What are the common problems in machining parts or molds?

Common problems encountered during part or mold machining directly impact product quality and production efficiency. As a professional machine tool manufacturer, Shandong GSK CNC Equipment Co., Ltd. has a deep understanding of the various challenges encountered by customers during production and has accumulated valuable experience. This article systematically examines common issues encountered during part and mold machining, drawing on real-world examples and industry trends to help manufacturers optimize production and enhance their competitiveness.

Machining Accuracy Difficulties

Machining accuracy is a key indicator of part quality. Dimensional deviation and surface roughness are common problems caused by precision limitations of equipment such as machining centers, CNC lathes, and milling machines, tool wear, or unstable fixtures. With the development of Industry 4.0, some companies have introduced high-precision gantry machining centers and automated measurement systems, effectively addressing these issues. However, for small and medium-sized enterprises, equipment selection, operating skills, and maintenance remain crucial.

Machining Deformation and Stress Concentration

Thermal deformation and residual stress encountered during mold and part machining are common phenomena, especially when machining large parts or complex molds. Localized heat and mechanical stresses in the cutting process cause deformation in the finished workpiece, impacting assembly and performance. SGSK recommends using multiple light cuts, combined with appropriate fixture design and reasonable cutting parameter adjustments, to reduce the risk of deformation.

Tool Wear and Shortened Life

Tools are the core of machining, and tool wear directly impacts cutting quality and production costs. The increasing demand for machining hard mold steels and various alloys places higher demands on tool performance. Improper tool selection, cutting parameters, and inadequate lubrication and cooling measures can all lead to rapid tool wear. Regularly monitoring tool condition and using high-quality coated tools are effective ways to ensure machining stability.

Equipment Failure and Inadequate Maintenance

Machine tools are prone to loose components, servo system failure, and poor lubrication after prolonged operation. Professional machining equipment such as vertical machining centers, horizontal machining centers, and multi-function drilling and milling machines require stringent maintenance. SGSK provides users with comprehensive equipment maintenance solutions and training to help extend equipment life and minimize downtime.

Improper Process Parameter Design

Many machining problems originate during the process planning stage. Incorrect settings for cutting speed, feed rate, or depth of cut can lead to poor surface quality, overheating, and even tool breakage. Digital and intelligent technologies enable more precise process parameters, but they still rely on experienced technicians to carefully control process details. Reasonable process design not only ensures processing quality but also improves production efficiency and reduces costs.

Mold Assembly and Matching Issues

After mold processing, assembly accuracy directly impacts mold life and product consistency. Common issues during assembly include uneven part clearances, inaccurate positioning, and loose fasteners. Introducing high-precision measuring equipment and assembly tooling is an effective solution to these problems. Professional training and standardized assembly processes are equally important.

Ignoring the Processing Environment and Process Stability

Environmental factors such as temperature, humidity, and vibration have the potential to affect processing accuracy, especially in high-precision machining environments. Process stability is also crucial in long-running tasks, as varying clamping forces and equipment conditions can impact final product quality. Properly designing the production workshop environment and implementing advanced monitoring methods can minimize environmental interference.

Recommendations

SGSK recognizes that problems arising during part and mold processing are multifaceted and intertwined. Only by comprehensively improving equipment performance, optimizing machining processes, and strengthening maintenance management can it remain competitive in the fiercely competitive market. Our vertical machining centers, horizontal machining centers, gantry machining centers, and various other CNC equipment, through continuous technological innovation and service improvement, are widely used in mold manufacturing, automotive parts processing, aerospace, and other fields.

Facing complex machining needs, choosing SGSK's high-performance equipment and professional technical support is an effective way to improve machining quality, reduce failure rates, and ensure stable production. We welcome manufacturers to gain a deeper understanding of our products and services and work together to advance the industry to higher levels.