Comprehensive analysis of the causes of tool collision in CNC machining centers

In the field of machine tool processing, the problem of tool collision is a major headache. The collision of equipment with knives may seem like a small matter, but in reality, it poses great harm. As a high-speed and high-precision automated precision equipment, the machining center can easily affect machining efficiency in the event of tool collision, and in severe cases, it can lead to a decrease in the overall accuracy of the machining center, even turning the entire tool library into scrap. Therefore, in our daily processing, we must pay attention to the issue of tool collision. Understanding the causes of knife collisions and taking preventive measures in advance is an effective way to reduce the occurrence of knife collisions.

01 Human error by operator

According to data statistics from the production line, the vast majority of tool collisions in machining centers are caused by operator errors. For example, during the tool alignment process, the speed of the machine tool drive shaft is too fast, resulting in tool collisions; For example, if the coordinate values of the machine tool axis are entered incorrectly, it can cause tool collisions during the spindle machining process, which is the reason for the most tool collisions in the machining center.

So improving the professional competence and sense of responsibility of machining center operators is the best way to prevent tool collisions, especially the sense of responsibility of machining center operators, which is an absolute culprit.

In fact, the professional competence of operators can be cultivated because back and forth are just a few commands and data. Anyone with relevant professional knowledge can master this skill in the short term, but the operator's sense of responsibility is difficult to regulate.

Even so, many operators, in order to avoid the responsibility of tool collision, basically do not actively admit their operational errors. They attribute the collision to the machine tool's own fault, and they even speak up and make a fool of themselves. If you don't want to continue working in machining center operations, you can join the editor QQ: 770573829 to learn UG CNC programming!

Even many people, including managers on the production line, believe that it is inevitable for operators of machining centers to collide with knives. Just a few more collisions are enough, and with experience, they will naturally avoid them. What kind of nonsense is this.

In fact, the collision of cutting tools in machining centers can cause serious damage to the machine tool, especially to the machining accuracy. The damage is basically irreversible, especially for some high-precision machine tools. After a few collisions, the accuracy is basically lost, and there may not be much change on the surface. In fact, the accuracy of the machine tool is no longer there.

So, it is important to try to avoid machine tool collisions as much as possible. Machine tool collisions are not much different from driving and hitting walls. For mechanical equipment, both are suicidal behaviors.

02 Workpiece clamping failure

The second reason for the collision of the machine tool with the tool is the failure of the clamping of the processed workpiece. For example, if the workpiece becomes loose during the machining process, the part will move under the cutting force of the tool. This can easily cause the tool to collide, and it can also easily lead to dangerous accidents such as the workpiece being thrown out of the fixture, and even breaking the doors and windows of the machine tool.

In addition, for many automatic machining production lines, there may be clamping errors caused by inaccurate positioning of parts. For example, when the robotic arm places the parts on the fixture, there may be a deviation in the placement position, resulting in the parts not being clamped in place. If there is no corresponding workpiece in place detection switch, there is a possibility of tool collision accidents during the cutting process.

And because the automatic production line is fully automated, the operator does not intervene in the machining process of the machine tool, so it is difficult for humans to detect the problems caused by clamping, which further increases the probability of tool collision. If you do not want to continue working in machining center operations, you can add the editor QQ: 770573829 to learn UG CNC programming!

At the same time, during the machining process of the machine tool, the wear and damage of the tool can also easily cause tool collision, such as sudden tool breakage or breakage accidents, which cause the tool to lose cutting force. However, the feed of the machine tool does not stop, which can easily cause tool collision. Therefore, real-time monitoring of the load in the feed direction of the machine tool is necessary. If there is any abnormality, it is necessary to be able to actively stop the machine to minimize the damage caused by tool collision to the machine tool.

03 Machine Tool Movement Fault

The so-called machine tool malfunction refers to the uncontrolled state of the operating system of the machine tool. For example, when a machine tool is executing a machining program, its machining trajectory does not follow the trajectory of the machining program, but rather deviates significantly. At this point, the machine tool will experience tool collision. And this kind of tool collision is very terrifying. Suddenly, I found that there was an abnormality in the cutting of the machine tool. I once encountered it. During the machining process, a 20 inch end milling cutter was buried and processed, causing sparks to splash and abnormal noises to be heard.

Later on, it was discovered that there was a problem with a certain motion module in the control system of the machine tool. Of course, such situations are relatively rare, but there are many excuses like this. Many operators use this reason as their excuse for tool collision after making mistakes, attempting to evade responsibility and punishment, and the reason is also difficult to find.

Especially some CNC systems in China, because these systems do have certain instability phenomena, they may occur once or twice a year, but they give many people the excuse of "hitting the nail on the head",

So, the orderly, timely, and professional operation and maintenance of processing equipment is very important. Do not overload the use of processing equipment, otherwise it will definitely be more than worth the loss.

04 Intentional knife collision

People's hearts are treacherous, especially in the workplace. Often, in order to evade small responsibilities and punishments, they are willing to create bigger things to cover up, and they often succeed. For example, if a certain operator's product processing qualification rate exceeds the standard, it is necessary for the enterprise to impose fines on the operator. However, if the operator is unwilling to be punished, they will think of outsourcing and cover up their own unqualified products by using machine tool collision accidents to reduce their unqualified rate and achieve the goal of avoiding fines.

This kind of thing is not without it, it's just that people who play this operation need more courage and attention, but I have really encountered it before, and now I think it's unbelievable.