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Development and maintenance of CNC
1946 On the birth of the world's first electronic computer, which indicates that human beings created to enhance and replace the mental part of the tool.It is human in the agricultural, industrial society created a tool that is enhanced compared to manual qualitative leap, he entered the information society for human foundation.Half a century, and the core of computer-driven information technology, both through the TV, modern communications, improve the quality of human life, but also improve productivity fast forward, creating a history of human civilization, the production history of the era.The rapid development of information technology led directly to the arrival of the knowledge economy.In 1952, computer technology applied to the machine.Born in the United States first CNC machine tools.Computers and control technology in the application of machinery equipment manufacturing industry within the century's most significant technological advances.Since then, the conventional machine produced a qualitative change.Nearly half a century, has undergone two phases of CNC machine tools and the development of six generations.(1)Numerical control(NC)phase(1952-1970 years)
early computing speed is low, which was affected scientific computing and data proceing is not large, can not meet the requirements of real-time control machine tools.People have used digital logic circuits, “ride” into a dedicated computer as numerical control machine tool system, known as the hardware connection NC(HARD WIREDNC), referred to as NC(NC).With the development of components, at this stage after three generations, that in 1952 the first generationthe transistor;1965, the third generationpresent)
In 1970, GM has a small computer and into ma production there.Its operation faster than the fifties and sixties have increased significantly, more than a special “ride” into a dedicated computer, low cost, high reliability.So it came as a CNC porting the core components, entered a computer numerical control(CNC)stage.By 1971, INTEL Corporation in the United States the world's first computer of the two core componentsthe microproceor;1990, the sixth generationBASED).CNC system nearly five decades gone through two stages six generation of development, but development to the fifth generation only after a fundamental solution to the reliability is low, the price is extremely expensive, extremely convenient application is very critical iue.Thus, even in industrialized countries, large-scale numerical control system has been applied and popularity in the late seventies early eighties after the thing, that is numerical control technology after nearly three decades of development before wider application to.Abroad has been renamed as early as the computer numerical control(ie CNC), while China is still often called numerical control(NC).So we talk about everyday, “NC” in eence is that “computer numerical control” of the.CNC machine tool numerical control system is the core component, therefore, the maintenance of CNC machine tool numerical control system is mainly to maintain.After a NC system for a longer period of use, performance of electronic components to aging or damaged, and some mechanical parts especially, to try to extend the lifetime of components and parts wear cycle, to prevent all kinds of failures, particularly fatal accidents the occurrence of the numerical control system must be routine maintenance.To sum up, pay attention to the following aspects.1 NC system maintenance formulate rules
