Ordinary lathes are common equipment in the mechanical industry, and their operation involves many technologies, such as motor technology, sensing technology, automation technology, etc., exhibiting comprehensive characteristics. Ordinary lathes have strong working capabilities and can provide high-precision and high-level mechanical manufacturing services. Although ordinary lathes have strong working capabilities, they still face interference from malfunctions.
1.Analysis of Ordinary Lathe
In the mechanical processing factory, ordinary machine tools occupy the majority of the influence proportion in the workshop and penetrate into the mechanical processing industry. The industry has increased its attention to ordinary lathe faults and is committed to adopting troubleshooting methods to ensure the effectiveness of ordinary lathes. In the mechanical industry, lathes are used to process various rotating surfaces, such as circular and conical surfaces, as well as threads, grooves, etc. They utilize the components of ordinary lathes such as bed bodies and tool holders, in conjunction with the working principles of ordinary lathes, to achieve main motion and feed motion. During the movement of lathe tools and workpieces, the blanks can be processed into specified geometric dimensions.
In the use of an ordinary lathe, faults are inevitable. If faults cannot be eliminated within a certain time frame, it will interfere with the operating level of the lathe, thereby affecting the accuracy and speed of the lathe processing, and not conducive to the efficiency of the lathe. The faults of ordinary machine tools occur in daily operation and use. In order to improve the working ability of ordinary lathes, faults should be the primary monitoring object to protect the operation process of ordinary machine tools. There are some typical symptoms in ordinary lathe faults. Experienced operators will roughly judge the operating faults based on the symptoms of lathe faults, timely control the fault information during lathe operation, make up for the defects during lathe operation, and then implement effective troubleshooting methods.
2. Reason for lathe malfunction
The causes of faults in ordinary lathes exhibit diverse characteristics, and the following are the common causes of Z faults in ordinary lathes:
The quality reasons for the components of an ordinary lathe include the mechanical devices and component equipment of the lathe itself. If quality problems occur during the operation of the lathe, resulting in malfunction or loss of control, it will affect the overall condition of the ordinary lathe, and problems such as wear and damage will directly affect the machining accuracy of the lathe, thereby interfering with the actual operation of the ordinary lathe. The quality of the components is the direct cause of Z failure in ordinary lathes, causing a series of fault problems.
Secondly, there is a lack of precision control measures in the installation and assembly process of ordinary lathes. For example, in the installation of the main body of an ordinary lathe, such as the spindle box and feed box, there is no strict control of accuracy during installation. As long as there is a malfunction, it will interfere with the overall accuracy of the ordinary lathe and cannot guarantee the effective assembly of the ordinary lathe, resulting in installation and assembly errors. Fault interference is introduced during the operation of the lathe, gradually reducing the accuracy of the lathe operation.
Thirdly, when using an ordinary lathe, there are unreasonable operations that interfere with the technical parameters of the lathe, resulting in a lack of effective working ability within its own processing range. In the operation of an ordinary lathe, if the operator cannot follow the working procedures of the lathe, it will cause many problems, especially the accuracy of the ordinary lathe, which directly increases the operating burden of the lathe and increases the pressure of the lathe.
Fourthly, the maintenance and repair measures for ordinary lathes are not in place during operation. Maintenance and repair are measures to reduce the incidence of malfunctions and determine the efficiency of lathe use. The lack of maintenance and repair of the lathe results in the lathe being in a state of operation with defects, which cannot maintain good working conditions, shorten the operating life of the lathe, and cannot improve the processing efficiency of ordinary lathes.
3. Common faults and troubleshooting of lathe
Based on the analysis of the lathe and its causes, list common faults and related troubleshooting methods in the operation of ordinary lathes, in order to maintain the operational performance of ordinary lathes.
3.1 Vibration Faults and Troubleshooting
The vibration fault of an ordinary lathe is a common type of fault. During the processing and production of the lathe, vibration is difficult to avoid, and there are some vibrations that belong to the normal operating range. When the vibration is severe, it will affect the processing accuracy of the ordinary lathe, reduce the production efficiency of the lathe, and also increase the wear of the lathe, which is not conducive to the stability of the lathe tool. When a vibration fault occurs in an ordinary lathe, the performance Z of the fault is obvious in ceramics and hard alloys.
When a vibration fault occurs in the lathe, several troubleshooting measures are proposed in practice to assist the ordinary lathe in quickly restoring to normal operation. For example, (1) the maintenance personnel of the ordinary lathe should check the fixed bolts on the lathe, such as foundation bolts, to ensure the accuracy of bolt installation. Once any loose or incorrectly installed bolts are found, on-site treatment should be carried out, and the fault should be immediately eliminated. After tightening the bolts, Ensure accurate installation position of bolts; (2) Control the jumping amplitude of rotating parts, especially adhesive tape components, to achieve radial circular jumping and prevent excessive jumping amplitude from causing vibration; (3) Check the spindle center of an ordinary lathe to avoid the problem of excessive radial swing. Maintenance personnel can actively adjust the spindle swing, reduce the spindle swing amplitude, or directly adopt the angle selection method to control the spindle swing; (4) Correct the grinding tool of an ordinary lathe, maintain a stable cutting path, maintain the position of the tool tip slightly above the center position, and eliminate vibration problems during lathe operation.
3.2 Noise Faults and Troubleshooting
Noise faults not only affect the operation of ordinary lathes, but also affect the operating environment of lathes. In general, noise is a prerequisite for the occurrence of faults. When an ordinary lathe is running, abnormal noise indicates that the lathe has malfunctioned. Maintenance personnel need to accurately analyze the source and cause of the noise in order to quickly troubleshoot. A regular lathe? After operation, the noise will increase with the increase of cycle, temperature, and load, ultimately leading to the lathe entering a poor operating state and interfering with normal operation.
