During the operation of high-speed end milling machines, loose tool clamping is a common type of fault. This fault not only directly affects the dimensional accuracy and surface roughness of the processed parts, but may also cause tool jumping, deviation, or even detachment, leading to equipment damage or safety accidents. Therefore, timely diagnosis and treatment work is needed.
The precise identification of the cause of the malfunction is the core of solving the problem. From the perspective of device structure and operational logic, common causes mainly include three aspects. One is the wear of the clamping mechanism, where core components such as the clamp head and pull rod are subjected to high-speed operation and periodic stress for a long time, which can lead to fatigue wear or deformation, resulting in an increase in clamping clearance; The second issue is insufficient air or oil pressure. For equipment using pneumatic or hydraulic clamping systems, when the pressure parameters do not reach the standard values, the clamping force will significantly decrease; Thirdly, improper operation, such as not cleaning the chips and oil stains on the tool handle and chuck before clamping, or not installing the tool properly, can damage the sealing and stability of the clamping.
Fault diagnosis should follow the principle of "from simplicity to complexity, from surface to interior". Firstly, conduct a visual inspection to check for oil stains, chip accumulation, scratches, and wear on the tool handle and the inner wall of the chuck, and confirm if the tool is properly installed. Subsequently, parameter verification will be carried out. For the pneumatic clamping system, a pressure gauge will be used to check whether the working air pressure meets the requirements of the equipment manual; For hydraulic systems, focus on checking the oil pressure value and oil circuit sealing. If there are no abnormalities in the first two checks, the clamping mechanism needs to be disassembled, and key indicators such as the elastic deformation of the clamp head and the clearance between the pull rods need to be tested to determine whether there is excessive wear on the components.
Targeted solutions need to be taken for different causes. If the clamping mechanism is worn, mild wear can be restored to accuracy by grinding the inner wall of the chuck and replacing the elastic washer. For severe wear, the chuck or rod needs to be directly replaced; If the pressure is insufficient, the pneumatic system needs to check whether the air pipe is leaking and adjust the pressure regulating valve to the standard pressure, while the hydraulic system needs to check for blockages in the oil circuit and replenish hydraulic oil; If it is an operational issue, it is necessary to standardize the clamping process and require the operator to clean the clamping area with a special cleaning agent before clamping, and manually check the amount of tool shaking after installation.
In addition, daily maintenance is the key to preventing this malfunction. It is recommended to establish a regular inspection system, clean the clamping mechanism of debris every week, check the pressure parameters and component wear every month, and conduct comprehensive disassembly and maintenance every quarter to reduce the probability of failure from the source and ensure the stable operation of high-speed end face milling machines.