1、 Equipment start stop specifications
Pre start check
Mechanical system: Confirm the tension of the sanding belt/drawing wheel (measured with a tension meter, deviation<5%), and the amount of lubricating grease on the guide rail (coverage rate of over 90%)
Electrical system: Emergency stop button reset, grounding resistance<4 Ω, no fault code in frequency converter (such as ABB ACS550 displaying "OK")
Gas source requirements: The air pressure should be stable at 0.6-0.8MPa, and the drip rate of the triple component oil mist device should be adjusted to 2-3 drops per minute
Cold machine preheating
The spindle runs without load for 5-10 minutes (gradually increasing the speed to 50% of the rated value), and the bearing temperature is less than 65 ℃ (monitored by an infrared thermometer)
2、 Processing process control
Material clamping iron law
When using magnetic fixtures, the residual magnetic strength should be greater than 1200 Gauss (to prevent sheet displacement)
Alien parts must be equipped with imitation pads with a contact area greater than 80% to avoid uneven texture caused by suspension
Parameter dynamic matching
Hardness velocity pressure three-dimensional matching table (taking 304 stainless steel as an example):
Target Ra (μ m) Drawing Wheel Hardness (Shore A) Linear Speed (m/min) Pressure (N/cm 2)
3.2 85-90 18-22 16-20
1.6 75-80 12-15 10-12
0.8 60-65 8-10 6-8
Real time monitoring points
Vibration monitoring: Install an acceleration sensor and immediately stop the machine for troubleshooting when the amplitude is greater than 0.15mm
Temperature control: The processing area is equipped with an infrared thermal imager, which automatically alarms when the material recrystallization temperature (such as aluminum alloy 230 ℃) is exceeded
3、 Security protection system
Triple guarantee of personal protection
Anti splash goggles (EN166 standard) and noise cancelling earplugs (NRR ≥ 25dB) must be worn
Do not wear gloves during operation. The cuffs and collar should be tightly tied, and long hair should be tucked into the work cap
Emergency Response Plan
Belt breakage protection: When the sand belt breaks, the brake should lock the spindle within 0.5 seconds (test cycle: once a week)
Fire prevention and control: When processing magnesium/titanium alloys, Class D fire extinguishers should be installed within 1 meter of the workbench (water-based fire extinguishers are strictly prohibited)
4、 Process quality assurance
First article inspection standard
Vertical/horizontal Ra difference<15%
The consistency between the texture within 5mm of the edge and the central area is greater than 90%
Use a surface roughness meter (such as Mitutoyo SJ-410) to detect 3 points:
Batch processing control
Use a colorimeter to detect the degree of surface oxidation (Δ E<1.5)
Check the wear of the wire drawing wheel (measure the diameter with a caliper, replace if the wear is greater than 2mm)
After processing 20 pieces:
5、 Equipment maintenance cycle
Daily maintenance
Post shift cleaning: Use a vacuum cleaner (explosion-proof type) to remove metal dust, apply WAY grease to the guide rail (butter is prohibited)
Electrical inspection: Use a megohmmeter to measure the insulation resistance of the motor (>5M Ω)
Deep maintenance
Monthly: Replace spindle bearing grease (SKF LGMT3), synchronous belt tension correction (frequency analyzer detection)
Quarterly: Servo motor encoder zeroing calibration, ball screw reverse clearance compensation (laser interferometer accuracy 0.005mm)
6、 Special working condition handling
Difficult problem solutions
Stripe defect: Adjust the parallelism of the feeding roller (check with a dial gauge, error<0.02mm/300mm)
Aluminum sticking phenomenon: spraying PTFE coating (thickness 0.01-0.03mm) on the surface of the drawing wheel, reducing the processing temperature by 40-60 ℃