Regulations according to the characteristics of various components to determine their maintenance regulations.Exprely provided, such as what areas need cleaning every day(such as CNC system input / output unit-optical reading machines for cleaning, inspection is well-oiled machine structural parts, etc.), which parts should be regularly checked or replaced(such as brush DC servo motors and commutator should be checked once a month).(2)As le as poible open CNC ark and high voltage ark of the door
Because in machining workshop in the air of general contain oil mist, dust and even metal powder.Once they fall within the NC system or electrical components on printed circuit, easily lead to decreased insulation resistance between components, and even lead to damage to components and printed circuits.Some users in the summer to make long-term work overload CNC system, CNC cabinet door open to heat, which is not desirable kind of approach will eventually lead to accelerated damage to the CNC system.The correct way is to reduce the numerical control system of the external ambient temperature.Therefore, there should be a strict requirement, unle the neceary adjustments and repairs, just open the doors is not allowed, but not allowed to open doors when in use.Regular cleaning the ark of the numerical control heat ventilation system
Should every day to check on the numerical control system each cooling fan is functioning properly, should inspect working environment condition, every half an year or quarterly review of a duct filter whether jam phenomenon.If exceive dust build-up Internet filter, the need for timely clean-up, otherwise it will cause the temperature inside the high numerical control system(generally not exceed 55 ℃), resulting in overheating or NC alarm system does not work reliably.CNC systems are often used to monitor voltage produced by FANUC CNC system, allowing the grid voltage rating of 85% to 110% of range fluctuations.If you exceed this range, it will cause the system not working properly, or even cause damage to electronic components within the NC system.periodic replacement of memory battery FANUC CNC production company within the system memory in two ways:(1)No batteries to keep the magnetic bubble memory.(2)the need to maintain the CMOS RAM with battery device is not powered on CNC system in order to maintain the contents of the storage period, with internal rechargeable battery to maintain the circuit, in the NC system is powered by the +5 V power supply through a diode to the CMOS RAM power, and can charge the rechargeable battery;cut off power when the numerical control system is replaced by a battery to maintain the information in CMOS RAM, under normal circumstances, even if the battery has not yet expired, the battery should be replaced once a year, in order to ensure that the system can work properly.In addition, we must note that the battery replacement should be carried out under the NC system power state.CNC long-term maintenance when not in numerical order to improve system utilization and reduce the numerical control system failure, CNC machine tools should be used at full capacity, and not long idle, for some reason, resulting