Machining equipment usually requires compressed air, its application is wide and critical, the specific needs and reasons are as follows:
core demand for compressed air for 1. machining equipment
- power drive
- pneumatic tools: Such as pneumatic wrenches, pneumatic grinding wheels, pneumatic engraving machines, etc., rely on compressed air to provide power, with light weight, flexible operation, adjustable torque and other advantages, especially suitable for high-intensity, high-frequency operation scenarios.
- Pneumatic clamp and positioning device: The clamp is driven by compressed air to quickly clamp or release the workpiece to improve the clamping efficiency and ensure the processing accuracy. For example, in CNC machine tools, pneumatic clamps can achieve rapid positioning and fixation of the workpiece.
- Cooling and lubrication
- tool cooling: Compressed air is blown to the cutting area through the nozzle to reduce the tool temperature, extend the tool life, and at the same time reduce the thermal deformation of the workpiece and improve the processing quality.
- Lubrication aid: Some equipment mixes compressed air with lubricating oil to form an aerosol and sprays it to the friction part to achieve the dual effects of lubrication and cooling, which is suitable for high-speed machining or precision machining scenarios.
- Cleaning and purging
- workpiece cleaning after the processing is completed, compressed air is used to purge the chips, oil and other impurities on the surface of the workpiece to ensure the smooth progress of subsequent processes (such as testing and assembly).
- Equipment maintenance: Regularly use compressed air to clean the dust on the machine tool guide rails, lead screws and other parts to maintain the accuracy of the equipment and extend the service life.
- automatic control
- pneumatic control system compressed air is used as a transmission medium to drive cylinders, pneumatic valves and other actuators to realize the automatic action of the equipment (such as workpiece handling, sorting, and assembly).
- Sensor and detection: Part of the pneumatic sensors through the detection of compressed air pressure, flow and other parameters, feedback equipment running status, fault warning or process control.
2. the specific requirements of different machining equipment for compressed air
| device Type | use of compressed air | pressure range (MPa) | flow demand (m & sup3;/min) | quality Requirements |
|---|
| CNC machine tools | tool cooling, spindle sealing, pneumatic fixture drive | 0.5-0.7 | 0.1-0.5 | oil content ≤ 3 mg/m & sup3;, water content ≤-40 ℃ dew point |
| machining center | spindle cooling, tool magazine tool change, protective door switch | 0.6-0.8 | 0.2-0.8 | high cleanliness, no impurities |
| stamping machine | clutch control, scrap purging | 0.4-0.6 | 0.5-1.5 | stable pressure and fast response |
| laser cutting machine | auxiliary gas (e. g. nitrogen, oxygen) supply (to be integrated with compressed air system) | 1.0-2.5 | 2-10 | high purity (according to cutting material requirements) |
| 3D printing equipment | powder cleaning, model support structure removal | 0.3-0.5 | 0.05-0.2 | no oil, no water, no impurities |
influence of 3. Compressed Air Quality on Machining Equipment
- oil content
- impact: The oil is attached to the surface of the workpiece or the inside of the equipment, resulting in a decrease in machining accuracy, accelerated tool wear, and even electrical failure (such as short circuit).
- Standard: Generally, oil content ≤ 3 mg/m & sup3 is required; (I .e. 3ppm), precision machining ≤ 1 mg/m & sup3;.
- Moisture content
- impact: Moisture combines with impurities in compressed air to form corrosive substances, damage pneumatic components (such as cylinders, solenoid valves), and shorten equipment life.
- Standard the pressure dew point is usually required to be ≤-40 ℃ (that is, the moisture content is extremely low) to ensure that the compressed air is dry.
- Particulate matter
- impact solid particles (such as dust and iron filings) enter the pneumatic system, block the filter element and scratch the seal, resulting in air leakage or malfunction of the equipment.
- Standard: Generally, particle diameter is required to be ≤ 5μm, and precision machining is required to be ≤ 1μm.
4. solutions and recommendations
- configuration of dedicated compressed air system
- according to the equipment needs to choose screw or piston air compressor, and equipped with post-processing equipment (such as freeze dryer, precision filter, adsorption dryer), to ensure that the compressed air quality standards.
- Example: CNC machine tools can be equipped with "screw air compressor freeze dryer three-stage precision filter" to meet the oil content ≤ 1 mg/m & sup3;, pressure dew point ≤-40 ℃ requirements.
- Split gas supply
- grading gas supply to different equipment as required, for example:
- general processing equipment: use first-level filtered compressed air (oil content ≤ 5 mg/m & sup3;).
- Precision processing equipment: use three-stage filtered and dried compressed air (oil content ≤ 0.01 mg/m & sup3;).
- Regular maintenance and inspection
- regularly check the operating status of the air compressor, replace the filter element, oil core and other consumables, to avoid the degradation of compressed air quality due to equipment aging.
- Use dew point meter, oil detector and other tools to monitor the quality of compressed air to ensure compliance with equipment requirements.
