Support and Maintenance for Machine Tools Is Important! Including Regular Inspection Methods

The Importance of Machine Tool Maintenance

Poor maintenance of machine tools will lead to machine failures. Failures not only cause production losses and inconsistent quality, but can also lead to employee injuries or other on-the-job accidents.

Thus, regular machine tool maintenance is also important to keep employees safe and to maintain stable quality and production volume. Performing regular maintenance properly can also be expected to extend machine service life.

Possible Problems With Machine Tool Failures

When a machine tool fails, it may result in the following problems:

• Line stoppages due to failure: From the moment of failure to repair completion, no products can be manufactured, and defective products may be produced
• Delayed deliveries: Losses due to manufacturing stoppages and defective products could prevent the scheduled amount from being produced by the delivery date
• Lost credibility: Reduced or inconsistent quality, delayed delivery, and other secondary affects of machine tool failure could damage credibility with customers, leading to a decline in sales

Also, in some cases, machining errors can serve as a precursor to machine tool failure. Therefore, when a failure occurs, product inspections must be performed going back a few lots before the failure. In the event of a failure, there are also the risks of loss due to inspections, loss from disposal of defective products, and outflow of defects.

As this shows, a machine tool failure can result not only in the cost of repairs for the machine itself, but can impact and result in losses in various aspects. Preventing failures through proper maintenance is also important for management stability.

Methods for Machine Tool Maintenance

Machine tool maintenance is basically performed in accordance with the manufacturer's maintenance manuals.

First, check the manufacturer's manuals for maintenance and inspections and the instruction manual for the equipment you are using, and then perform maintenance as instructed for the items listed. Maintenance should be performed regularly according to the manufacturer's maintenance manual, determining service spans, such as weekly or monthly.

In addition, it is important to create a maintenance check sheet that describes the contents of the manufacturer's maintenance and inspection manual, post it in multiple locations, and create a system for on-site employees to perform maintenance while checking the check sheet.

Regular Inspections to Extend Service Life

Regular inspections involve performing maintenance centered on lubrication oil, air-related components, coolant, and the control box with the aim of extending the service life of machine tools. Here's a closer look at how to perform these inspections.

Lubrication Oil Inspections

With use, the oil used in various parts of the machine will degrade or decrease in volume. If the degrading or decreasing oil is left alone, it may cause a machine failure. Check the oil condition and amount regularly, replacing or refilling as necessary.

Areas which use oil include coolant oil, bearings, screws, and gearboxes. When checking the oil for these areas, make sure that the rate of oil degradation is normal and that oil is not significantly lower than usual.

If the oil has degraded or is drastically lower than normal, it may be signaling a component failure or oil leak. In such cases, in addition to the oil, also check for failures in the surrounding area.

Air-Related Inspections

Many machine tools have components that operate with an air supply. As these components are important parts of production, regular inspections are essential to prevent failures.

A clogged filter can cause a malfunction or failure. To prevent this, remove any dust or iron powder adhering to the machine. The filter itself must also be replaced regularly.

A compressor compresses the air along with airborne moisture content. Take caution when using compressed air with moisture content, as this may cause problems with equipment operation.

An air dryer is the proper means for removing moisture from the air. Doing so prolongs the life of the equipment and will reduce maintenance costs.

It is also important to check air pressure. Check the air pressure using a pressure gauge, and if the pressure does not reach the reference value after adjusting the valve, inspect the supply circuit.

Coolant Inspections

If coolant is not functioning properly to cool the machine, the heat can cause the tool to deteriorate or workpieces to warp. When inspecting the coolant unit, make sure that the coolant level sensor is working properly, that the tank and filter are clean, and that there are no clogs.

Switches around the coolant area are prone to failure due to dirt. Make sure these switches are functioning properly. Along with the inspection, also clean up and replace the filter.

It is also important to check whether the coolant fluid has degraded or changed in concentration. Degradation of the coolant fluid may cause poor quality or bad odors, so be sure to check it during maintenance and replace if there is an issue.

Control Box Inspection

The control box, cooling fans, and exhaust fans are also to be routinely inspected. The control box is sensitive to heat and must be checked frequently in summer. Dirty cooling fans or exhaust fans could result in a heat failure, so check them regularly.

The control box itself is inspected by checking whether any wiring is loose or disconnected, whether the servo motor is operating correctly, and whether the power switch is functioning.

Machine Cleaning

Cleaning should be done frequently to prevent part failure due to a build-up of chips. Chip build-up can lead to ball screw or bearing failure. Regularly inspect and clean the cover to prevent chips from building up on the cover.

Clean any dirt on the machine with a dry cloth, brush, or compressed air. Clean not only the machine, but also the surrounding floor.

Inspection of Various Parts

First, visually inspect the various parts for deformation or scratches. Check for loose screws and surrounding dirt, and re-tighten if loose.

After each area has been inspected, turn on the power to confirm that the machine is working properly. At this time, also check the spindle speed and listen for any abnormal noises.

Manufacturer Support for More Peace of Mind

As seen here, maintenance of machine tools with many inspection points takes time and effort. For that reason, regular inspections can be a challenge due to labor shortages.

If handling inspections in-house is proving to be difficult, it is reassuring to have the manufacturer's support. Proper maintenance before failures will extend the machine's service life and prevent various losses due to failure.