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The quality of assembly and debugging in horizontal CNC lathes directly impacts the machine's average trouble-free operating time. A higher standard of assembly and commissioning reduces downtime and maintenance costs, ultimately improving overall efficiency. This paper provides a comprehensive overview of the mechanical assembly process for horizontal CNC lathes, emphasizing not only the geometric accuracy of the bed installation but also the machining precision of the entire machine. These factors collectively define key considerations during the mechanical assembly and commissioning stages.
First, the installation of the headstock of a horizontal CNC lathe requires careful attention. The headstock must be combined with the bed, and the bottom should be equipped with a scraping bed. Key process requirements include: 1) Using a coloring method to test the contact points between the headstock and the bed, ensuring at least six grinding points per square inch; 2) Ensuring that no feeler gauge of 0.06 mm can pass through the joint surface in its natural state; 3) Guaranteeing full contact between the bottom plane and side of the headstock and the bed. Additionally, the bottom of the spindle box must be scraped to ensure parallelism between the spindle axis and the bed rail in the vertical direction. During summer, the right end of the headstock may be slightly higher than the left within the allowable tolerance, while in winter, it may be slightly lower. This is due to thermal expansion effects on the bearings, which cause the front end of the spindle to expand more than the rear end. Proper thermal inspection is essential alongside cold inspection to maintain accuracy.
Second, the installation of the cross slide involves ensuring the parallelism of the dovetail rail to the center of the transverse feed screw in both vertical and horizontal directions. This is achieved by scraping the lower plane of the cross slide, the vertical slide’s dovetail rail, and aligning the transverse screw positioning holes. The dovetail rail surface must also be scraped for flatness and parallelism. The horizontal slide dovetail guide rails are aligned with the vertical slide’s rails. The lower rail surface of the vertical slide is trimmed until it achieves 10–12 contact points per 25 mm × 25 mm area. Proper scraping improves the oil storage conditions and ensures smooth movement. Too many or too few contact points can affect lubrication and friction, so a balanced number is necessary for optimal performance.
Third, the tailstock installation focuses on achieving three key accuracy requirements: parallelism of the tailstock’s bottom plate with the bed rail, the center of the tailstock cone hole relative to the bed rail, and the height difference between the tailstock and the spindle. A laser interferometer is used to measure backlash, linear motion positioning accuracy, and other critical parameters. Adjustments are made to compensate for any discrepancies in the ball screw nut pair.
Fourth, the tool holder installation includes mounting the square knife holder on the inclined sliding plate, which is then attached to the horizontal sliding plate. The transverse feed screw drives the tool holder for lateral movement. The installation must ensure perpendicularity of the lateral movement to the spindle axis, with a flatness error of no more than 0.02 mm over a 300 mm diameter. Parallelism errors must remain within 0.04 mm over 300 mm.
Fifth, the machine tool's positioning accuracy is checked using a laser interferometer to measure backlash, repeat positioning accuracy, and mechanical origin return accuracy. Adjustments are made as needed to ensure precision.
Sixth, an air running test is conducted, starting from the lowest speed and gradually increasing to maximum, with each stage running for at least 5 minutes and the final stage for 30 minutes. The feeding mechanism is also tested at low, medium, and high speeds to check oil pumping and system stability.
Seventh, cutting accuracy tests are performed under real machining conditions, including load tests, vibration resistance tests, torque force detection, and various cutting operations such as outer circle cutting, finishing, grooving, and threading.
In conclusion, the installation and commissioning of a horizontal CNC lathe require careful attention to both mechanical and machining accuracy. By considering factors that may affect part quality during machining, appropriate measures can be taken during the assembly process to minimize their impact and ensure long-term performance and reliability.
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