Factors affecting the effective use of CNC machine tools and countermeasures
2026-04-06 02:25:33··#1
CNC machine tools are advanced equipment that utilize computer technology, servo control technology, and machine tool manufacturing technology to achieve various mechanical processing and manufacturing processes. Due to their unparalleled advantages over ordinary metal-cutting machine tools, they have become the mainstream product in machine tool development and a key factor in revitalizing the equipment manufacturing industry. CNC machine tools are technologically advanced, structurally complex, and expensive. If they are not used effectively, it will inevitably affect manufacturing efficiency, increase product costs, and also increase the failure rate of CNC machine tools, raising maintenance and management costs and hindering the full realization of their performance. Therefore, it is necessary to strengthen research on the effective use of CNC machine tools. This article discusses the factors affecting the effective functioning of CNC machine tools and the countermeasures to be taken from the perspectives of operation, maintenance, and management. 1. Main Influencing Factors 1.1 Human Factors CNC machine tools employ computer technology, servo control technology, and machine tool manufacturing technology, resulting in high technological content and complex technology. Therefore, the use of CNC machine tools is not a simple matter of using ordinary equipment, but a technical application project. This requires personnel involved in the operation, maintenance, and management of CNC machine tools to possess high levels of education and technical skills. Especially for operators, their understanding of the mechanisms of CNC machine tools, operating skills, CNC system knowledge, and basic knowledge of daily maintenance directly affects the full utilization of the CNC machine tool's functions. Currently, operators, maintenance personnel, and managers lack in-depth understanding of CNC technology, have an inadequate understanding of the mechanisms of CNC functions, and are unfamiliar with computer hardware and software technology and programming techniques. This leads to the application of CNC machine tools only on the basis of ordinary machining technology, resulting in outdated processing techniques and making it difficult to effectively utilize the inherent functions of the CNC machine tool. At the same time, there is a shortage of CNC machine tool maintenance personnel, and their maintenance skills are not high. When CNC system malfunctions occur, diagnosis is unclear, and repair is difficult, resulting in a high downtime rate for CNC machine tools. 1.2 Management Factors Many enterprises lack systematic consideration and planning when purchasing CNC machine tools, and lack comprehensive management systems and measures for their use and management, leaving numerous problems in their operation. 1.3 Environmental Factors CNC machine tools not only require excellent performance, but their CNC and servo systems also need high stability and reliability. Ensuring system stability and reliability is not only related to the machine itself but also significantly influenced by environmental conditions. CNC machine tools require a good working environment. Many enterprises experience machine tool alarms due to uncontrolled temperature and humidity, excessive dust, and general dirt and disorder, sometimes preventing normal machine operation and impacting normal use. In conclusion, the aforementioned problems in actual production use of CNC machine tools will inevitably affect their effective use, thus impacting the enterprise's economic benefits. Therefore, these issues should be given high priority, and solutions are analyzed below. 2. Countermeasures and Measures 2.1 Establishing a High-Quality Team of Operators, Maintenance Personnel, and Managers 2.1.1 Requirements for Operators, Maintenance Personnel, and Managers For CNC machine tool operators, the requirements are not only a certain level of process knowledge and experience operating ordinary machine tools, but also specialized technical theoretical training and operational training in the structural characteristics, working principles, and programming of CNC machine tools. Only those who pass the assessment can operate the machine, ensuring the correct and effective use by operators. Simultaneously, they should have a deep understanding of the process, scientifically write programs, continuously optimize programs in practical applications for workpieces with large batches and frequent processing, and be adept at summarizing operational experience to make correct comprehensive judgments and handle various CNC machining situations. For CNC machine tool maintenance personnel, the requirements are a high level of theoretical knowledge and maintenance skills. Maintenance personnel should understand some electromechanical maintenance knowledge of CNC machine tools, and electrical maintenance personnel should understand the structure and programming knowledge of CNC machine tools. Maintenance personnel should possess high levels of mechanical, electrical, and hydraulic professional knowledge to comprehensively analyze and accurately determine the root cause of faults, achieve efficient maintenance, and minimize downtime. The requirements for management personnel regarding CNC machine tools: All personnel working with CNC machine tools should possess basic knowledge of CNC machine tool technology and receive enhanced training in this area. This enables them to quickly and promptly identify which machine has malfunctioned, the location of the malfunction, and the cause of the malfunction, allowing for proactive coordination and organization to resolve the issue quickly and restore the equipment to normal operation. Management personnel should fully mobilize the enthusiasm and initiative of operators and maintenance personnel to maximize the combined human-machine productivity. Having a highly qualified team of operators, maintenance personnel, and managers can prevent equipment malfunctions caused by human error or inexperienced operators, thus ensuring the normal operation and efficiency of the equipment. Statistics show that in the first year of use, one-third to more than half of CNC machine tool malfunctions are caused by improper operation and programming errors, highlighting the importance of a highly qualified team of operators, maintenance personnel, and managers. 2.1.2 Strengthening Professional Knowledge Training for Personnel Training is also crucial for the operation, maintenance, and management of CNC machine tools. Effective training within a company can ensure smooth operation, maintenance, and management, as well as stable equipment operation, thereby maximizing equipment performance. The training targets CNC machine tool operators, maintenance personnel, management personnel, and other relevant staff. Training content includes the company's established equipment maintenance and management systems, basic knowledge of CNC machine tools, structural characteristics, application scope, and programming knowledge of CNC machine tools, technical documents such as user manuals, system operation manuals, and maintenance manuals, relevant process knowledge and operating requirements, new technologies, knowledge, and standards in maintenance management. Training should be conducted in a planned and targeted manner. 