperation of certain parts.Raw material specifications, performance, material using, machine vibration, clamp pressure or looseness, elastic deformation of the process system, workers operation, testing methods and inspectors errors etc., all have an impact on the quality of the machined products. When we talk about the quality of working prototype, it is not hard to think of the following 5 major factors:
As machine functions become more complex, the level of programming and operating personnel varies widely. Combining high human skills with computer information technology can make the most use of machines. To make this, machine operators must be familiar with the equipment performance. If the operator does not know enough about the equipment performance, he may operate in wrong way, thus accelerating wear of the machine parts and even causing machine damage.
Therefore, this will require much repair costs and a long maintenance time. In order to restore the original accuracy of the equipment, machine operator must understand and master the machine tool manual and its operating precautions so that civilized production and safe processing. It’s necessary to strengthen the skills training for all personnel in processing and production, rationally arrange primary and secondary processing positions, improve personnel’s quality awareness and work responsibility.
A complete machining system consists of machine, workpiece, jig and cutter. Machining accuracy relates to the accuracy of the entire process system. The various errors of the process system will reflected in different forms as machining tolerance in different situations.
Machine accuracy is an important factor affecting the quality of prototype parts. When the machine accuracy is poor, some parts are damaged or the gaps of each part are not properly adjusted, there will be various defects on prototypes during processing.
Therefore, we should not only choose the right turning angle, proper cutting amount and the processing method, but also understand the influence of the machine precision on the processing quality. The maintenance of machine directly affects the processing quality and production efficiency of the prototypes. In order to ensure the working accuracy and prolong its working life, all machines must be maintained properly. Usually after machine operated for 500 hours, a first-level maintenance is necessary.
There are many kinds of processing methods, cutting process is one of the most common ones among them. During the cutting process, the workpiece is subjected to changes in force and heat, physical and mechanical properties of the metal material will be also slightly hardened, so the choice of cutter plays an important role.
Under normal circumstances, the material for making cutter should be selected according to the material of workpiece to be processed. Otherwise, the workpiece surface would form a thorn related to cutter, which easily increasing the roughness of workpiece while reducing surface quality. Except cutter factor, the cutting environment and the processing of cutting conditions, such as cutting amount and cutting lubrication also have influence on the machining quality.
In the machining process, the processing system is general command of the whole cutting process. All machining processes are implemented according to the system, so the accuracy and rigidity of the processing system are also one of the main factors affecting the machining quality.
There are two principles of machining process arrangement:
- Processing dispersion: using multi-process to make complex parts, decomposing them into multi machines for processing.
- Processing concentration: compounded machine functions, like turning and milling compounded, laser ultrasonic vibration processing, grinding, five-axis linkage, and even more.
All processes are completed by one machine. Depending on the structural analysis of the workpiece, use different processing method is also an important factor affecting the machining quality.
Machined materials are generally divided into plastic and metal. Each material has its own characteristics. It is also important to select the right material according to the requirements of the workpiece and the application during machining process. The consistency of the materials should be good, otherwise the quality of the same part would may be different. Try to make sure there is no deformation of the material while the hardness of the material is suitable. These are important prerequisites for evaluating quality.
After the machine has finished machining the workpiece, inspection is the last crucial step before being delivered to customers. The inspection of machining generally needs to pay attention to two aspects:
1.Inspection procedure- The inspection process includes the inspection process, and related regulations, systems, standards, and so on. Generally speaking, the inspection process is where the inspection is intervened during the production process and how it is intervened, including the first inspection, self-inspection, mutual inspection and full-time inspection.
2.Inspection method-it refers to how to inspect and inspect standards. The inspection of machining parts is generally based on mechanical drawings, and the products are qualified by inspection instruments and measuring tools.
Traditional machining inspection Vs More Modern Machining Inspection
Traditional machining inspection instruments include micrometer, dial indicator, vernier card, flat, ruler, level and various plug gauges, ring gauges and so on. The more modern machining inspection instruments include optical collimator, projector, three-dimensional measuring instrument, theodolite, laser detector and so on.
A qualified mechanical product inspector must master knowledge of the inspection instruments and measuring tools that related to the unit product.
In the machining process, to control the machining quality, it is necessary to understand and analyze various influencing factors that the processing quality cannot meet requirements while taking effective technical measures to overcome them.
With the continuous improvement of the modern production level, the machining products demand for quality is also getting higher and higher. Only if comprehensive measures are taken to control quality can ultimately in the purpose of improving the serviceability and working life of equipment, economic benefits and energy saving be considered during machining. At the same time, we must ensure the machining quality so as to promote the long-term stable development of the machining industry.