Analysis of the problems and causes of the cooling and filtering system of the machining center
1. The cooling system of the machining center often has a clogging alarm failure, and the cover of the cooling pump station is disassembled and found. Cannot enter the drum through the stainless steel wire mesh of the filter drum, which causes the low water pressure of the internal cooling pipe of the spindle, and the reason for the alarm and shutdown of the machine tool cooling system:
- 1) Since the company is located in the south and the air is humid, in order to prevent the steel castings from rusting, the cast cylinder body and cylinder head must be sprayed with anti-rust oil on the inner and outer surfaces. The oil dissolves into the cooling fluid, and when it meets iron filings, it is easy to stick with the iron filings and block the outer surface of the filter drum
- 2) The lubricating oil of the machine tool guide rail is directly discharged in the cooling liquid, and it is also easy to form sludge with iron filings, thereby blocking the filter drum
- 3) Aluminum cylinder castings have been widely used for cylinder block and cylinder head castings in Europe, and there is no problem of casting rust. Therefore, when designing the machine tool coolant filtration system, the manufacturer only considered the two-stage scraper chip removal machine and the last stage using a mesh filter drum, and did not consider the method for oil pollution treatment.
2. Because the filter drum is often clogged, it needs to be removed and cleaned every 1-2 months on average. It is easy to damage the stainless steel mesh after frequent removal and cleaning, and it needs to be replaced in about 2 years. Order, the price is very high
3. The cooling filter system has poor filtering effect, which causes the coolant to be replaced once a month. Some of the machining centers of the rough machining process can only be used for half a month, which does not meet the design requirements for the coolant to be replaced within 3 months. Therefore, the production cost is higher
4. The cooling filter system is often clogged, which causes the internal cooling pressure of the spindle to be low, the tool wears too fast, and the tool cost is too high. At the same time affect the processing quality. The application of the machining center to the production line is mainly considering the characteristics of its multi-variety and flexible production. However, compared with special machine tools, frequent tool replacement takes a long time, and slow production cycle is another major disadvantage. In order to make up for this shortcoming, a large cutting amount and rapid feed must be used during processing, because the tools of the machining center are all foreign products, and the price is expensive
5. The working process of the original cooling filter system is: cutting fluid → chip removal of the first-level scraper chip removal machine → sedimentation of the low-level water tank → cooling water pump → chip removal of the second-level scraper chip removal machine → filter drum stainless steel wire mesh filter → inside the main shaft Cold system II. In order to solve the problem of frequent blockage of the cooling and filtering system, a set of secondary filtering device was added on the premise that the original cooling and filtering system was not significantly modified. The first stage uses a magnetic separator to separate iron filings and sludge. The second stage uses a paper belt filter to filter rust-preventing sludge. It can also filter fine iron filings and oil stains. The secondary filtering device is installed above the partitioned water tank. The set of secondary filtering devices added by a single machining center mainly includes the following configurations
- 1) Divided water tank
- 2) Magnetic separator
- 3) Paper belt filter
- 4) Vertical multistage water pump
- 5) Level switch
The working process of the cooling filter system after the transformation is: cutting fluid → chip removal of the first-level scraper chip removal machine → low-level water tank sedimentation → cooling water pump → magnetic separator to separate fine iron scraps, oil sludge → paper belt filter to filter anti-rust oil sludge, oil stain → Separated sedimentation of separate water tank → Cooling water pump → Chip removal of second-level scraper chip removal machine → Filter drum stainless steel wire mesh filter → Spindle internal cooling system III. Transformation result The effect produced by adding a set of secondary filtering device
- 1. Cooling system cutting fluid replacement cycle has been extended from the previous 1 / month to 1/3 month
- 2. The cooling filter system of the machine tool has no filter clogging failure within a period of 3 months of use of the coolant
- 3. Solve the problem that the filter drum is damaged due to frequent disassembly and washing, ensure that the filter drum can be used for more than 3 years, and save maintenance costs
- 4. The internal cooling pressure of the spindle is stable, which solves the problem of excessive tool wear and reduces the cost of tool use. Through the transformation of the cooling filter system of the machining center, not only the failure of the cooling filter system is often blocked, but also the life cycle of the coolant is less than 1 The month is extended to 3 months to achieve the purpose of reducing costs, the investment in the renovation cost can be recovered within 1 year, and the effect is obvious
