Technical Training And Troubleshooting

发布时间：

2018-11-15 16:08

来源：

Grinding wheels:

一、 Installation and adjustment of grinding wheels：

1. Identification and installation of base side：On the marked side, there is a non-base side. The grinding wheel cone is clean and greased. The base side of the grinding wheel is close to the positioning surface of the Bystronic cone and is locked.

2. locking and testing:Make sure that there is no damage to the surface of the Bystronic-cone cap (Bando no cap), and press the grinding wheel, tighten the bolts of the grinding wheel gently in turn, then tighten them in turn! Before installation, check that the radial runout of grinding wheel groove is not more than 0.06mm. If the runout exceeds the standard, check whether there are impurities in the installation hole and face, and confirm that the base runout of pallet installation is less than 0.02mm.

Trial-grinding a piece of glass to confirm the installation level of the grinding wheel, and adjust the glass thickness center and the grinding wheel groove center level at the same time.

4.After the grinding wheel is loaded and clamped, the glass is ground at a low speed (the starting speed of Bystronic line is generally 8000-10000mm/min, the maximum tempering speed is 20000mm/min after normal operation, and the maximum sandwich speed is 25000mm/min; the starting speed of Bando line is 30-40%, and it can reach 90-100% after normal operation. The actual speed can be appropriate according to the condition of field equipment and product requirements. When adjusted).
二、 Troubleshooting：

1）chips

Chips: glass grinding edge is larger crack, slight blasting edge - burr edge
Cause Analysis	Inspection of grinding wheel installation accuracy, radial jump less than 0.06mm
	Inspection of grinding wheel cone accuracy, end runout less than 0.02mm
	Average life and profile change of grinding wheel need be repaird
	Grinding speed is more than recommended speed
	Grinding parameter settings
	Unreasonable setting of cutting and breaking parameters
	Check cooling system
	Whether the pulling nails on the cone of Bando grinding wheel are worn or not

2）Burns：

Burning edge: The grinding debris is spherical, the surface of the ground glass shines, and the glass marks melt and agglomerate.
Cause Analysis	Check Cooling system
	Whether the cooling water pressure and quantity meet the requirement of operation
	Whether the cooling water is directly sprayed to grind the groove center (spray position)
	Are there excessive glass chips in cooling water (no more than 5% glass powder in cooling water) and excessive water temperature (focus on summer)
	Adjustment of grinding quantity, single side no more than 0.5mm
	Whether the grinding speed/speed is higher than the recommended speed or not can be improved by reducing the grinding speed/speed.
	The grinding wheel efficiency is low and the frequency of sharpening is properly increased.
	The center of the stick and the grinding wheel is not on the same horizontal line, which results in the groove side not being repaired.

3） Edge (bevel)：

Edge (bevel): Unbalanced and asymmetrical curvature of glass edge
Cause Analysis	The horizontal center of glass is not on the same plane as the center of grinding groove.
	The height of stick and grinding wheel are not on the same horizontal plane.
	The glass platform is uneven and the height of the suction cup is fine-tuned (the edge is easy to appear at the corner)
	The profile of grinding wheel is changed, so the arc edge can not be guaranteed.
	Grinding wheel life is close to be repaired
	The position of the starting point is far from the corner to reduce the starting speed of the grinding head.
	Irrational position of vacuum cup or insufficient vacuum degree cause local vibration

3） bright spot:

Bright spot: Ungrinded part (cutting surface) appears irregularly above and below the ground surface of glass.
Cause Analysis	Check whether the glass position on the table is in harmony with the running way of the grinding wheel.
	The radius of the grinding wheel is greater than the curvature radius at the corner of the glass
	Excessive Retention of Cutting and Breaking Dimensions
	Low Grinding Efficiency of Grinding Wheel
	Too small grinding dimension

Drills：

1.Installation and commissioning:

1）Drills recognition:
Before installation, confirm the specifications of the drill bit, select the drill bit matching the equipment, and the product identifier meets the requirements of aperture and thickness for glass processing.

2）Drill cleaning：
Wipe and clean the positioning part of the bit with a clean rag. The surface of the positioning part should be undamaged.

3）Drill Bit Inspection after Installation：
A set of bits with long edges are mounted on the upper drill and the length of the edges on the lower drill. Installation should check that the radial runout value of the bit after installation is less than 0.05 mm, and can also be monitored by the glass hole diameter after drilling, which is less than the bit edge diameter + 0.1 mm.

4）Drill Bit debugging：
Low-speed test drilling glass after boarding, confirm the size and quality of each part of the upper and lower drilling;
After the cutting edge is drilled with 50-60% feed rate of normal speed. After drilling 20-30 holes, the feed speed will be adjusted to 70-80% after checking the quality of the holes. After drilling 20-30 holes, the quality of the holes will be checked. After no defects, the quality of the holes can be adjusted to normal work.