in long idle CNC system, in order to numerical control system to avoid damage, please note the following two points:(1)should always power to the CNC system, especially in high humidity environment of the rainy season and even more so, lock the machine does not move in the case(that is, the servo motor does not turn time), let dry run CNC system.Use of electrical components to disperse their heat moisture within the NC system, to ensure stable and reliable performance of electronic devices, proved in the air humidity areas, power is to reduce the failure rate is often an effective measure.(2)CNC machine tool feed servo drives using DC and DC servo spindle drive, brush should be removed from the DC motor, so as not due to chemical corrosion, the commutator surface corrosion, resulting in change to the performance deterioration, and even entire motor damage.At present, the field of sheet metal stamping, CNC punching machine / CNC turret punch pre with its fast, high precision machining, mold versatile, flexible products, etc., are widely used.User in choosing a quality mold, its use and maintenance of the level of direct impact to the workpiece machining quality and mold life.Mold control equipment is also an important part of operating costs.First,ensure the best mold clearance
Mould clearance is to point to the punch into the next model, the sum of the clearance between the sides.It and thickne, material and the stamping proce and suitable mould clearance, can guarantee good punching quality, reduce burr and collapse and keep the sheet metal level off, effectively prevent take material, prolong die life.Through the examination of stamping waste, we can determine whether appropriate mould clearance.If too much clearance waste will be rough rolling fractures and smaller light face.The greater the clearance, fractures and light the viewpoint of the formation of surface and the more they can form punching edge and fracture, appear even a thin rim bumps.Conversely, if the clearance is too small, waste will be small Angle fractures and larger light face.When slot, step blunt, cutting local stamping, lateral force will make the punch deflection and cause unilateral gap is too small, sometimes edge migration will scratch lower die, causing the lower die quickly wear.Mould to best clearance stamping, waste of fractures and bright surface with the same Angle, and overlap each other, so that can make the cutting force minimum, punching the burr was very small.Second, timely grinding can effectively extend the life of the mold if too large of a workpiece or stamping burrs generated when abnormal noise may die paivation.Check the punch and the die, when its blade edges have a radius of approximately 0.10mm wear arc, it is neceary sharpening of.Practice has shown that frequent small amounts of sharpening rather than waiting until non-grinding mill can not be again when, not only to maintain good quality of the workpiece, reducing the blanking force, but die life can be extended more than doubled.In addition to knowing when to die grinding, the grinding master the correct method is especially important.Mold grinding procedure is as follows:
