Introduction of Kunshan Gaoli Seiko: What matters should be paid attention to when the knife die carving machine processes fiber plates?

The core of processing MDF/HDF by Kunshan Gaoli Seiko Knife Mould Precision Carving Machine is dust control, stable adsorption, optimal parameters, deformation prevention and tool protection. The following points for attention are given according to the whole processing process:

First, preparation before processing (equipment+materials+clamping)

1. Equipment inspection (standard requirement of Gaoli Seiko)

Vacuum system: check the vacuum pump pressure (-0.08~-0.09MPa), partition valves and pipelines on the adsorption table for air leakage; The countertop is clean and free of dust and sundries, so as to ensure uniform adsorption.

Spindle and cooling: confirm that the water-cooled/air-cooled spindle is normal and the water temperature is ≤ 35℃; Check that the tool chuck is clean and free from abrasion, and the tool loading length should be as short as possible (1.5 times or less of the blade length).

Transmission and lubrication: guide rail and screw are cleaned and greased; Check the servo, rack/screw for looseness and abnormal sound.

Dust removal system: turn on the high-power vacuum cleaner to ensure that the dust suction port on the table and the filter screen of the electric cabinet are unobstructed.

2. Pretreatment of fiberboard materials

Material selection: use homogeneous E0/E1 medium/high density fiberboard (density 700 ~ 850 kg/m) without delamination, bubbling and impurities; Thickness ≥ engraving depth+2mm to avoid penetrating deformation.

Aging and environment: put the plate into the workshop 24 hours in advance (temperature 20~25℃, humidity 40%~60%) to eliminate internal stress; It is forbidden to use damp and deformed plates.

Benchmark treatment: the board surface is clean and free of oil stain and dust; The edge is smooth, and the flatness per meter is ≤ 0.5mm..

3. Clamping and positioning (special for high vacuum table)

Zoning adsorption: open the corresponding vacuum zone according to the plate size, and use multi-zone linkage for small materials to ensure that the adsorption area is ≥ 70% of the plate and there is no local suspension.

Auxiliary fixation: thin plate/special-shaped parts press blocks/flanges to prevent edge warping and displacement during high-speed cutting; The compact avoids the machining area.

Tool alignment: use the automatic tool alignment instrument to calibrate the Z axis, and the tool change must be re-aligned; The X/Y origin is set at the reference angle of the plate to ensure batch consistency.

Second, the processing parameter setting (recommended by KOLIK Seiko)

1. Tool selection (special for fiberboard)

Material: solid carbide single/double-edged spiral milling cutter (coating can be TiN/TiCN), with sharp cutting edge, large chip removal groove, anti-sticking knife and edge collapse.

Specification: rough machining φ6~φ10mm and finish machining φ 3 ~ φ 6mm; Blade length ≥ machining depth+1mm, to avoid scratching the handle.

Service life: check the wear and tear every 30~50㎡ of machining, and replace the cutting edge immediately if it is broken and passivated, so as to prevent the surface from fuzzing and out-of-tolerance in size.

2. Cutting parameters (according to spindle power of 6~9kw)

Spindle speed: 12,000 ~ 18,000 rpm for rough machining and 18,000 ~ 24,000 rpm for finish machining (high speed and low feed to reduce burrs).

Feed speed: 8000~15000mm/min for rough machining and 4000 ~ 8000 mm/min for finish machining; Cut in layers, with the depth of each layer ≤2mm (thick plate is divided into 3~5 layers).

Cutting mode: diagonal cutting/spiral cutting is adopted to avoid plate cracking and tool edge cracking caused by vertical cutting.

3. Path and technology

Order: first rough, then fine, first inside and then outside; The complex contour is added with corner clearance tool path to avoid residual internal angle and stress concentration.

Avoidance: the tool path avoids pressing blocks and blocking edges; Reserve 0.1~0.2mm finishing allowance to ensure dimensional accuracy.

Cooling: dry cutting is the main method, and compressed air (0.4~0.6MPa) is used to blow chips to cool down, and water/emulsion (fiberboard is deformed by water absorption) is prohibited.

III. Monitoring during processing (safety+quality+equipment)

1. Safety monitoring

Open the safety door, emergency stop and grating in the whole process; It is forbidden to open the door and reach out when starting; Stop the machine immediately if it is abnormal (abnormal sound, peculiar smell and overload).

Dust control: real-time dust collection and regular cleaning of dust collection barrels; Workshop ventilation, wearing dust masks and goggles.

2. Quality and equipment monitoring

The first article must be inspected: size, contour, depth and surface finish; Batch processing shall be sampled once every 10 pieces.

Equipment status: monitoring spindle temperature (≤50℃), vacuum pressure and servo load; Reduce the parameters or stop the machine for inspection when it is abnormal.

Chip removal: clean the dust on the table, guide rail and screw rod every 1~2 hours to prevent jamming and wear.

Four, finishing after processing (workpiece+equipment+environment)

Workpiece processing: slowly release vacuum after processing to avoid cracking of the plate caused by forced pulling; The finished products shall be laid flat and moisture-proof, and stacked with ≤10 sheets to prevent deformation.

Equipment cleaning: thoroughly clean the filter screen of table top, dust collection system and electric cabinet; Lubricating grease for guide rail and screw rod; Turn off the vacuum pump, spindle and main power supply.

Record: fill in the processing log (parameters, tools, output, anomalies) for traceability and optimization.

V. Exclusive Maintenance of Gaoli Precision Equipment (Extended Life)

Daily work: clean the vacuum table top and vacuum bucket in each shift; Check vacuum pressure and spindle cooling.

Every week: tighten the table top and guide rail bolts; Clean the electric cabinet and check the wiring; Calibrate the tool alignment instrument.

Monthly: change vacuum pump oil and clean filter element; Guide rail/screw rod is fully lubricated; Check the tool holder for wear.

Quarter: test the tightness of vacuum system; Calibration equipment geometric accuracy (verticality, parallelism); Check the status of servo motor and reducer.