Six Critical Actions for Maintaining Micrometer-Level Precision

Want to maintain micron-level machining accuracy over the long term? This article provides six practical tips for daily maintenance, covering key aspects such as equipment cleaning, environmental control, and tool calibration. These simple methods will help operators prevent accuracy degradation and prolong the lifespan of precision equipment.

Cleaning and inspection are basic skills.

Don't let dust become an invisible killer.

After finishing each day's work, he first uses a soft brush to sweep away the metal shavings from the tracks, and then wipes down the work surface with a lint-free cloth soaked in special cleaning solution.In particular, if even a fragment of a sesame seed is left at the point where the spindle and the tool meet, it could cause the next cut to be 0.5 microns off.

Listening to the sound of the engine can also help detect problems.

Before starting the machine, spend two minutes checking the sound.If you hear a sound like sandpaper rubbing, then it's probably time to lubricate the bearings.If these minor deviations are left uncorrected, the accuracy of the clock will be off in three days.

Environmental control is more important than one might think.

Fluctuations in temperature should be taken seriously.

Every 1 ° C change in the temperature of the workshop causes a 20-cm-long aluminum alloy workpiece to expand or contract by 4.8 microns.We recommend that the temperature in the processing area should be kept at 20 ± 1 ° C. In the summer, air conditioners should not be aimed directly at the equipment, and in the winter, heaters should be at least three meters away.

Managing humidity is a tricky business.

Before work starts in the morning, he first checks the humidity and temperature gauges. If the relative humidity is over 65 %, he has to activate the dehumidifier.In particular, in the rainy season, the moisture that condenses on the knife handle can cause the precision of the clamping to decline. Last year we got burned on this, with three batches of workpieces all having to be reworked.

Calibration is like eating--it's a regular thing.

You can't cut corners with a micrometer.

Every Wednesday morning is set aside as "calibration day," during which all micrometers are checked against the standard.If the error is greater than one micron, then the lens should be isolated and not used.Last week, a neighboring department lost a piece of titanium worth NT $ 80,000 because of this.

Don't let the laser interferometer gather dust.

Each month, we use a laser interferometer to give the equipment a complete checkup, with the main focus being on the precision of the X and Y axes.The data obtained by comparing tests under different loads, such as with and without a load, can often help spot early signs of wear and tear on the screw.

Be decisive about replacing worn parts.

The lifespan of a bearing is measured in hours of operation.

The main shaft bearings must be replaced every 4000 hours, and you can't wait until the vibration is too much to stand before you act.We did comparative tests: bearings that were changed according to schedule had processing roundness error within 0.8 microns, but bearings that were used past their expiration date had error that shot up to over 3 microns.

The gaskets age faster than yogurt.

Check the gasket every six months, and replace it if it is hard or cracked.Last Friday night, for example, the seal failed and the coolant got into the screw, so when we turned the machine on in the morning it gave an alarm for excess error.

Lubrication and maintenance are no joke.

You can't use any old type of oil.

The track oil must be ISO VG 32 grade, and the spindle grease must be a high-temperature type.The last time the new guy used ordinary butter, the equipment overheated and shut down. When the repairman took it apart, he found that the butter had carbonized.

The amount of oil used is carefully measured.

When lubricating the track, remember the "three-drop rule": three drops for every 20 cm of travel.Too much will attract dust and form a grinding paste, while too little will not provide sufficient lubrication.This is something that the old master craftsmen worked out after wasting five sets of rails.

Developing sensitivity to precision among operators.

Hand training can't stop.

Every week, workers are blindfolded and asked to feel the fit of a fixture to see if it is properly aligned.Last year's champion, Old Zhang, now just has to hear the sound of the screws being tightened to know if they are in place. The pass rate for the parts he handles has remained at 99.98 % for years.

Establishing equipment health records.

Each machine is equipped with a record book, in which the vibration level, temperature, and processing error are recorded daily.After three months of data collection, the curves are connected, and it is clear where the equipment needs to be fixed.Last month, we discovered an anomaly in the main shaft three days in advance, and avoided a major quality accident.