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Flange facing machine is a common processing technology in precision manufacturing. It is mainly used to process the end face, aperture and workpieces with high surface finish requirements of flanges. However, in actual operation, overheating often occurs during flange end facing machine, which not only affects the machining accuracy and surface quality, but also may shorten the service life of the tool and even cause damage to the equipment. Therefore, how to effectively control the overheating problem during flange facing machine has become an important technical problem in the machining process. This article will discuss in detail from multiple aspects such as the cause analysis of overheating, the impact of overheating, preventive measures and solutions.

1. Analysis of the causes of overheating in flange facing machine

Unreasonable cutting parameters: The selection of cutting parameters directly affects the temperature distribution during the machining process. When the parameters such as cutting speed, feed rate and cutting depth are unreasonable, overheating often occurs. For example, too high cutting speed, too large feed rate, too deep cutting depth, etc. will cause a large amount of friction heat to be generated on the workpiece surface and the tool, which will lead to overheating in the machining area.

Tool wear or improper selection: The material, shape and coating of the tool will affect the temperature distribution during machining. After the tool is worn, its cutting ability is greatly reduced, and more heat is generated during the cutting process. If the tool material and coating are not properly selected and the heat resistance is poor, it is also easy to cause overheating.

Insufficient or improper use of coolant: Coolant plays a vital role in flange facing machine. It not only takes away the heat generated during the cutting process, but also reduces the friction between the tool and the workpiece and reduces the impact of thermal expansion. If the coolant flow is insufficient or the type of coolant is not suitable, it will cause the temperature to rise, which will cause overheating.

The temperature of the processing environment is too high: The ambient temperature has a certain effect on the heat generated during machining. In a high temperature environment, the heat generated during machining is more difficult to dissipate and is easy to accumulate, resulting in overheating of the workpiece or tool.

Differences in thermal conductivity of workpiece materials: Flanges of different materials have different heat absorption capabilities during machining. For example, materials with higher hardness usually generate more cutting heat, while materials with low thermal conductivity are more difficult to export heat in time, resulting in a rapid increase in temperature during machining.

2. The impact of overheating in flange facing machine

Decrease in machining accuracy: In an overheated state, the size of the workpiece may undergo thermal expansion, resulting in machining errors. Especially in the flange end face processing with high precision requirements, the expansion caused by overheating may cause the size of the flange end face to not meet the design requirements, or even cause scrap.

Surface quality problems: Overheating will increase the surface roughness of the workpiece, and even cause burns, discoloration and other phenomena. Excessive temperature during processing may also cause changes in the hardened layer on the surface of the material, affecting the performance and life of the flange.

Shortened tool life: Under high temperature conditions, the tool material will anneal or oxidize, resulting in a decrease in tool hardness, thereby aggravating tool wear. Overheating will not only significantly reduce the wear resistance of the tool, but may also cause the tool to break or damage.

Equipment damage: Long-term overheating will cause damage to processing equipment, especially key components such as the spindle and bearings of the machine tool. At high temperatures, the performance of the lubricating oil will decrease, increase friction resistance, and then aggravate equipment wear and shorten service life.

3. Solutions for overheating in flange facing machine

Optimize cutting technology: During the processing process, the temperature can be reduced by adjusting the cutting method. For example, a segmented cutting method can be used to gradually remove material to avoid excessive heat caused by one-time cutting. In addition, using lower cutting speeds and higher feed rates can effectively reduce unit cutting forces and reduce the probability of overheating.

Enhance cooling effect: In the use of coolant, a higher pressure coolant injection system can be used to make the cooling effect more uniform and efficient through the injection coolant. In addition, you can also consider using oily coolant or adding coolant additives to improve the cooling effect.

Use internal cooling tools: Internal cooling tools are tools with cooling channels that can directly guide coolant to the vicinity of the cutting edge to achieve a more efficient cooling effect. The use of internal cooling tools can significantly reduce the temperature of the cutting area and avoid overheating.

Use more efficient cutting fluids: The selection of cutting fluids is crucial to temperature control. Using cutting fluids with higher lubricity can effectively reduce the generation of frictional heat. For the processing of some high-hardness materials, you can choose cutting fluids with high temperature resistance to cope with the high temperatures generated during the processing.

Improve the heat dissipation capacity of the equipment: Modern flange end facing machines are generally equipped with a heat dissipation system, but in order to more effectively control the temperature, additional cooling devices such as water cooling systems or air cooling systems can be installed. In addition, regularly cleaning and maintaining the cooling system of the machine tool to ensure its normal operation can also help reduce the occurrence of equipment overheating.

The overheating problem in flange facing machine is a multifaceted technical problem that requires comprehensive consideration and optimization from multiple aspects such as cutting parameters, tool selection, coolant use, and machining environment. By taking reasonable preventive measures and solutions, not only can the overheating problem in the machining process be effectively controlled, but also the machining efficiency and quality can be improved, and the service life of tools and equipment can be extended. Therefore, in-depth understanding and resolution of the overheating problem during flange facing machine is an important issue that every processing plant and technician must face.

As a leading flange facing machine enterprise, we are well aware of the impact of overheating on equipment performance and machining quality. Therefore, we continue to optimize technology and processes to provide customers with more efficient and reliable flange facing machine solutions.

https://www.nodha.com/
NODHA Industrial Technology Wuxi Co., LTD

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