1)grinding, it will punch a vertical grip on the surface grinder's magnetic chuck or fixture within the V-groove, each grinding capacity of 0.03 ~ 0.05mm, repeat until the punch grinding sharp, the maximum amount of grinding is generally 0.1 ~ 0.3mm.2)the use of sintered aluminum oxide grinding wheel, the hardne D ~ J, grit sizes 46 to 60, preferably for high-speed steel grinding wheel.3)When the grinding force or mold near the wheel, add coolant to prevent overheating and cracking the mold or annealing, should be required in accordance with the manufacturer of high quality multi-purpose coolant.4)The amount of feed wheel down 0.03 ~ 0.08 mm, lateral feed rate 0.13 ~ 0.25 mm, lateral feed rate 2.5 ~ 3.8m/min.5)After grinding, oil stone polished edge, remove the burr, and grind the radius of 0.03 ~ 0.05 mm round, to prevent edge cracking.6)punch to the magnetic treatment and sprayed with oil to prevent rust.Third, the elimination and reduction of adhesive material way because when the preure and heat stamping, sheet metal fine particles will bond to the surface of the punch, resulting in poor quality punching.Removal of binder used fine whetstone grinding, sanding should be directed to the direction of movement with the same punch, so the light will avoid the generation of further binder.Do not use gauze and other coarse grinding, to avoid the punch surface is more rough and more prone to sticky material.Reasonable die clearance, good stamping proce, and the neceary lubrication sheet, will reduce the production of sticky material.Prevent overheating, the general lubrication of the way, this will reduce the friction.If you can not waste lubricating or rebound occurs, may take the following approach: alternate punch than the same size turns punching,Can make its repeated in before use have long cooling time.Overheating will use all die.Through the programming control changing mould, the interrupt their long time of repetition of work, or reduce its preing frequency.Four, blunt is when the deformation of sheet metal porous to prevent measures
If in a rush on board a porous, due to the accumulation of shear stre plank cannot maintain level.Every time punching, around the hole material will down deformation, causing the surface appears on the sheet metal tensile stre, and under the surface have compreive stre.For a small amount of punching, and its effect is not obvious, but when punching quantity is increased, the pull, compreive stre somewhere in accumulation, until materials.Eliminate such deformation of a method is: to every one KongChong cut, and then returns to the rest of the punching holes.So although also can produce stre, but easing in the same direction order stamping of stre at accumulation, also can make the two groups before and after the stre of offset each other holes, so as to prevent the deformation of sheet metal.Five, try to avoid cutting through the narrow strip material
When the used for cutting width of le than in the proce of sheet metal sheet thickne, lateral force for and make the punch to bending deformation, make side of the gap is too small or wear is intensified, serious scratch when the mould, make fluctuation mode and damage.Suggestions don't step blunt width of le than 2.5 times the thickne of the narrow a sheet metal sheet.Cutting through the narrow strip material, sheet metal tend to turn into the mode of open, and not be completely cut off, and even wedge dies profile.If can't avoid the above situation, the proposed use output slabs supported the role of the punch fully guided mold.Six, the punch surface hardening and the applicable scope
