一、Abnormal machining accuracy

1、Parallelism deviation

Troubleshooting: Check if the thickness difference on both sides of the workpiece is greater than 2 μ m or if the surface roughness is inconsistent

Solution:

Calibrate the parallelism between the workbench and the grinding wheel holder (with the assistance of a laser interferometer)

Replace unevenly worn grinding wheels (priority given to diamond dressing wheels)

2、Surface scratches/spiral patterns

Troubleshooting: Observe the direction of scratches and confirm if the grinding wheel has become dull or if foreign objects have entered

Solution:

Reduce the feed rate by 50% and adjust the grinding wheel to a particle size of # 400 or above

Clean the impurities in the gap between the grinding discs and check the coolant filtration system

二、mechanical failure

Abnormal vibration/noise

Troubleshooting:

Bearing abnormal noise (frequency>1000Hz) or belt slippage

The fixing screw of the grinding disc is loose (it needs to be tightened when the torque is less than 5N · m)

Solution:

Replace the spindle bearings (recommended lithium grease lubrication)

Adjust the belt tension to a deflection of ≤ 10mm/100N

The device cannot start

Troubleshooting:

Power indicator light status/fuse blown

Abnormal resistance of motor winding (normal value 0.5-2 Ω)

Solution:

Reset the PLC control system and check the emergency stop switch

Replace burnt out motor (matching original factory power ± 10%)

三、Process parameter malfunction

Workpiece horn mouth/tapered hole

Troubleshooting: Aperture length>1.5 times the width of the grinding wheel or insufficient rigidity of the connecting shaft

Solution:

Replace with short and thick long axis (diameter/length ratio ≥ 1:3)

Adjust the tilt angle of the headstock to within ± 0.01 °

Surface burn

Troubleshooting: Coolant temperature>35 ℃ or blocked grinding wheel

Solution:

Switch grinding wheels with particle size below # 200 and increase the coolant flow rate by 30%

Activate high-pressure air gun to clean the air holes in the grinding wheel

四、Maintenance suggestions

Daily: Check the flatness of the grinding disc (measure the gap with a plug gauge<0.02mm)

Monthly: Calibrate spindle runout (requires micrometer detection, standard<0.005mm)

Quarterly: Replace gear oil (ISO VG68 grade) and clean hydraulic pipelines