Dewek CNC Small Classroom: A Complete Guide To Optimizing Cutting Performance of Turning And Milling Machine Tools

As a "jack of all trades" in modern manufacturing, turning and milling machine tools are widely favored for their high efficiency and precision. But how to give full play to their potential and improve cutting performance? Listen to the small suggestions of Dewek CNC:

1. Basic settings: Paving the way for efficient cutting
   1. Tool selection is particular**
   - Multifunctional composite tools are preferred to reduce tool change time
   - Tool materials are matched for different materials: carbide is suitable for steel parts, CBN is suitable for hardened steel, and diamond tools specialize in non-ferrous metals
   - Coated tool life can be increased by 3-5 times, TiAlN coating is suitable for high-temperature processing, and DLC coating reduces built-up edge
   
   2. Wisdom of clamping method**
   - Use hydraulic or heat shrink chucks to ensure runout <0.01mm
   - Use special fixtures for complex workpieces to avoid secondary clamping errors
   - Consider soft claw turning when processing thin-walled parts and customize the contact surface shape
   
   3. Scientific use of coolant**
   - High-pressure cooling (70-100bar) can effectively remove chips, especially suitable for deep hole processing
   - Minimum quantity lubrication (MQL) technology saves up to 90% of coolant consumption
   - Adjust the concentration for different materials: 5-8% for aluminum alloy, 8-12% for steel

II. Process parameter optimization: find the "sweet spot"
Golden rule for cutting parameters:
- Speed: low for hard materials, higher for soft materials, but the rated speed of the tool must be considered
- Feed: 80% of the tool recommended value for roughing and 60% for finishing
- Depth of cut: generally no more than 1/2 of the tool diameter, 0.1-0.2mm margin for finishing
Practical adjustment tips:
1. Hear a shrill scream? Reduce the speed or increase the feed appropriately
2. Does the chip color turn blue? It means the temperature is too high, and the parameters need to be adjusted or the cooling needs to be strengthened
3. Vibration marks appear on the surface? Check if the tool overhang is too long, or try to change the feed direction

III. Advanced optimization strategy: moving towards professionalism
1. Intelligent tool path planning
- Use spiral interpolation instead of linear milling to make the load more uniform
- Contour processing strategy keeps the cutting depth constant
- Slow down in advance at corners to avoid overcutting and tool breakage

2. Practical skills of vibration control
- When vibration occurs, the speed can be adjusted to more than 1.5 times the natural frequency of the machine tool
- Use damping tool holders to reduce vibration by 40-60%
- When machining asymmetric allowances, first machine parts with good rigidity

3. Machine status monitoring
- Pay attention to the change of spindle load, and check if it suddenly increases by more than 15%
- Use a dial indicator to check the spindle radial runout regularly (should be <0.005mm)
- Use a listening stick, abnormal noise is often a precursor to failure

IV. Practical case analysis
Problems encountered when machining stainless steel flanges:
- Original process: speed 800rpm, feed 0.15mm/r, tool life only 50 pieces
- After optimization: speed 650rpm, feed 0.12mm/r, using corrugated edge milling cutter
- Result: tool life increased to 120 pieces, surface roughness Ra reduced from 1.6μm to 0.8μm
Key point: stainless steel processing should control the line speed at 80-120m/min, and choose a tool with a sharp edge.

V. Daily maintenance list
1. Daily: clean chips, check air pressure and oil pressure, and lubricate guide rails
2. Weekly: check the power turret and clean the tool change mechanism
3. Monthly: check the spindle taper accuracy and calibrate the machine tool level
4. Quarterly: replace the spindle bearing oil cooling device and check the servo motor encoder
Remember: 1 hour of preventive maintenance can avoid 8 hours of unexpected downtime!

There is no "one-trick" to optimize cutting performance, and it needs to be continuously adjusted according to specific working conditions. It is recommended to establish a processing parameter database to record the effect of each optimization. Through systematic optimization, the processing efficiency of turning and milling machine tools can be improved by more than 30%, and the tool cost can be reduced by 20-40%. Practice makes perfect, so why not try these tips from today, and you will be pleasantly surprised to find that the performance of the machine tool has been significantly improved!