Although heat treatment and surface coating can improve the punch surface properties, but is not the solution to the problems and prolong die life is preing the general method.Generally speaking, the coating surface hardne and improve the punch that side lubricity improved, but in large tonnage, hard materials stamping, these advantages in about 1000 times after stamping and disappeared.According to the following circumstance can use surface hardening the punch: Blunt soft or sticky materials(such as aluminum);
Blunt thin non-abrasive materials(such as gla epoxy pieces);Blunt thin hard material(such as stainle steel);Frequent point blunt;Abnormal lubrication.Surface hardening usually adopts of titanium coating and seepage nitrogen, method, its surface hardening layer thickne for 12 ~ 60 μ m molecular structure, it is a part of the matrix punch, and not only is the coating.Surface hardening of the mould can pre usually way further.Through the surface hardening will lower mould in the stainle steel plate wear behavior, but can not prolong its service life, and the appropriate and timely lubrication, according to procedures, burrs, is the effective way.Seven, CNC turret punch die a neutral is bad for the overhaul
If a punch mould to neutral is bad, cause mould fast paivation, workpiece machining quality is poor, can the following maintenance: Check the level of the machine tool, when neceary to adjust;
Check and lubrication of model hole on the wheel and the direction key, if there is damage timely repair;
Clean the next mould seat, so as to lower die accurate installation, check and its key or the keyway wear and, when neceary, to change;
Use the special mandrel calibration mould location, such as a deviation adjust in time.The contents of the situation is usually concerned, in view of the pre and the concrete types die specifications are different, the user should combine the actual to know and summarizing the experience, and displays the best use of the mould performance.数控的发展及设备维护浅谈
1946年诞生了世界上第一台电子计算机，这表明人类创造了可增强和部分代替脑力劳动的工具。它与人类在农业，工业社会中创造的那些只是增强体力劳动的工具相比有了质的飞跃，他为人类进入信息社会奠定了基础。半个世纪以来，以计算机为主导和核心的信息技术，既通过电视，现代通信等提高了人类生活的质量，还促进生产力飞速向前发展，开创了人类文明史，生产史的新纪元。信息技术的飞速发展直接导致了知识经济的到来。
在1952年，计算机技术应用到了机床上。在美国诞生了第一台数控机床。计算机及控制技术在机械制造设备中的应用是世纪内制造业发展的最重大的技术进步。从此，传统机床产生了质的变化。近半个世纪以来，数控机床经历了两个阶段和六代的发展。
1.数控(NC)阶段(1952-1970年)
早期计算机运算速度低，这对当时的科学计算和数据处理影响还不大，不能适应机床实时控制的要求。人们不得不采用数字逻辑电路“搭”成一台机床专用计算机作为数控系统，被称为硬件连接数控(HARD WIREDNC)，简称为数控(NC)。随着元器件的发展，这个阶段历经了三代，即1952年第一代— 电子管;1959年第二代— 晶体管;1965年第三代— 小规模集成电路。2.计算机数控(CNC)阶段(1970-现在)
到1970年，通用小型计算机业已出现并成批量生产。其运算速度比五，六十年代有了大幅度的提高，这比专门“搭”成的专用计算机成本低，可靠性高。于是将它移植过来作为数控系统的核心部件，从此进入了计算机数控(CNC)阶段。到1971年美国INTEL公司在世界上第一次将计算机的两个最核心的部件— 运算器和控制器，采用大规模集成电路集成在一块芯片上，称之为微处理器(MICROPROCESSOR)，又称为中央处理单元(简称CPU)。
1974年微处理器被应用于数控系统。这是因为小型计算机功能太强，控制一台机床能力有富裕，不及采用微处理器经济合理，而且当时的小型机可靠性也不理想。早期的微处理器速度和功能还不够高，但可以采用多处理器结构来解决。由于微处理器是通用计算机的核心部件，故仍称为计算机数控。到了1990年，PC机(个人计算机，国内习称微机)的性能已发展到很高的阶段，可以满足作为数控系统核心部件的要求，而且PC机生产批量很大，价格便宜，可靠性高。数控系统从此进入了基于PC的时代。总之，计算机数控阶段也经历了三代。即1970年第四代一一小型计算机;1974年第五代— 微处理器;1990年第六代— 基于PC(国外称为PC--BASED).数控系统近五十年来经历了两个阶段六代的发展，只是发展到了第五代以后，才从根本上解决了可靠性低，价格极为昂贵，应用很不方便等极为关键的问题。因此，即使在工业发达的国家，数控系统大规模地得到应用和普及，是在七十年代末八十年代初以后的事情，也即数控技术经过了近三十年的发展才走向普及应用的。国外早己改称为计算机数控(即CNC)，而我国仍习称数控(NC)。所以我们日常讲的“数控”实质上已是指“计算机数控”了。数控系统是数控机床的核心部件，因此，数控机床的维护主要是数控系统的维护。数控系统经过一段较长时间的使用，电子元器件性能要老化甚至损坏，有些机械部件更是如此，为了尽量地延长元器件的寿命和零部件的磨损周期，防止各种故障，特别是恶性事故的发生，就必须对数控系统进行日常的维护。概括起来，要注意以下几个方面。1.制订数控系统日常维护的规章制度
