How to monitor roughing when machining?

Roughing is a crucial step in the machining process. It usually serves as the starting stage of the entire machining process, with the purpose of quickly removing excess material and forming the basic shape of the part. Therefore, how to effectively monitor the roughing process to ensure machining efficiency and quality has become a key concern.

1. Tool condition is one of the important factors affecting machining quality. In the roughing process, due to the large amount of cutting, the tool is subjected to a relatively heavy load, and is prone to wear or breakage. By monitoring the vibration signal, cutting force and acoustic emission signal of the tool, we can understand the working condition of the tool in real time, and once abnormalities are found, adjust or replace the tool in time to avoid the machining quality being affected.

2. Machine load is also a monitoring object that should not be ignored. Roughing high loads easily lead to large deformation of the machine tool, thus affecting the machining accuracy. Through the installation of load sensors, you can monitor the real-time load of each axis of the machine tool, and combined with the dynamic characteristics of the machine tool itself to analyze, in order to optimize the cutting parameters, reduce the load on the machine tool, improve machining stability.

3. Workpiece size is a visual measure of machining quality. Although in the roughing stage, the accuracy of the size of the workpiece is not as strict as that of the finishing process, but still need to ensure that the workpiece meets the basic shape and size requirements of the subsequent processes. The use of modern measurement technology, such as laser scanning, optical projection and other methods, can be in the case of non-contact workpiece to quickly and accurately obtain the geometric dimensional information of the workpiece, to achieve online or near-line inspection.

4. Surface quality is also an important indicator for assessing the effectiveness of roughing. In the roughing process, due to the fast cutting speed and large cutting depth, it is easy to cause high surface roughness of the workpiece. The use of surface roughness meter or other visual inspection equipment can detect the microstructure of the machined surface, detect surface defects in time, and provide a good basis for subsequent finishing.

5. Cooling lubrication in roughing should not be ignored. Appropriate cooling lubrication can not only extend tool life, but also reduce the thermal deformation of the workpiece and improve machining efficiency. Therefore, monitoring the flow and pressure of the coolant to ensure its full coverage in the cutting zone is equally important to ensure the quality of roughing.