5）Recommendation of Drill Bit Processing Parameters
θDrill Bit feed rate
     Direct Drilling Part - 1.2mm/s (Maximum)
     Chamfer part - 1.0 mm/s (maximum)
     The thinner the glass, the slower the feeding speed should be.
θDrill Bit speed
    φSpeed of specification below 20 mm: 4000-6000 rpm/min
    φSpeed of specification above 20 mm: 2800-4000 rpm/min
    φSpecification speed of 40-60mm: 1800-2800 rpm/min
    φSpecification Speed of 60-85mm: 1200-1800 rpm/min

6）钻头修锐
θThe drill bit is drilled into 150-200 mesh alumina stick 2-3 times at normal or lower feed speed and rotational speed, and the wet grinding disc immersed with coolant or water is used for sharpening, which will cause diamond shedding during dry repair.
θThe initial surface of diamond is sharper and passivated after grinding, so it is necessary to use abrasives to re-expose the diamond edge. The drilling state can be maintained by setting the frequency of sharpening according to the performance and quality of the hole edge.
θDaoTian Drill Bit Recommendation: 20-25 hole redress once.

7）Setting of Water Pressure and Water Volume Parameters of Coolant
Coolant passes through the middle hole of drill pipe and keeps a certain amount of water and pressure.
Recommended hydraulic pressure: 0.2-0.3 Mpa; water volume: 15-25L/min

Troubleshooting：

Glass cracking：

Cracks: Cracks occur after drilling holes in automobile glass, resulting in crack defects
Cause Analysis	Drill speed is too high or too low Drill bit wear is aggravated by high speed and too little friction heat. Drill speed is too low, which does not match the feed speed, resulting in excessive pressure on the glass causing cracks.
	Drill bit feeding speed is too high At the same speed, the feed speed is too high, the drilling efficiency is insufficient, and the glass bears too much feed pressure, which is easy to cause cracks. The thinner the glass, the slower the feeding speed should be.
	Too loose clamp, wrong use of clamp,too much clamp The glass is not uniformly loaded, resulting in crack defects.
	The working table is uneven, and there are glass debris or impurities on the table. The base surface of glass positioning is uneven, and the force is uneven in the process of processing, resulting in crack defects.
	The water pressure is too high or too low. At the same time, check the quantity of water and the cleanliness of coolant. If the water pressure is too high in the process of processing, the glass near drilling will be impacted greatly, resulting in glass cracks. In the process of processing, such as low water pressure, insufficient water, inadequate cooling of the bit in high-speed drilling, excessive temperature leading to diamond graphitization, matrix deformation, mechanical performance reduction, inadequate cutting force, resulting in glass cracks, or the occurrence of bit material layer mold shedding.
	The accuracy of bit transmission device is poor or the positioning accuracy of bit is poor. Excessive accuracy of motor drive shaft or poor positioning and installation accuracy of drill lead to excessive radial runout, uneven force on glass, and easy to cause crack defects.
	The setting of drilling bit is wrong and too much glass is drilled. Drilling under the drill bit is too much, the thickness of glass to be processed is too thin, and the pressure can be low. It is easy to cause glass cracks when drilling up.
	The length of upper and lower drill edges is unreasonable. If the blade length is set unreasonably, the drilling depth can be improved by adjusting the bit chamfering. The chamfer depth of the bit is usually set to 0.5mm.
	Drill Bit drilling efficiency is low. Drill Bit drilling efficiency is low, and it is easy to cause crack defects. The manifestations of low drilling efficiency include diamond passivation, diamond shedding and inappropriate formula.

2）Chips

Chips: After glass drilling, the hole edge has a large crack.
Cause Analysis	Overexposed diamond bits need to be redressed
	The angle of chamfer is too small. The angle of chamfer should be adjusted.
	The drill bit is passivated and its surface is polished and needs to be redressed.
	Over-tolerance of radial runout of Drill bit working position, re-mounting to ensure installation accuracy
	The chamfer is inefficient and needs to be redressed.
	Diamond grit size at chamfer of bit is too coarse, so the formula needs to be adjusted.

3）Drill bit wears too fast

Drill bit wears too fast: the material layer of drill bit loses quickly in the process of drilling and does not reach the ideal life.
Cause Analysis	Feed speed is too low, adjust it according to recommended parameters
	The formula of chamfer part is too soft, adjust the formula
	Diamond peeling off and polishing on the surface of drill bits need to be repaired and redressed.
	Drill Speed too high, adjust it according to recommended parameters

Product Design And Development

Grinding Wheel Repair Center

Product Design And Development

Grinding Wheel Repair Center