Introduction
This project focuses on surface cracking caused by the turning of engine blocks with CNC lathes. CNC machine tools are one of the most common and most important machines used in the machining process. The surface integrity of the workpiece being machined is affected by both the design parameters and the choice of cutting tools. Therefore, any surface crack interference phenomenon will affect the machining precision and processing quality, resulting in inferior quality and reduced service life. In order to analyze and solve surface cracks caused by CNC lathes, this article will focus on the causes, analysis and improvement measures of surface cracks caused by the turning of engine blocks.
Background
In today’s modern production systems, CNC machine tools play an important role in improving the accuracy, efficiency and quality of machining operations. CNC lathes are widely used in the machining of engine blocks. CNC lathe is a kind of equipment to realize automatic machining, which has the advantages of high machining accuracy, high machining efficiency and high production efficiency. However, due to the complex processes and severe cutting parameters, surface cracks may appear in the machined workpiece.
Causes Analysis
Surface cracks in the machined workpiece are caused by various factors during the machining process. The main factors that affect the surface crack fault in CNC lathes are as follows:
1. Cutting parameters: Unreasonable cutting parameters can lead to poor chip formation and cracking.
2. Tool materials: The tool material affects the cutting performance and the tool life. Poor cutting performance and a short tool life will increase the possibility of surface cracks.
3. Cutting fluid: Cutting fluid composition, cleanliness and cooling effect has a great influence on heat transfer and therefore has a great effect on machining accuracy and surface defects.
Analysis:
Surface cracks caused by CNC lathes can cause catastrophic failure of the machine, stability of machining accuracy and reduced service life. Therefore, it is necessary to analyze and detect surface cracks of CNC lathe. The following methods can be adopted for the analysis and detection of surface cracks:
1. Ultrasonic testing: Ultrasonic testing can be used to detect surface and subsurface cracks. It can quickly detect low reflectivity and high energy reflection of ultra-fine cracks within the depth of material.
2. Stroboscope: The stroboscope can be used to detect surface cracks of CNC lathe. It can realize rapid check of surface cracks and detect the change of cracks in the original position.
3. Slitting: Slitting can detect surface cracks of CNC lathe. The slitting method can quickly trace the surface crack of CNC lathe, so that the exact position of the crack can be determined.
Improvement Strategies
In order to prevent and reduce the occurrence of surface crack defects in the machining process, the following improvement strategies can be adopted:
1. Reasonable cutting parameters: Reasonable cutting parameters must be selected to ensure efficient cutting performance and prevent surface cracks.
2. Tool optimization: The use of suitable tools, such as polycrystalline diamond (PCD) cutting tools, can reduce surface cracking and improve tool life.
3. Corrosion protection measures: Use appropriate anticorrosion protection measures such as using air coolant to increase cooling and reduce oxidation of the workpiece.
4. Stress relief measures: Applying appropriate stress relief measures, such as preheating, can reduce the stress concentration of the workpiece and prevent surface cracks.
Conclusion
In conclusion, improved machining accuracy and quality can be achieved by understanding the causes and analyzing the surface cracks of CNC lathes. Reasonable selection of cutting tools and cutting parameters, adapting appropriate anti-corrosion and stress relief measures can prevent and reduce surface cracking and improve machining quality.
