During the CNC machining process, it is common for various reasons to lead to deviations from the intended outcome of the produced products. Many newcomers to the field often encounter issues and malfunctions. Today, we have compiled some solutions for problems that may arise, such as excessive cutting of workpieces, tooling faults, centering errors, collisions caused by operations, collisions caused by programming, and insufficient surface accuracy. Let's delve into each of these problems and their respective solutions.

Excessive Cutting of Workpieces
There are several main reasons for this situation:
Insufficient tool strength, using excessively long or small tools leading to tool deflection.
Improper operator techniques.
Uneven cutting allowances.
Improper cutting parameters, such as excessive tolerances or fast feed rates.
To address these issues:

When selecting tools, try to follow the rule of choosing larger tools without going too small and shorter tools without going too long.
Implement corner-clearing programs and ensure even cutting allowances.
Adjust cutting parameters properly, rounding corners with larger allowances.
Utilize the SF (spindle speed override) function of the equipment and allow operators to fine-tune the speed for optimal cutting results.

Tooling Faults
The primary causes of tooling faults include:
Operator errors during operation.
Improper tool clamping.
Incorrect tool inserts on the tool holder.
Deviation between the R tool, plane bottom, and tool holder.
To rectify these faults:

Before manual operation, carefully inspect and center the tools consistently at the same point.
Clean the tool holders using an air gun or cloth before clamping.
When measuring the tool insert and the tool bottom, use the same insert.
Utilize a separate tooling program to minimize errors between the R tool, plane tool, and tool holder.

Centering Errors
The main reasons for this issue are as follows:
Inaccurate manual operation by operators.
Presence of burrs or roughness around the mold.
Magnetic effect on the centering pin.
Lack of verticality in the mold's four sides.
To address and improve centering errors:

Before manual operation, conduct thorough checks, ensuring consistent centering at the same point and height.
Use an oilstone or file to remove burrs around the mold, wipe it clean with a cloth, and manually confirm the cleanliness.
Demagnetize the centering pin before initiating centering procedures.
Verify and check the verticality of the mold's four sides.

Collisions Caused by Operator Errors
Collisions can occur due to the following factors:
Z-axis tool depth misalignment.
Errors in centering or operation count.
Incorrect tool selection.
Programming errors.
Mistakes in the direction of manual operation or rapid feed.
To prevent collisions caused by operator errors:

Pay close attention to the tool depth alignment in the Z-axis.
Perform thorough checks on centering and operation count after completion.
Verify the tool clamping by comparing it with the program sheet.
Follow the programmed sequence step by step.
Operators should enhance their proficiency in machine tool operation during manual operations.
Before manually moving the machine, raise the Z-axis above the workpiece.

Collisions Caused by Programming Errors
The main causes of these collisions are:
Insufficient or nonexistent safety height settings.
Discrepancies between the tooling specified on the program sheet and the actual program.
Errors in the specified tool length and the actual machining depth on the program sheet.
Mistakes in depth Z-axis values between the program sheet and the actual settings.
Coordinate setting errors during programming.
To address programming-related collisions:

Accurately measure the height of the workpiece and ensure the safety height is above it.
Ensure consistency between the tools specified on the program sheet and the actual program.
Measure the actual machining depth on the workpiece and clearly document the tool length and blade length on the program sheet.
Clearly specify the actual Z-axis values on the workpiece in the program sheet.

Insufficient Surface Accuracy
The main causes of this phenomenon are:
Improper cutting parameters resulting in rough surface finish.
Blunt tool edges.
Excessive tool clamping length and excessive tool deflection.
Poor chip evacuation, insufficient air blowing, and insufficient coolant.
Programming errors in tool path selection.
Surface burrs on the workpiece.
To improve surface accuracy:

Set cutting parameters properly, including tolerances, allowances, spindle speeds, and feed rates.
Regularly inspect and replace tools as necessary.
Clamp tools as short as possible and minimize tool deflection.
Choose appropriate spindle speeds and feed rates for flat, R, and ball-nose tools.
Surface finish is affected by equipment, tools, and tool paths, so it is important to have a good understanding of CNC machining centers. Use additional tooling on parts with burrs.

These are the causes and solutions for some common issues in the production of high precision parts, such as excessive cutting of workpieces, tooling faults, centering errors, collisions caused by operations, collisions caused by programming, and insufficient surface accuracy. We hope this information is helpful to you. Peak Fasten Technologies Co., Ltd,  located in Shenzhen, specializes in the customization and batch production of high-precision components. We are managing over one hundred CNC machining devices. If you have any related component processing needs, please feel free to contact Peak Fasten. We will provide you with comprehensive product solutions and quality services.