As a high-precision tool processing equipment, the operational stability of CNC tool grinders directly affects the accuracy and service life of tool edges. The principle of "observing the phenomenon first, then locating the cause, and finally implementing precise measures" should be followed when dealing with common faults to avoid blind operation leading to the expansion of faults. The core is to combine the structural characteristics and operating logic of the equipment to dismantle the essence of the fault.
From the actual working conditions, the common faults of CNC tool grinders can be divided into three categories, which need targeted treatment:
The first type is abnormal grinding accuracy faults, manifested as tool edge size deviation, unqualified surface roughness, or edge angle deviation. This type of malfunction is mainly caused by "reference deviation" and "grinding parameter mismatch": if there are impurities or wear on the tool clamping reference surface, it will cause positioning deviation. It is necessary to clean the impurities on the clamping surface and check the fixture accuracy. If necessary, replace the worn fixture; If the grinding wheel is worn or improperly selected, such as the surface roughness exceeding the standard due to coarse grinding wheel particles, it is necessary to replace the grinding wheel with a suitable particle size and regularly adjust the grinding wheel contour through a grinding wheel conditioner to ensure grinding accuracy; If the combination of feed rate and grinding depth is unreasonable, such as high-speed feed combined with large grinding depth, it is easy to cause vibration. It is necessary to appropriately reduce the feed rate or reduce the single grinding depth to reduce the impact of vibration on accuracy.
The second type is motion system failure, with common symptoms such as axis motion lag, abnormal noise, or inaccurate positioning. It is necessary to investigate from two aspects: "mechanical transmission" and "electrical control". At the mechanical level, if the guide rail lubrication is insufficient or there is chip accumulation, it will increase the movement resistance and cause jamming. It is necessary to clean the guide rail debris and replenish special lubricating oil; If the ball screw is worn or the reverse clearance is too large, it will affect the positioning accuracy. It is necessary to check the wear of the screw and adjust it through the reverse clearance compensation function of the CNC system. In severe cases, the screw needs to be replaced; On the electrical level, if the connection wire of the servo motor is loose or the driver parameters are abnormal, it will cause the motor to operate unstably. It is necessary to check the connection status of the circuit, verify whether the driver parameters are consistent with the equipment manual, and recalibrate the parameters if necessary.
The third type is system alarm faults, usually triggered by abnormal signals detected by the CNC system, such as "overtravel alarm" and "emergency stop alarm". When handling, it is necessary to first check the fault description corresponding to the alarm code: the overtravel alarm is often caused by the axis movement exceeding the set range. The "overtravel release" button needs to be pressed to manually move the axis back to the safe area, and at the same time, check whether the travel limit switch is blocked or damaged by debris; The emergency stop alarm may be caused by the emergency stop button being pressed incorrectly, or the device detecting safety hazards such as overload or short circuit. The emergency stop button needs to be reset first, and then the motor load and circuit connection should be checked for normal operation. After eliminating safety hazards, the system can be restarted.
When dealing with faults in CNC tool grinders, it is necessary to avoid one-sided operations that cause headaches. The internal connections between various systems of the equipment (mechanical, electrical, CNC) should be linked to the fault phenomenon. At the same time, trial operation verification should be carried out after fault handling to ensure that the equipment returns to normal accuracy and operational stability, and to provide guarantees for the quality of tool processing.