The elimination of noise faults should be carried out according to the actual situation of ordinary lathes. List common troubleshooting methods in common lathe noise fault, such as: (1) maintenance personnel check the Kinematic pair of common lathe, adjust and repair the parts causing noise in combination with the feedback of Kinematic pair, so as to make the lathe spindle return to normal, deal with noise interference, and ensure the working accuracy of lathe; (2) Thoroughly inspect the pipes of ordinary lathes to prevent any obstruction of the pipes and clear any blocked pipes; (3) A large part of the noise fault is due to mutual friction, so regular lubrication work is arranged, lubricating oil is added at appropriate positions, and the amount and position of lubricating oil are controlled to ensure that the lubricating oil meets relevant regulations.
3.3 Heating faults and troubleshooting
During the operation of an ordinary lathe, heating faults are concentrated at the spindle position, as the spindle is connected to rolling and sliding bearings, forming an integrated operating structure. Therefore, when the spindle is in a high-speed rotating state, heat will be emitted. The spindle is the main heat source of an ordinary lathe. When the heat cannot be dissipated normally, it will cause excessive heating of the spindle and surrounding connecting devices. The temperature in local positions of the lathe will increase, causing thermal deformation. When the heating fault is severe, the problem of the spindle and tailstock not being the same height will occur, directly reducing the machining accuracy of the lathe, and there may also be situations of burning the spindle. The spindle heating fault may be due to the accumulation of heat between the spindle and bearings through long-term friction, resulting in changes in the stiffness of the spindle under full load lathe operation, which affects the stability of the spindle. In the troubleshooting methods for spindle faults, before the lathe runs, it is necessary to actively adjust the distance between the spindle and the bearings, arrange lubrication work, maintain the smoothness of the oil circuit, and then control the workload of the spindle to avoid overloading the working environment.
3.4 Oil leakage faults and troubleshooting
Oil leakage is common in common lathe failures, which increases the oil consumption of the lathe, causes significant economic losses, and interferes with the operating performance of the lathe. The handling of oil leakage faults in ordinary lathes requires daily detection methods, arrangement of oil leakage inspection related work, timely detection and handling of oil leakage problems.
3.5 Bearing Faults and Troubleshooting
The bearing failure of an ordinary lathe affects the transmission work of the lathe processing and the operation of the load, which belongs to the fault prone point. The troubleshooting of bearing faults requires replacement and improvement measures, checking the performance of the bearings, and selecting appropriate troubleshooting measures. Generally, if the bearing components are damaged, they can be replaced directly. If the transmission bearing is broken, it is necessary to improve the internal structure and re install the bearing device to solve the problem.
3.6 Tool holder faults and troubleshooting
The malfunction of the tool holder of an ordinary lathe is manifested as a jamming of the tool and burning of the contactor, which ultimately leads to the cutter head not rotating. When troubleshooting the tool rest, it is necessary to gradually narrow the scope of the fault according to the specific fault, identify the cause of the fault and locate it. The components of the lathe tool position are damaged, and the reason for replacing the theme is that the tool disc is not in place. It is necessary to keep the tool holder locked and use a wrench to loosen the magnetic steel disc, aligning the Hall element with the magnetic steel.
3.7 Handle Faults and Troubleshooting
The lathe handle Z is prone to detachment faults. Taking the detachment fault of the automatic feed handle of the slide box of an ordinary lathe as an example, analyze the troubleshooting methods, such as adjusting the spring pressure of the handle to maintain its stability under normal load, repairing the handle fault using welding repair, and drilling the positioning hole through riveting repair after wear.
3.8 Bed Saddle Faults and Troubleshooting
The sinking fault of the bed saddle results in the inability of an ordinary lathe to work properly and the loss of its function. The troubleshooting of the bed saddle can be achieved through daily repair methods, improving the scale of the gears and dial, ensuring stable meshing between the pinion and rack, and restoring the bed saddle.
4. Maintenance and repair of ordinary lathes
The maintenance and repair of ordinary lathes can greatly improve the work efficiency of lathes and reduce the probability of lathe failures.
Firstly, in the maintenance and repair of the lathe, the staff actively identify potential small problems, prohibit the operation of the lathe with defects, avoid the escalation of small problems, eliminate emerging problems, improve the efficiency of the lathe, and control the operation process of the lathe.
Secondly, the staff arranges daily inspections during the maintenance and repair of the lathe, in order to grasp the operating status of the lathe, replace the parts in the lathe, maintain the parts of the lathe according to the safe and reliable operating standards of ordinary lathes, repair faulty devices, and optimize the operating environment of the lathe.
After Z, the staff comprehensively recorded various information about the maintenance and repair of the ordinary lathe, clarified the time and location of the problem, refined the maintenance and repair information of the lathe, provided a standard basis for subsequent maintenance and repair of the lathe, improved the operating status of the ordinary lathe, and reflected the importance and practical value of maintenance and repair in the ordinary lathe.
5. Conclusion
The failure of an ordinary lathe occurs in practical operation. When the lathe is in a high load operating state, it increases the probability of mechanical failure and cannot guarantee the normal state of the lathe, thereby increasing the pressure on the ordinary lathe. Reliable troubleshooting measures should be taken for ordinary lathes, and comprehensive maintenance and repair should be implemented to improve the working ability of ordinary lathes, avoid safety issues, and more importantly, maintain the performance of ordinary lathes, create a good operating environment, and improve the working level of ordinary lathes.
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2023-07-24