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1 the transformation of the new machine and the lathe for overhaul of the old machine must undergo the same transformation as follows.
(1) change the X shaft, Z shaft wire rod, bearing and motor.
(2) increase the electric tool holder and the spindle encoder.
(3) increasing the driving device of the axial motor, limiting the stroke switch running over the overrange, adding the frequency converter (customer needs), and the electrical parts required for processing and safety.
(4) the scraper on both ends of the supporting shaft of the X axis and Z axis, the scraper of the ball screw bracket and the saddle, and the bed body are matched with the saddle guide pair of the saddle.
(5) as required, additional protective facilities, such as the protective cover of the wire rod, the safety door, and the protective device for the trip switch, should be added.
2 the difference between the new machine transformation and the old machine overhaul lathe transformation.
(1) the main shaft and tailstock part of the new machine has not been changed, and the spindle part and tailstock part need not be reformed.
(2) the old machine large repair lathe because of long time use, guide rail has been worn, in order to ensure the long repair, can continue to use for a long time without deformation, must pass through the quenching process, and grinding guide, and grinding guide rail must ensure that the guide rail hardness more than HRC47.
(3) the old machine overhaul lathe should be reconstructed and adjusted according to the needs of customers.
3 the accuracy test of new machine transformation and overhaul machine tool transformation is an important item of inspection.
The accuracy is verified by the implementation of JB/T8324.1-1996 “precision CNC lathe horizontal lathe”.
4 the quality control of the renovation of the new lathe is as follows
(1) scraping test. The new lathe modification is used to match and scrape the supporting surfaces of the two ends of the X and Z shafts, and to match and scrape the ball screw pair bracket and the bed saddle, and to match the bed and the guide rail of the saddle. The spindle and tail part of the lathe have not been removed. The test methods are as follows: using the matching surface for color painting, combining with each other, and relative friction, then testing the scraping point number of the scraping surface, and checking the bonding degree with the tape measure, in which the scraping and grinding point should not be less than 6 /25*25mm, 0.03mm’s plug junction.
(2) parallelism test of lead screw and guide rail: when the screw bar is assembled, the parallelism between the screw bar and the guide rail must be less than 0.02mm.
(3) the straightness of the guide rail in the vertical plane of the accuracy test G1 (only convex) should be guaranteed by the lathe manufacturer, not as a key inspection item.
(4) the accuracy of G4, G5 and G6 in the accuracy test should also be ensured by ordinary lathe manufacturers, not as key inspection items.
(5) the top two equal height of G11 bed head and tailstock is guaranteed by ordinary lathe manufacturers, not as a key project for quality control of manufacturers.
Accuracy test of 5 user overhaul lathes
As the grinding guide is carried out, the reference surface has been changed, so all the items in the precision inspection must be checked and the control should be strictly controlled to ensure the performance after the transformation.
6 other important quality control points for overhaul lathe transformation and new machine transformation.
(1) rust check: all horizontal and longitudinal guide surfaces, spindle, spindle flange, and tailstock hollow sleeve.
(2) the surface of non paint must be taken as antirust measures, such as cleaning, using grease and so on for antirust inspection: the scraping surface, wire rod and bearing must be cleaned before the assembly is carried out, and no red powder, iron and other dirty substances should be retained; there is no dust or dirt on the inside of the electric box and the inside of the protective cover.
(3) leakage inspection: the spindle bearing and gear of the renovation lathe must be lubricated. The axial screw and bearing must be lubricated in the renovation of the lathe and the new lathe, and the cooling device must be made.
(4) machine noise, temperature rise, rotation speed and air lift test:
The main shaft is continuously transported to 4min at various speeds, and the highest speed is not less than 2 hours. The empty running time of the whole machine is more than 16h, and the simulation tests of circular turning, thread, outer circle and end face are carried out.
After the spindle bearing temperature is stable, bearing temperature and temperature rise rolling bearing: temperature less than 70 degrees, temperature rise less than 40 degrees, sliding bearing: temperature less than 60 degrees, temperature rise less than 30 degrees.
3. The noise pressure level of machine tool is less than 83dB (A) under the condition of air transportation, and there is no abnormal scream and impact sound. The feed motion of each axis should be stable without obvious vibration, trembling and crawling.
4. The continuous air lift test of the machine tool has no fault during the continuous air transfer time, and runs reliably and stably.
(5) transformation of the replacement parts of the user (including the maintenance of the parts of the machine tool): there are many transformation items of the replacement parts of the lathe, mainly the replacement of the spindle bearing, the axial wire rod, the axial motor, the axial bearing and the system.
(1) replacing the spindle bearing: since the replacement of the spindle bearing is to ensure the precision of the machining circle and the end face, the noise of the spindle must not exceed 83dB (A) in the case of no abnormal noise when the bearing is replaced. Then the machining precision is tested and the surface roughness of the workpiece is tested.
2. Replace the axial screw inspection: check the accuracy of the position, ensure that the running of the running machine reaches the normal impact noise and noise within the prescribed range. Change the axial motor: because other projects have not been reformed, the inspection of the noise of the running machine only is tested, and the axial operation is without normal sound and noise. Check its axial reverse clearance to prevent the reverse difference in assembly due to assembly.
3. Replace axial bearing: for the replacement of axial bearing, we must ensure that the axial reverse difference reaches the requirement and check the abnormal noise.
4. Change the system test: replace the system, only check the system work.