Head polishing machine standard operating procedures (SOP)

Operating Procedures for Head Polishing Machine

I. Pre-Operation Preparation

1. Safety Inspection

• Check power cables, switches, and grounding (insulation resistance ≥1 MΩ).

• Ensure protective covers are intact (removal prohibited).

• Verify polishing wheel/block is securely installed with no cracks or excessive wear (wear limit ≤1/3 thickness).

2. Workpiece Preparation

• Measure head dimensions (diameter, curvature radius) and select matching fixtures.

• Clean surface contaminants (oil, welding slag) to avoid wheel contamination.

3. Parameter Settings

• Polishing Wheel Selection by Material:

  Material	Wheel Type	Recommended Speed (rpm)
  Stainless Steel	Wool wheel + diamond paste	1500–2500
  Carbon Steel	Nylon wheel + alumina	1200–1800
  Aluminum Alloy	Cloth wheel + silicone wax	800–1200

• Pressure Adjustment: 0.2–0.5 MPa (≤0.3 MPa for mirror finish).

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II. Operating Procedures

1. Head Clamping

• Secure the head with hydraulic/magnetic fixtures (radial runout ≤0.1 mm).

• For large heads (>1.5 m diameter), polish in sections with marked zones.

2. Test Run

• Operate without load for 1 minute to check vibration/noise (≤2.8 mm/s).

• Test emergency stop button functionality.

3. Sectional Polishing

• Rough Polishing: Remove welds/oxidation (60–120# abrasive, feed rate 0.5–1 m/min).

• Fine Polishing: Achieve Ra ≤0.4 μm (400–800# abrasive, feed rate 0.2–0.5 m/min).

• Mirror Finish (Optional): Use 1500#+ polishing paste, peripheral speed ≥20 m/s.

4. Real-Time Monitoring

• Inspect surface quality every 10 minutes (verify with roughness tester).

• Control wheel temperature (≤60°C to avoid material annealing).

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III. Safety Precautions

1. Personal Protection

• Wear dust masks (NIOSH N95), safety goggles (ANSI Z87.1), and earplugs (NRR ≥25 dB).

• No gloves near rotating parts.

2. Equipment Safety

• Press emergency stop (red mushroom button) for critical situations.

• Install splash guards in polishing fluid zones.

3. Environmental Compliance

• Keep dust collection system ON (airflow ≥2000 m³/h).

• Dispose of waste polishing paste as hazardous material (HW08 standard).

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IV. Maintenance & Servicing

1. Daily Maintenance

• Clean residual abrasives post-polishing (prevent clogging).

• Check hydraulic oil level (ISO VG46, replace monthly).

2. Periodic Maintenance

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V. Troubleshooting

Warnings:

• Only authorized personnel may disassemble motors/control systems.

• Release hydraulic pressure if idle >24 hours.

This procedure complies with GB/T 15706-2012 (General Safety Standards for Machinery). Violations may cause equipment damage or injuries. New operators must pass practical assessments before independent use.

Technical Support: 0551-65571688 (24/7 manufacturer hotline).