根据各种部件特点，确定各自保养条例。如明文规定哪些地方需要天天清理（如CNC系统的输入／输出单元——光电阅读机的清洁，检查机械结构部分是否润滑良好等），哪些部件要定期检查或更换（如直流伺服电动机电刷和换向器应每月检查一次）。
2.应尽量少开数控柜和强电柜的门
因为在机加工车间的空气中一般都含有油雾、灰尘甚至金属粉末。一旦它们落在数控系统内的印制线路或电器件上，容易引起元器件间绝缘电阻下降，甚至导致元器件及印制线路的损坏。有的用户在夏天为了使数控系统超负荷长期工作，打开数控柜的门来散热，这是种绝不可取的方法，最终会导致数控系统的加速损坏。正确的方法是降低数控系统的外部环境温度。因此，应该有一种严格的规定，除非进行必要的调整和维修，不允许随便开启柜门，更不允许在使用时敞开柜门。
3.定时清扫数控柜的散热通风系统
应每天检查数控系统柜上各个冷却风扇工作是否正常，应视工作环境状况，每半年或每季度检查一次风道过滤器是否有堵塞现象。如果过滤网上灰尘积聚过多，需及时清理，否则将会引起数控系统柜内温度高（一般不允许超过55℃），造成过热报警或数控系统工作不可靠。
4.经常监视数控系统用的电网电压
FANUC公司生产的数控系统，允许电网电压在额定值的85%～110%的范围内波动。如果超出此范围，就会造成系统不能正常工作，甚至会引起数控系统内部电子部件损坏。
5.定期更换存储器用电池
FANUC公司所生产的数控系统内的存储器有两种：
(1)不需电池保持的磁泡存储器。
(2)需要用电池保持的CMOS RAM器件，为了在数控系统不通电期间能保持存储的内容，内部设有可充电电池维持电路，在数控系统通电时，由+5V电源经一个二极管向CMOS RAM供电，并对可充电电池进行充电；当数控系统切断电源时，则改为由电池供电来维持CMOS RAM内的信息，在一般情况下，即使电池尚未失效，也应每年更换一次电池，以便确保系统能正常工作。另外，一定要注意，电池的更换应在数控系统供电状态下进行。
6.数控系统长期不用时的维护
为提高数控系统的利用率和减少数控系统的故障，数控机床应满负荷使用，而不要长期闲置不用，由于某种原因，造成数控系统长期闲置不用时，为了避免数控系统损坏，需注意以下两点：
(1)要经常给数控系统通电，特别是在环境湿度较大的梅雨季节更应如此，在机床锁住不动的情况下（即伺服电动机不转时），让数控系统空运行。利用电器元件本身的发热来驱散数控系统内的潮气，保证电子器件性能稳定可靠，实践证明，在空气湿度较大的地区，经常通电是降低故障率的一个有效措施。
(2)数控机床采用直流进给伺服驱动和直流主轴伺服驱动的，应将电刷从直流电动机中取出，以免由于化学腐蚀作用，使换向器表面腐蚀，造成换向性能变坏，甚至使整台电动机损坏。
当前，在板金冲压加工领域，数控冲床/数控转塔冲床 以其冲压速度快、加工精度高、模具通用性强、产品灵活多样等特点，得到广泛应用。用户在选购某种品质的模具后，其使用和维护的水平，直接影响到工件的加工质量和模具的使用寿命。模具也是控制设备运行成本的重要环节。
一、保证最佳的模具间隙
模具间隙是指冲头进入下模中，两侧的间隙之和。它与板厚、材质以及冲压工艺有关，选用合适的模具间隙，能够保证良好的冲孔质量，减少毛刺和塌陷，保持板料平整，有效防止带料，延长模具寿命。
通过检查冲压废料的情况，可以判定模具间隙是否合适。如果间隙过大，废料会出现粗糙起伏的断裂面和较小的光亮面。间隙越大，断裂面与光亮面形成的角度就越大，冲孔时会形成卷边和断裂，甚至出现一个薄缘突起。反之，如果间隙过小，废料会出现小角度断裂面和较大的光亮面。
当进行开槽、步冲、剪切等局部冲压时，侧向力将使冲头偏转而造成单边间隙过小，有时刃边偏移过大会刮伤下模，造成上下模的快速磨损。
模具以最佳间隙冲压时，废料的断裂面和光亮面具有相同的角度，并相互重合，这样可使冲裁力最小，冲孔的毛刺也很小。
二、适时刃磨可有效延长模具的使用寿命
如果工件出现过大的毛刺或冲压时产生异常噪音，可能是模具钝化了。检查冲头及下模，当其刃边磨损产生半径约0.10mm的圆弧时，就要刃磨了。
实践表明，经常进行微量的刃磨而不是等到非磨不可时再刃磨，不仅会保持良好的工件质量，减小冲裁力，而且可使模具寿命延长一倍以上。
除了知道模具何时刃磨之外，掌握正确的刃磨方法尤其重要。模具刃磨规程如下：
1)刃磨时，将冲头竖直夹持于平面磨床磁性卡盘的V型槽或夹具内，每次磨削量为0.03~0.05mm，重复磨削直至冲头锋利，最大磨削量一般为0.1~0.3mm。
2)使用烧结氧化铝砂轮，硬度D~J，磨粒大小46~60，最好选适用于高速钢磨削的砂轮。
3)当磨削力大或模具接近砂轮时，加冷却液可防止模具过热而开裂或退火，应按照制造商要求选用优质多用途冷却液。
4)砂轮向下进刀量0.03~0.08 mm，横向进给量0.13~0.25 mm，横向进给速率2.5~3.8m/min。
5)刃磨后，用油石打磨刃口，去除毛刺，并磨出半径0.03~0.05 mm的圆角，可以防止刃口崩裂。
6)冲头去磁处理并喷上润滑油，防止生锈。
三、消除和减少粘料的方法
由于冲压时的压力和热量，会将板料的细小颗粒粘结于冲头表面，导致冲孔质量差。去除粘料可用细油石打磨，打磨方向应与冲头运动的方向相同，这样光后会避免进一步粘料的产生。不要用粗纱布等打磨，以免冲头表面更粗糙，更容易出现粘料。
合理的模具间隙、良好的冲压工艺，以及必要的板料润滑，都会减少粘料的产生。防止过热，一般采用润滑的方式，这样会减少摩擦。如果无法润滑或出现废料回弹，可采取以下方法：
交替使用多个相同尺寸的冲头轮流冲压，可使其在被重复使用之前有较长的冷却时间。
将过热模具停歇使用。通过编程控制换模，中断其长时间重复工作，或降低其冲压频率。
四、冲很多孔时防止板料变形的措施
如果在一张板上冲很多孔，由于冲切应力的累积板材就不能保持平整。每次冲孔时，孔周边的材料会向下变形，造成板料上表面出现拉应力，而下表面则出现压应力。对于少量的冲孔，其影响并不明显，但当冲孔数量增加时，拉、压应力在某处累积，直至材料变形。
消除此类变形的一个方法是：先每隔一个孔冲切，然后返回冲切剩余的孔。这样虽然也会产生应力，但却缓解了在同一方向顺序冲压时的应力累积，也会使前后两组孔的应力相互抵消，从而防止板料的变形。
五、尽量避免冲切过窄条料
当模具用于冲切宽度小于板材厚度的板料时，会因侧向力作用而使冲头弯曲变形，令一侧的间隙过小或磨损加剧，严重时会刮伤下模，使上下模同时损坏。
建议不要步冲宽度小于2.5倍板材厚度的窄条板料。剪切过窄条料时，板料会倾向弯入下模开口中，而不是被完全剪掉，甚至会楔入冲模的侧面。如果无法避免上述情况，建议使用退料板对冲头有支撑作用的全导向模具。
六、冲头的表面硬化及其适用范围
虽然热处理和表面涂层可改善冲头表面特性，但并不是解决冲压问题和延长模具寿命的一般方法。一般地说，涂层提高了冲头表面硬度并使侧面的润滑性得到改善，但在大吨位、硬质材料冲压时，这些优点在大约1000次冲压后就消失了。
针对以下情况可使用表面硬化的冲头：
冲软或粘性的材料（如铝）；
冲薄的研磨性材料（如玻璃环氧片）；
冲薄的硬质材料（如不锈钢）；
频繁地步冲；
非正常润滑的情况。
表面硬化通常采用镀钛、渗氮等方法，其表面硬化层为厚度12~60μm的分子结构，它是冲头基体的一部份，而并非仅是涂层。
表面硬化的模具可按通常的方式刃磨。通过表面硬化会降低模具在冲不锈钢板时的磨损，但并不能延长其使用寿命，而适当润滑、及时刃磨以及按规程操作等，却是有效的方法。
七、数控转塔冲床 模位对中性不好时的检修
如果冲床模位的对中性不好，造成模具快速钝化，工件加工质量差，可就以下几点检修：
检查机床的水平情况，必要时重新调整；
检查并润滑转盘上的模孔及导向键，如有损伤及时修复；
清洁转盘的下模座，以便下模准确安装，并检查其键或键槽的磨损情况，必要时更换；
使用专用芯棒校准模具工位，如有偏差及时调整。
上述内容是对通常的情形而言，鉴于冲床及模具的具体类型规格有所不同，用户还要结合实际去认识和总结经验，发挥出模具的最佳使用性能。
