Quality control is an important aspect of any working prototype. Nowadays, mechanization and automation have become the mainstream of industry development. In the application process, due to the lack of coordination or cooperation between certain parts, the machines and equipment assembled from various parts are prone to problems. Raw material specifications, performance, material use, machine vibration, clamping pressure or looseness, elastic deformation process system, worker operations, testing methods and inspectors’ errors, etc., will all have an impact on the quality of processed products.
The following are the main factors that affect the quality of the working prototype.
Humanity
As machine functions become more and more complex, the level of programmers and operators varies greatly. People play an important role in operating the processing system. Machine operators must have advanced operating and programming skills. This, combined with the use of the computer, can ensure the maximum use of the computer. For this, machine operators must be familiar with equipment performance. If the operator does not know enough about the performance of the equipment, he may operate in the wrong way, thereby accelerating the wear of machine parts and even causing damage to the machine.
Therefore, this will require a lot of maintenance costs and a long maintenance time. In order to restore the original accuracy of the equipment, the machine tool operator must understand and master the machine tool manual and its operating precautions for civilized production and safe processing. It is necessary to strengthen the skill training of all processing and production personnel, rationally arrange first and second processing positions, and improve the quality awareness and work responsibility of the personnel. People with good quality awareness and work responsibility will produce high-quality working prototypes. (related post How Important Is The Management Of Mechanical Machining Factory)
Machine
The complete processing system consists of machine, workpieces, fixtures and tools. The machining accuracy is related to the accuracy of the entire process system. Various errors in the process system will be reflected in different forms as machining tolerances under different conditions.
Machine accuracy is an important factor affecting the quality of prototype parts. When the accuracy of the machine is poor, some parts are damaged or the gap of each part is adjusted improperly, various defects will appear during the processing of the prototype.
Therefore, we must not only choose the appropriate corner, appropriate cutting amount and processing method, but also understand the impact of machine accuracy on processing quality. The maintenance of the machine directly affects the processing quality and production efficiency of the prototype. In order to ensure the accuracy of work and prolong its service life, all machines must be properly maintained.
Processing Methods
There are many processing methods, of which cutting is the most common one. During the cutting process, the workpiece will be subject to changes in force and heat, and the physical and mechanical properties of the metal material will be slightly hardened, so the choice of tools plays an important role.
Under normal circumstances, the material of the tool should be selected according to the material of the workpiece to be processed. Otherwise, the surface of the workpiece will form thorns related to the tool, which can easily increase the roughness of the workpiece and reduce the surface quality. (related post How To Choose The Right Tool For Different Material Machined Parts?)
The second machining quality factor is the amount of lubrication and cutting the amount used in processing. Poor lubrication results lead to a build-up of heat. This causes part deformation lowering part quality.
In the machining process, the machining system is the general command of the entire cutting process. All processing processes are carried out according to the system, so the accuracy and rigidity of the processing system are also one of the main factors affecting the processing quality.
There are two principles for processing arrangement:
Processing dispersion: use multiple processes to manufacture complex parts and break them into multiple machines for processing.
Processing concentration: compound machine functions, such as compound turning and milling, laser ultrasonic vibration processing, grinding, five-axis linkage, etc.
All processes are completed on one machine. According to the structure analysis of the workpiece, the use of different processing methods is also an important factor affecting the processing quality.
Material
Machined materials are usually divided into plastics and metals. Each material has its own characteristics. It is also very important to select suitable materials according to the requirements and applications of the workpiece during the processing. The material should be able to maintain the consistency of the parts to ensure the same quality. Otherwise, the quality of each part of the working prototype will be different. In addition, during the hardening of the plastic prototype, no part deformation should occur. These are some of the functions we should consider when checking the quality of parts. (related post Material Selection Guide For CNC Machining)
Inspection
After the machine finishes processing the workpiece, inspection is the last critical step before delivery to the customer.
Machining inspection generally needs to pay attention to two aspects:
1. Inspection procedure
the inspection process includes the inspection process and related regulations, systems, standards, etc. Generally speaking, the inspection process is the location and method of intervention during the production process, including the first inspection, self-inspection, mutual inspection and full-time inspection.
2. Inspection method
refers to how to inspect and inspect standards. The inspection of machined parts is usually carried out according to the mechanical drawings, and the products are identified through inspection instruments and measuring tools.
Traditional processing inspection and more modern processing inspection
Traditional machining testing instruments include micrometer, dial indicator, vernier card, flat ruler, straight edge, level meter and various plug gauges, ring gauges, etc. More modern machining inspection instruments include optical collimators, projectors, three-dimensional measuring instruments, theodolites, laser detectors, etc.
Qualified mechanical product inspectors must master the knowledge of inspection instruments and measuring tools related to unit products.
In the processing process, in order to control the processing quality, it is necessary to understand and analyze the various influencing factors that the processing quality cannot meet the requirements, and take effective technical measures to overcome them. (Link to check page)
Conclusion
With the continuous improvement of modern production levels, the requirements for quality of processed products are getting higher and higher. Only by taking comprehensive measures to control the quality, can we finally achieve the purpose of improving the service life and service life of the equipment, and can we consider economic benefits and energy saving in the processing process. At the same time, the processing quality must be guaranteed to promote the long-term stable development of the processing industry.