How to operate a large CNC vertical lathe?

I. Preparations before Startup

Environmental and equipment inspection ‌

Confirm that the workshop temperature (usually 20±2℃) and humidity (40%-60%) meet the equipment requirements to avoid thermal deformation affecting accuracy.

Check whether the oil levels in the hydraulic, lubrication and cooling systems are normal and there is no leakage in the pipelines. The air source pressure is stable at 0.5-0.7MPa, and there is no water accumulation on the filter.

Clear obstacles around the machine tool to ensure sufficient working space, good lighting and clear safety warning signs.

Safety device verification ‌

Check whether the functions of safety facilities such as the emergency stop button, the interlock device of the protective door, and the light curtain are normal.

Make sure the electrical cabinet door is closed. It is strictly forbidden to open the protective door inside the machine or change the system parameters without authorization.

Workpiece and tool preparation ‌

Clean the workbench surface. Do not place the blanks directly on the workbench. Use shims or screw jacks for support.

Select the cutting tool according to the process requirements, check the integrity of the blade, and firmly install the cutting tool at the corresponding position of the tool turret.

Ⅱ. Startup and Reset to Zero

Power startup sequence ‌

Connect the main power supply, the power supply of the machine tool and the power supply of the numerical control system in sequence, observe the self-check process of the system and confirm that there is no alarm information.

Mechanical zeroing operation ‌

Execute the "Return to Reference Point" command (press REF or HOME key) to automatically move the X-axis and Z-axis to the mechanical origin, establishing an accurate machine coordinate system. This step cannot be omitted and serves as the foundation for subsequent tool setting and processing.

Ⅲ. Workpiece Clamping and Alignment

Clamping and fixing ‌

Use a special fixture or pressure plate to firmly install the workpiece on the turntable, ensuring uniform force distribution to prevent loosening or deformation during processing.

For heavy workpieces, hydraulic or pneumatic clamping methods can be adopted to ensure sufficient clamping force.

Alignment calibration ‌

Measure the runout of the outer circle or end face of the workpiece with a dial indicator or a laser tool setting instrument, adjust the position, ensure that the rotation center is concentric with the spindle, and control the radial runout within ≤0.01mm.

When aligning, only point operation and low-speed rotation are allowed. High-speed correction is strictly prohibited.

Iv. Tool Installation and Tool Setting

Tool clamping ‌

Insert the tool into the tool holder and lock it, then insert the tool holder into the tool turret. Make sure it is locked in place to prevent loosening.

Tool setting operation ‌

The tool length and radius can be preset by using an external tool setter, or the data can be input into the tool compensation table (TxxDxx).

It is recommended to conduct trial cutting and tool setting for key dimensions: measure the actual dimensions after slight cutting, input the values into the system to complete the offset setting, and improve the accuracy.

V. Program Input and Simulation

Program loading ‌

Import G-code programs via a USB flash drive, network or RS232 interface, or directly write them in MDI mode.

The program should start with safety instructions (such as G50 setting the maximum spindle speed), and end with tool retraction and stop instructions (such as M30).

Program verification ‌

Before processing, an idle run test must be conducted to simulate the tool path and check for any risks of interference or overtravel.

Preview the processing trajectory using the graphic simulation function to confirm the correctness of the program.

Ⅵ. Automatic processing Procedure

Start processing ‌

Close the protective door, start the main shaft and enter the automatic operation mode.

The operator should concentrate, observe the movement of the knife tip, control the feed adjustment switch with the right hand, and be ready to deal with any abnormality at any time.

Exception handling ‌

If any abnormality is detected, immediately press the "Emergency Stop" button to cut off the power source and ensure the safety of personnel and equipment.

After the fault is eliminated, it is necessary to return to zero and reset the system before continuing the operation.

Ⅶ. Operation after processing is completed

Clean and maintain ‌

Remove the chips, wipe the machine tool, and keep the equipment and the environment clean.

Check the condition of the lubricating oil and coolant, and replenish or replace them in time.

Shutdown sequence ‌

Move the tool rest to a safe tool changing position and turn off the power of the operation panel and the main power supply in sequence.

For machine tools with multiple vertical tool rests, they should be symmetrically placed at both ends of the crossbeam. The single-tool rest stops at the middle position.

Record and maintain ‌

Keep detailed written records, including the number of processed items, equipment status, abnormal conditions, etc., to facilitate traceability and maintenance.