In mold factories, CNC machining centers are mainly used for the processing of mold cores, inserts and other key mold parts and copper cores. The quality of mold cores and inserts directly determines the quality of mold forming parts. The quality of copper core processing directly restricts the impact of EDM processing. The key to ensuring the quality of CNC processing lies in the preparation before processing. For this position, in addition to having rich processing experience and mold knowledge, you must also pay attention to good communication at work, especially with the production team and colleagues.
1) Read drawings and program sheets
2) Transfer the corresponding program to the machine tool
3) Check the program header, cutting parameters, etc.
4) Determine the machining size and allowance of the workpiece
5) Reasonable clamping of the workpiece
6) Accurate alignment of the workpiece
7) Accurate establishment of workpiece coordinates
8) Selection of reasonable tools and cutting parameters
9) Reasonable clamping of tools
10) Safe trial cutting method
11) Observation of the machining process
12) Adjustment of cutting parameters
13) Timely feedback of problems and relevant personnel during the machining process
14) Inspection of workpiece quality after machining
1) For new molds, the machining drawings must meet the requirements and the data must be clear; the machining drawings of new molds must be signed by the supervisor, and the columns of the machining drawings must be filled in.
2) The workpiece has a qualified mark from the quality department.
3) After receiving the program sheet, check whether the workpiece reference position is consistent with the drawing reference position.
4) Look carefully at each requirement on the program sheet and confirm whether the program and the drawing requirements are consistent. If there is a problem, it must be solved together with the programmer and the production team.
5) According to the material and size of the workpiece, judge the rationality of the tool selected by the programmer for the roughing or polishing program. If the tool application is found to be unreasonable, the programmer should be notified immediately to make corresponding changes to improve the processing efficiency and workpiece processing accuracy.
1) When clamping the workpiece, pay attention to the position of the code and the extension length of the nut bolt on the pressure plate. In addition, the screws should not hit the bottom when locking the corner.
2) The copper male is generally processed by locking the plate. Before loading the machine, the number of cutting materials on the program sheet should be checked to ensure consistency, and the plate closing screws should be checked to see if they are tightened.
3) For the case of collecting multiple pieces of copper materials on one plate, check whether the direction is correct and whether there is interference during the processing of each copper material.
4) Clamp the workpiece according to the shape of the program sheet and the workpiece size data. It must be noted that the workpiece size data is written as XxYxZ. At the same time, if there is a loose parts drawing, it is necessary to check whether the graphics of the program sheet and the graphics of the loose parts drawing are consistent, pay attention to which direction is out, and the swing of the X and Y axes.
5) When clamping the workpiece, it is necessary to check whether the workpiece size meets the size requirements of the program sheet. If there is a loose parts drawing, it is necessary to check whether the size of the program sheet is the same as the size of the loose parts drawing.
6) The workbench and the bottom of the workpiece should be cleaned before the workpiece is put on the machine. The machine table and the workpiece surface should be pushed away with oilstone to remove the burrs and damaged positions.
7) When coding, ensure that the coder will not be hurt by the knife. If necessary, communicate with the programmer. At the same time, if the bottom is squared, the coder must be aligned with the square pad position to achieve the purpose of force balance.
8) When using a vise for clamping, it is necessary to understand the tool processing depth to prevent the clamped position from being too long or too short.
9) The screw must be received in the T-block, and only part of the thread must not be used. If the screw needs to be connected, the upper and lower screws must each use half of the thread of the joint, and the thread of the nut on the pressure plate must be fully used, and only a few threads must not be received.
10) When determining the Z depth, you must clearly see the position of the program sheet touch number and the data of the highest Z point. After entering the data into the machine tool, you must check it again.
1) When dragging the workpiece, you must pay attention to the verticality. Drag one side flat and then drag the vertical side.
2) When centering the workpiece, you must center it twice for verification.
3) After centering and touching the number, you should check the center position according to the external dimensions provided by the program sheet and the dimensions on the loose parts drawing.
4) All workpieces must be centered using the centering method. The zero position on the edge of the workpiece must also be centered using the centering method and then moved to the edge. It must ensure that the margins on both sides are consistent. If special circumstances require single-sided data, you must obtain confirmation from the production team again before passing. After single-sided data, remember to compensate for the radius of the centering rod.
5) The zero position input of the workpiece center must be the same as the three-axis center of the workstation computer diagram.
1) When the allowance on the top surface of the workpiece is too large, remember not to cut too deep when using a large knife to manually remove the allowance.
2) The most important part of machining is the first cut, because if you operate and check carefully, you can know whether the tool length compensation, tool diameter compensation, program, speed, etc. are wrong, avoiding damage to the workpiece, tool and machine tool.
