1. First, the dimensional changes caused by the system are unstable.

Causes: Inappropriate system parameter settings; unstable operating voltage; external interference causing system synchronization failure; added capacitors, but impedance mismatch between the system and the driver, resulting in signal loss; abnormal signal transmission between the system and the driver; system damage or internal issues.

Solutions: Check for excessive speed and acceleration time; whether the spindle speed and cutting speed are reasonable; whether operator parameter modifications alter system performance; install a voltage regulator; ensure reliable grounding; add anti-interference capacitors to the driver pulse output contacts; select appropriate capacitor models; check if the signal connection between the system and the driver is shielded and reliable; check for system pulse signal loss.

2. The workpiece develops a taper dimension.

Causes: Poor machine tool leveling, uneven placement; when turning long shafts, the feed material is too hard, causing deeper cutting depth and cutting edge; misalignment between the tailstock center and the spindle.

Solutions:
1. Use a level to adjust the machine’s level, ensure a solid foundation, and secure the machine to improve its resilience; select a reasonable process and appropriate cutting feed to avoid tool stress; adjust the tailstock.

2. The drive phase lights are normal, but the size of the machined workpieces varies.

Causes: Long-term high-speed operation of the machine tool carriage causes wear on the leadscrew and bearings; the tool post’s repeatability accuracy deviates over long-term use; the carriage accurately returns to the machining starting point each time, but the dimensions of the machined workpiece still change. This phenomenon is generally caused by the spindle; the high-speed rotation of the spindle causes severe bearing wear, leading to changes in the machining dimensions.

Solutions: Place a dial indicator against the bottom of the tool post, edit a fixed cycle program in the system, check the carriage’s repeatability accuracy, adjust the leadscrew backlash, replace the bearings; use a dial indicator to check the tool post’s repeatability accuracy. Adjust the machine or replace the tool post; use a dial indicator to check if the workpiece accurately returns to the program starting point.

4. The workpiece dimensions differ from the actual dimensions by several millimeters, or there is a significant change in one of the axial directions.

Possible causes: Rapid positioning speed is too high, the driver and motor do not respond; after long-term friction wear, the mechanical lead screw and bearing are stuck too tightly; the tool holder is too loose after tool change, and the locking is not tight; the program is corrupted, the beginning and end do not respond, or the tool completion is not canceled; the electronic gear ratio or step angle setting of the system is incorrect.

Solutions: If the rapid positioning speed is too high, adjust the speed appropriately. Adjusting the cutting acceleration, deceleration, and time will ensure the driver and motor operate normally at their rated operating frequency. After machine wear, the carriage and screw crane bearings may become too tight, requiring readjustment for repair; if the tool holder is too loose after tool change, check if the tool holder reversal time is sufficient, check if the worm gear inside the tool holder is worn, if the clearance is too large, and if the installation is too loose, etc.

If you have future projects requiring CNC machining, please send drawings to this email address for evaluation and quotation: info1@us.cjcncmachining.com