1. Equipment Optimization

Blade Selection & Tension Calibration

Use high-precision variable-pitch carbide-tipped blades (e.g., 1.1mm narrow-width blades), with tooth geometry adjusted based on material thickness (fine teeth for thin sheets, coarse teeth for thick materials).

Calibrate tension using a tension gauge within ±10% of the recommended value (typically 300–400 N/mm²) to avoid over-tightening (causing breakage) or under-tightening (leading to blade drift).

Precision Adjustment of Guide System

Check clearance between side guide wheels and backup bearings (≤0.03mm) to eliminate lateral blade deflection.

Use a dial indicator to verify parallelism of guide arms, ensuring total deviation ≤0.05mm.

Transmission System Maintenance

Replace worn worm gears (backlash <0.05mm) or timing belts to prevent jerky feed motion.

Maintain hydraulic system pressure fluctuation within ±0.2MPa to avoid sudden feed rate changes.

2. Fine-Tuning Process Parameters

Optimal Cutting Parameters

Cutting Speed: 1200–1500 m/min for aluminum, 30–50 m/min for stainless steel, with appropriate feed pressure.

Feed Rate: Adjust based on chip formation—ideal chips are curled and silver-white (for steel); powdery chips indicate excessive feed.

Coolant & Lubrication Optimization

Use high-penetration cutting fluid (e.g., EP-additive emulsion) with a flow rate ≥8 L/min for full lubrication.

For difficult-to-cut materials (e.g., titanium alloys), oil-based coolants are recommended to minimize thermal distortion.

3. Workpiece & Clamping Control

Enhanced Fixture Rigidity

Use hydraulic clamping (pressure >2 MPa) with V-blocks (runout <0.02mm).

For long workpieces, add intermediate supports (one every 300mm overhang).

Cutting Path Planning

For complex contours, adopt segmented cutting and reduce feed speed by 30% at sharp turns.

For high-hardness materials (HRC >45), pre-annealing or pulsed feed mode is recommended.

4. Environmental & Measurement Compensation

Temperature Control

Maintain workshop temperature at 20±2°C; warm up the machine for 30 minutes before precision cuts.

Monitor blade temperature with an IR thermometer—pause cooling if exceeding 150°C.

Real-Time Monitoring & Compensation

Install laser displacement sensors (resolution: 0.001mm) for in-process tracking, with PLC-based dynamic correction.

Verify dimensions with gauge blocks every 50 cuts and adjust tool compensation for drift.

5. Operational Standards

First-Piece Inspection: Validate all dimensions using a CMM before batch production.

Blade Break-In: Run new blades at 50% normal parameters for 20–30 cm² of cutting before full operation.

By implementing these measures alongside an ISO 9001-compliant equipment checklist (daily guide system checks, weekly feed accuracy verification), cutting accuracy can be consistently maintained within ±0.08mm, meeting high-end demands such as precision molds and aerospace components. The key lies in integrating dynamic process control with static maintenance to establish standardized workflows.