Troubleshooting Poor Surface Finishes on Machined Parts

The Importance of a High-Quality Finish

Surface finish affects a machined part’s durability, performance, and appearance. A smooth finish can reduce friction and wear, allowing the part to operate more efficiently and last longer. High-quality finishes with tight tolerances also help optimize final product assembly by providing a precise fit.

Understanding a machined part’s critical features and characteristics is essential in identifying the root causes of poor finishes and other quality problems.  A critical characteristic is a feature or specification that is crucial to the quality of a machined part. These characteristics are referred to as “critical” because any deviation from the specified requirements could have a significant impact on the performance and quality of the final product.

Troubleshooting poor part quality during a machining process is vital because it directly affects a company’s operational success. Identifying the underlying factors early enough allows operators to make the required adjustments to improve a part’s critical characteristics and overall quality. Overall, addressing problem areas promptly helps decrease scrap, reduce reworks, and minimize downtime.

 

How to Troubleshoot Poor Part Quality

Producing high-quality machined parts involves evaluating many of the fundamentals of machining. While there are limitless factors that can affect product quality, some of the primary ways to troubleshoot poor part finishes include:

  • Reviewing the machine settings: Incorrect cutting speeds, feed rates, and tool alignment are often the culprits of poor surface finishes. Adjusting these settings based on the recommended requirements for the specific material type is essential for ensuring high quality. Improper chip removal or breakage can also significantly affect surface quality.
  • Checking the workpiece’s stability: Ensuring a workpiece doesn’t flex and stays in place when machined is vital. Vibrations, chatter, and deflection can cause poor finishes and inaccurate dimensions. The same rules for ensuring stability apply to the machine tool and the tool holder.
  • Verifying the tool path and program: Operators must review the machining program and tool path to confirm they are correct. Making the necessary adjustments or corrections remedies the errors or inaccuracies affecting the surface finish.
  • Monitoring the coolant and lubrication levels: Adjusting the coolant flow or replacing it entirely when necessary, helps achieve superior surface finishes. Sufficient lubrication helps reduce friction and maintain desired contact between the cutting tool and the workpiece, creating smoother and more efficient machining while reducing heat generation and wear.
  • Inspecting the machine tools: Cutting tools are the workhorses of any CNC machine. Any issues with these components can cause poor finishes. Carefully evaluating the tools for sharpness, damage, or mechanical issues helps identify potential problem areas.
  • Assessing the spindle: Spindle issues can lead to poor surface finishes, reduced efficiency, and costly downtime. Alignment, bearing condition, thermal growth, and excessive vibration can affect spindle performance. Proactively monitoring these elements and other factors is critical for achieving a high-quality finish. It is common for operators and manufacturing engineers to overlook the spindle when troubleshooting part quality issues. The spindle is the heart of your machining center, and it’s health is essential to producing quality parts.

How Setco Can Help

If a machine’s spindle shows signs of runout, vibration, noise, or other issues, Setco can provide the professional spindle repair services needed to remedy the problem. As the largest independent spindle rebuilder and manufacturer in the United States, we specialize in servicing and repairing over 350 machine tool brands. In addition, we can rebuild or repair machine slides to customized or OEM specifications.

Professionals globally recognize Setco products and services as the most accurate and reliable in the industry. Whether a customer needs us to install new bearings and seals, test the spindle motor, or reverse-engineer parts, we can accommodate their needs.

Contact Us Today for Additional Information

To learn more about how our products and services benefit machining applications, the experts at Setco can help. We walk customers through the most practical and effective solutions that meet their operational needs. Contact us online today to get started.

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