3) Test the cutting procedure in the following way:
a) The first point height is the highest rise of 100mm, and use your eyes to feel whether it is correct;
b) Control "fast move" to 25% and feed to 0%;
c) When the tool approaches (about 10mm) the machining surface, pause the machine;
d) Check whether the remaining stroke and program are correct;
e) After restarting the machine, put one hand on the pause button, ready to stop at any time, and control the feed speed with the other hand;
f) When the tool is very close to the workpiece surface, it can stop again, and the remaining stroke of the Z axis must be checked.
g) After the machining and cutting are smooth and stable, adjust each control back to normal.
4) After entering the program name, copy the program name on the screen with a pen, and then check it with the program sheet. When opening the program, pay attention to check whether the tool diameter size in the program is consistent with the program sheet, and fill in the file name and tool diameter size in the signature column of the processor on the program sheet immediately. It is forbidden to fill in it afterwards or in advance.
5) In principle, NC technicians should not leave when the workpiece is roughing. If they have to leave due to tool change or assistance in adjusting other machine tools, they must ask other NC team members or come back regularly to check.
6) When doing intermediate polishing, NC technicians should pay special attention to the areas that were not opened during roughing to prevent the tool from hitting this area.
7) Program cutting. If the program is interrupted during processing and it takes too much time to run it from the beginning, the team leader and programmer should be notified to modify the program and cut off the part that has been run.
8) Program abnormality. If the program has an abnormal situation and you are not sure, you can hang it up to observe the process and then decide the next step.
9) During the processing, the speed and rotation speed provided by the programmer can be adjusted by the NC technician according to the situation. However, special attention should be paid to the speed when roughing small copper parts, so as to avoid the workpiece from loosening due to vibration.
10) During the workpiece processing, the NC technician should check with the loose parts drawing to see if there are any abnormal conditions. Once the two are found to be inconsistent, the machine must be stopped immediately to notify the team leader to check if there are any errors.
11) When using a tool longer than 200mm for processing, attention must be paid to issues such as allowance, feed depth, rotation speed, and speed to avoid tool swinging. At the same time, the speed of the corner position should be controlled.
12) For the tool diameter detection required on the program sheet, the operator must be responsible and record the tested diameter. If it exceeds the tolerance range, it should be reported to the team leader or the tool should be changed immediately.
13) When the machine tool is in automatic operation or free, the operator should go to the workstation to understand the remaining processing programming, prepare and grind the appropriate tool for the next processing to avoid downtime.
14) Process errors are the main reason for wasting time: incorrect use of inappropriate tools, errors in the order of processing, wasting time in positions that do not need to be processed or are not computer-processed, and improper processing conditions (too slow speed, empty tool, too dense tool path, too slow feed, etc.). When the above events occur, you can contact programming, etc.
15) During the processing, you must pay attention to the wear of the tool, and you should replace the tool particles or tools appropriately. After replacing the tool particles, pay attention to whether the connecting boundaries of the processing are consistent.
1) Confirm that each program and each instruction required by the program sheet has been completed.
2) After processing is completed, it is necessary to check whether the shape of the workpiece meets the requirements, and at the same time, perform a self-check of the workpiece size according to the loose parts drawing or process drawing to find errors in time.
3) Check whether there are any abnormalities in each position of the workpiece. If there are any questions, notify the NC team leader.
4) When a larger workpiece is unloaded from the machine, the team leader, programmer and production team leader must be notified.
5) Pay attention to safety when the workpiece is unloaded from the machine, especially when a larger workpiece is unloaded from the machine, the workpiece and NC machine should be well protected.
Surface quality of polishing:
1) Mold core, insert
2) Copper male
3) Avoid empty space at the top pin plate support head hole, etc.
4) Eliminate vibration marks
Dimensions of polishing:
1) Measurable dimensions must be strictly self-checked after processing
2) Tool wear must be considered during long-term processing, especially at the sealing position and other cutting edges
3) New carbide tools should be used as much as possible for polishing
4) Determine the mold saving after polishing according to the processing requirements
5) Confirm the quality of production and quality after processing
6) Control tool wear during the processing of the sealing position according to the processing requirements
1) Confirm the operation status of the shift, including processing status, mold status, etc.
2) Confirm whether the equipment is working normally during the shift.
3) Other handovers and confirmations, including drawings, program sheets, tools, gauges, fixtures, etc.
Workplace organization
1) Follow the 5S requirements.
2) Tools, gauges, fixtures, workpieces, tools, etc. are classified and placed neatly.
3) Cleaning of machine tools.
4) Cleaning of the floor of the workplace.
5) Return of processed tools, idle tools, and measuring tools to the warehouse.
6) Sending processed workpieces to quality inspection or relevant departments.
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