Common Fault Analysis And Maintenance Methods Of Steel Bar Cutting Machine

Cutting blade wears too fast

Fault manifestation

The cutting blade shows obvious wear in a short time, the cutting ability decreases, and the cut is rough and uneven.

Cause analysis

Cutting material is not suitable: using cutting blades with inappropriate hardness to cut steel bars, such as using ordinary carbon steel blades to cut high-strength alloy steel bars, the blade is difficult to withstand the huge cutting force and wears quickly.

Improper cutting parameters: If the cutting speed is too fast, the friction between the blade and the steel bar will increase, generating a lot of heat, causing the blade to wear more; if the feed rate is too large, the pressure on the blade will be too large, causing excessive wear of the blade.

Lack of lubrication: The blade and steel bar are not effectively lubricated during the cutting process, and dry friction will greatly increase the degree of wear of the blade.

Maintenance method

Choose a suitable blade: According to the material and hardness of the steel bar, choose a matching cutting blade. For example, ordinary high-speed steel blades can be used to cut ordinary hot-rolled steel bars; carbide blades are required to cut high-strength steel bars.

Adjust cutting parameters: Reasonably set the cutting speed and feed rate. For steel bars of different diameters and materials, refer to the equipment manual or determine the best cutting parameters through actual tests. Generally speaking, for steel bars with larger diameters or harder materials, the cutting speed should be appropriately reduced, and the feed rate should also be reduced.

Strengthen lubrication measures: During the cutting process, use professional cutting fluid to fully lubricate the blade and steel bar to reduce the friction coefficient and reduce blade wear. At the same time, the cutting fluid can also play a cooling role to prevent the blade from being damaged due to overheating.

Inaccurate cutting accuracy

Fault manifestation

The length of the steel bar after cutting is inconsistent, or the incision is not vertical, which affects the subsequent construction and use.

Cause analysis

The positioning device is loose: The positioning device of the steel bar cutting machine is used to determine the cutting position of the steel bar. If the fixing bolts of the positioning device are loose, the steel bar will be displaced during the cutting process, resulting in inaccurate cutting length.

Rail wear: The rail of the equipment is a key component to ensure the linear motion of the cutting tool. After long-term use, the rail will wear, causing the motion trajectory of the cutting tool to deviate, resulting in non-vertical incisions or errors in cutting length.

Improper blade installation: If the blade is not installed firmly, or the concentricity of the blade and the knife shaft is not enough, the blade will shake during cutting, affecting the cutting accuracy.

Repair method

Tighten the positioning device: Check the fixing bolts of the positioning device regularly, and tighten them in time if they are loose. At the same time, before each cutting, make sure that the steel bar is accurately positioned on the positioning device.

Repair or replace the rail: For rails with less wear, they can be repaired by grinding, scraping, etc.; if the rail is severely worn and cannot be repaired, a new rail needs to be replaced. After replacing the rail, precise debugging should be carried out to ensure the motion accuracy of the cutting tool.

Reinstall the blade: Carefully check the installation of the blade to ensure that the blade is firmly installed and the concentricity with the knife shaft meets the requirements. After the installation is completed, you can make a trial cut to observe the cutting effect. If necessary, readjust the installation of the blade.

Abnormal vibration and loud noise during equipment operation

Fault manifestation

During the operation of the steel bar cutting machine, the machine body vibrates violently, accompanied by harsh noise.

Cause analysis

Motor failure: Problems such as motor bearing wear, rotor imbalance or motor winding short circuit will cause abnormal vibration and noise during the operation of the motor, which will be transmitted to the entire equipment.

Loose or worn transmission parts: For belt-driven cutting machines, loose or worn belts will cause unstable transmission, vibration and noise; for chain-driven cutting machines, similar problems will occur if the chain is too loose or the sprocket is worn. In addition, gear wear and tooth surface damage of gear transmission will also cause vibration and noise during operation.

Cutting tool damage: The cutting blade has broken edges, notches and other damages, which will generate impact force during cutting, causing vibration and noise of the equipment.

Maintenance method

Check the motor: Perform a comprehensive inspection of the motor. If the bearing is worn, replace it with a new one; for rotor imbalance, the rotor needs to be dynamically balanced; if the motor winding is short-circuited, the motor winding should be repaired or replaced.

Adjust or replace transmission parts: For belt-driven equipment, adjust the tension of the belt. If the belt is severely worn, replace it with a new one in time; for chain-driven equipment, adjust the tightness of the chain, and replace the worn sprocket and chain in time; for gear-driven equipment, check the wear of the gears and repair or replace the worn gears.

Replace the cutting tool: When the cutting blade is found to be damaged, stop using it immediately and replace it with a new one. When installing a new blade, pay attention to the correctness and firmness of the installation.