In the field of pipe processing, the cutting accuracy of the pipe cutting machine directly determines the quality of the workpiece and the subsequent assembly effect. Once there is an abnormality in cutting accuracy, it not only leads to material waste, but may also affect the entire production schedule. To solve this problem, it is necessary to conduct a thorough analysis of the causes and take targeted measures from various aspects such as machinery, control, and cutting tools.
1、 Troubleshooting mechanical structural faults
The stability of mechanical structure is the foundation for ensuring cutting accuracy. As key transmission components, the guide rail and screw can directly cause cutting path deviation if there is wear, deformation, or installation error. Regularly check the surface of the guide rail for scratches and wear, measure its straightness error with a dial gauge, and repair or replace it when the error exceeds 0.02mm/m. The pitch error of the screw can also affect the accuracy, which can be detected by a laser interferometer. If the error exceeds the allowable range, the pitch compensation function or the screw can be replaced. At the same time, check the stability of the machine tool foundation to ensure that the equipment is installed horizontally and avoid accuracy degradation caused by foundation settlement or vibration.
2、 Calibrate control system parameters
The control system is the "brain" of the cutting machine, and incorrect parameter settings or system failures can cause accuracy issues. Firstly, check if the coordinate origin setting of the CNC system is correct, and perform the zeroing operation again to ensure the accuracy of the coordinate system. Secondly, verify the interpolation algorithm parameters of the system, such as speed gain, position loop gain, etc. These parameters affect the smoothness and accuracy of the cutting path and need to be optimized and adjusted according to the equipment manual. In addition, the encoder should be calibrated regularly. If the encoder experiences pulse loss or counting errors, it may cause the actual motor speed to deviate from the command, resulting in cutting deviation. Professional instruments can be used for detection and calibration.
3、 Optimize the performance of cutting tools and consumables
The condition of cutting tools and consumables directly affects the cutting quality. For mechanical cutting methods, tool wear and passivation can widen the incision and increase burrs. It is necessary to replace the tool in a timely manner and select appropriate tool materials and geometric parameters. For example, when cutting stainless steel pipes, using hard alloy cutting tools with appropriate front and back angles can improve cutting accuracy. Laser cutting requires attention to the focal length and spot quality of the laser head, regular cleaning of the lens to prevent dust and oil from affecting the transmission of laser energy. At the same time, ensure the purity and pressure stability of the auxiliary gas. Impurities or pressure fluctuations can cause uneven cutting surfaces, affecting accuracy.
4、 Control processing environmental factors
The processing environment also has an undeniable impact on cutting accuracy. Temperature changes can cause thermal expansion and contraction of pipes, thereby affecting cutting dimensions. It is necessary to control the temperature in the processing workshop within the range of 20 ± 2 ℃. At the same time, reduce environmental vibration interference by setting up anti vibration grooves or using vibration damping pads around the cutting machine to prevent external vibrations from being transmitted to the equipment. In addition, keep the work area clean and promptly remove chips and dust to prevent them from entering transmission components such as guide rails and screws, causing component wear or jamming, which can affect cutting accuracy.
To solve the problem of abnormal cutting accuracy in pipe cutting machines, systematic investigation and optimization are required from multiple aspects such as mechanical structure, control system, tool consumables, and processing environment. Through the comprehensive implementation of the above measures, the cutting accuracy can be effectively improved, ensuring the high quality and efficiency of pipe processing.