2.2 Establishing a Scientific Management System for CNC Machine Tools Marshal Liu Bocheng, a renowned military strategist both in China and abroad, successfully commanded many major battles. He once vividly described the importance of thorough pre-battle planning: "If the five elements are not determined, you will lose completely." These five elements refer to: mission, time, terrain, enemy situation, and our own situation. This is a valuable lesson for us. The author believes that CNC machine tools, due to their unique characteristics, differ significantly from traditional machine tools. Therefore, the management of CNC machine tool use requires a more stringent management system and control process. I believe there are five main aspects that should be controlled: investment management—preliminary management—acceptance management of new machine tools—spare parts management—post-operation management. Management systems should be developed for each aspect, and effective control measures should be implemented. 2.2.1 Investment Management CNC machine tools require significant investment and are technologically advanced. Therefore, extensive work is needed in equipment selection and CNC system selection. Factors such as the required workpiece precision, factory process flow, and even the factory's economic situation must be considered when choosing different grades and types of machine tools to minimize initial investment risks. The selected machine tools must not only meet the company's actual production needs but also offer good value for money. 2.2.2 Acceptance Management of New Machine Tools The acceptance of new machine tools is a crucial task that must be given due attention. Insufficient understanding can affect the use of the machine tools and the company's production, resulting in economic losses. The acceptance process includes unpacking inspection, visual inspection, acceptance of machine tool performance and CNC functions, and acceptance of machine tool precision. 2.2.3 Preliminary Management: After the CNC machine tool is put into use, the relationships between relevant departments involved in its use should be streamlined, the responsibilities and authority of each department should be rationally divided, the behavior of relevant departments should be standardized, and the tasks and requirements of each work during the use of the CNC machine tool should be clarified. Employees and departments should be educated, guided, and supervised to strictly and conscientiously implement various systems for the operation, maintenance, and management of the CNC machine tool equipment. This will lay a solid foundation to avoid blind management and ensure that there are systems, standards, and procedures—that is, rules to follow and laws to abide by. 2.2.4 Spare Parts Management: To ensure normal production and the optimal performance of the CNC machine tool, necessary spare parts should be prepared based on the failure mechanisms of the CNC machine tool and the failure patterns continuously summarized in practical applications. Necessary spare parts can reduce downtime of the CNC machine tool, facilitate reliable system operation, aid in troubleshooting, and improve the safety of machine tool maintenance and upkeep. 2.2.5 On-site Management On-site management is particularly important, and its main contents include fault prevention, maintenance, diagnosis, troubleshooting, and production quality assurance. Branch plants (workshops) are required to implement preventative maintenance management (autonomous maintenance) such as cleaning and hygiene, daily inspection and maintenance, periodic inspection and maintenance, lubrication (automatic and manual lubrication), daily and periodic maintenance, and periodic adjustments, in accordance with the company's established CNC machine tool equipment maintenance and management system and standards during the on-site use and management of CNC machine tools. Adaptive maintenance (on-demand maintenance) should also be implemented based on the actual conditions of different CNC machine tools, developing different maintenance strategies. 2.2.6 Post-Management The post-management of CNC machine tools must be based on investment management, pre-management, new machine tool acceptance management, and on-site management. It must be handled with caution regarding the overhaul, modification, storage, and scrapping of CNC machine tools, in accordance with relevant standards and the company's CNC machine tool operation, maintenance, and management system. This will fully realize the value of CNC machine tools and generate greater benefits for the company. 2.3 Creating a Suitable Working Environment To ensure the good working performance and reliability of CNC machine tools, and to guarantee the stability and reliability of the CNC and servo systems configured on them, a good working environment is essential. The requirements for the working environment are comprehensive. To ensure the normal operation of CNC machine tools, the following conditions must be considered and carefully managed to create favorable conditions for their effective use: 1) Mains Voltage: The mains voltage fluctuation should ideally be within ±10%, and absolutely must not exceed ±15%, otherwise it will inevitably damage electrical components; 2) Working Humidity: The environment around the machine tool should not be too humid. Excessive humidity can easily cause corrosion of cable plugs and printed circuit board connectors, resulting in poor contact and control failure; 3) Working Temperature: The working temperature has many effects. Ideally, the temperature should be controlled at around 20℃. Temperatures that are too high or too low will cause the machine tool's working accuracy to exceed tolerances. This is the first point. Second, the operating temperature of semiconductor components in electrical control systems is generally 40-45℃. When the room temperature reaches 35℃, the internal temperature of the machine tool cabinet may reach above 40℃, and the system cannot guarantee normal operation. Third, the electrical components of the machine tool cabinet will also not work properly when the temperature is too low; 4) Operational interference: There should not be too many electromagnetic interference sources around the CNC system when it is working; 5) Grounding: The ground wire of the CNC machine tool should not be connected to the common ground wire of the workshop production. It is best to have a separate grounding device; 6) Civilized and hygienic working environment: A clean working environment is also a necessary condition for improving the reliability of machine tool operation, etc. 3 Conclusion In short, with the popularization and development of CNC machine tools, the operation, maintenance and management of CNC machine tools will inevitably become an emerging technical discipline. It is necessary to establish a talent team for operation, maintenance and management, give full play to the characteristics of high speed, high precision, high efficiency and flexibility of CNC machine tools, reduce maintenance and management costs, rationally arrange its production plan, and strive to expand its processing range, thereby reducing product costs and achieving the goal of improving its production efficiency. This is an important part of the enterprise's market competitiveness and affects the enterprise's future. 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