1、 Equipment Start Stop Specification Pre Start Inspection Mechanical System: Confirm the tension of the sand belt/wire drawing wheel (measured with a tension meter, deviation<5%), the amount of lubricating grease on the guide rail (coverage rate of over 90%) Electrical System: Reset the emergency stop button, ground resistance<4 Ω, no fault code on the frequency converter (such as ABB ACS550 displaying "OK") Air Source Requirements: The air pressure should be stable at 0.6-0.8MPa, The droplet speed of the three piece oil mist device should be adjusted to 2-3 drops per minute.

The main spindle should be preheated and run without load for 5-10 minutes (gradually increasing the speed to 50% of the rated value).

The bearing temperature should be less than 65 ℃ (monitored by an infrared thermometer).

Secondly, when using magnetic fixtures for material clamping, the residual magnetic strength should be greater than 1200 Gauss (to prevent thin plate displacement).

Irregular parts must be equipped with imitation pads with a contact area greater than 80% to avoid uneven texture caused by suspension.

Parameter dynamic matching hardness speed pressure three-dimensional matching table (taking 304 stainless steel as an example): target Ra (μ m) wire drawing wheel hardness (Shore A) line speed (m/min) pressure (N/cm ²) 3.2 85-90 18-22 16-20 1.6 75-80 12-15 10-12 0.8 60-65 8-10 6-8 Real time monitoring points Vibration monitoring: Install an acceleration sensor with an amplitude greater than 0.15mm Immediately stop the machine and check the temperature control: the processing area is equipped with an infrared thermal imager, which automatically alarms when the material recrystallization temperature exceeds (such as aluminum alloy 230 ℃).

Thirdly, the personal protection of the safety protection system must be triple guaranteed.

Anti splash goggles (EN166 standard) and anti noise earplugs (NRR ≥ 25dB) must be worn.

Gloves are prohibited from operation.

The cuffs and placket must be tied tightly, and long hair should be tied into the work cap.

Emergency response plan for belt breakage protection: when the sand belt breaks, the brake should lock the spindle within 0.5 seconds (test cycle: once a week).

Fire prevention and control: when processing magnesium/titanium alloys, Class D fire extinguishers (water-based fire extinguishers are strictly prohibited) must be equipped within 1 meter of the workbench.

Fourth, process quality assurance first article inspection standard: The longitudinal/transverse Ra difference should be less than 15%.

Edge 5mm When the consistency between the internal texture and the central area is greater than 90%, use a surface roughness meter (such as Mitutoyo SJ-410) to detect 3 points: batch processing control, use a colorimeter to detect the degree of surface oxidation (Δ E ＜ 1.5), check the wear of the wire drawing wheel (caliper to measure the diameter, replace if the wear is greater than 2mm).

After processing 20 pieces: 5.

Equipment maintenance cycle.

Daily maintenance after shift cleaning: Use a vacuum cleaner (explosion-proof type) to remove metal dust, apply WAY grease to the guide rail (butter is prohibited).

Electrical inspection: Use a megohmmeter to detect the motor insulation resistance (＞ 5M Ω).

Deep maintenance.

Monthly: Replace the spindle bearing grease (SKF LGMT3), synchronous belt tension correction (frequency analyzer detection).

Quarterly: Servo motor encoder reset calibration.

Ball screw reverse clearance compensation (laser interferometer accuracy 0.005mm) 6、 Solution to difficult problems in special working conditions: Stripe defect: Adjust the parallelism of the feeding roller (detected with a dial gauge, error<0.02mm/300mm).

Aluminum sticking phenomenon: Spray PTFE coating (thickness 0.01-0.03mm) on the surface of the drawing wheel, and reduce the processing temperature by 40-60 ℃