The activity uses computerized instructions to remove excess material, leaving a finished shape or part. It’s cutting, milling, and turning capabilities allow it to be used in various applications with different raw materials, although it is usually used for metal. The greatest beauty of the CNC machine tool is its precision. Because computers do the cutting instead of humans, these machines can achieve a much higher accuracy. The ability to meet stringent specifications makes CNC machining worthwhile for high-precision industries such as aerospace and medical device manufacturing. Of course, it is also great for general manufacturing, providing highly accurate cuts. Although CNC machines are highly accurate, they use tolerances to determine how far a part can deviate from traditional standards. Some products like our mentioned applications may require narrower tolerances than toy or children’s furniture manufacturers.
Improving the accuracy of CNC machines
Perhaps the most important reason for such improvements is to save project time. Finer cuts can avoid the need for rework. In addition, automating many aspects of machining, such as tool setup, can reduce the time required to complete each task. If you use machined parts, more efficient operations will speed up the process needed to complete a project. Accurate measurement of machined parts will also save valuable time. Variations can affect the initial accuracy of a part and the ability to create replicas of it, so changing your equipment to reduce these variables will produce repeatable and desirable results. As you strive to improve machine accuracy, you will need to reduce human input. Automating the process reduces the risk of error, resulting in a more accurate copy of every part you machine. Since the number of mistakes is finite, you can bring your equipment to the highest precision by controlling potential errors and leveling them. While you don’t need to measure every part, you should still constantly use laser measurement and inspection to verify your process’s accuracy. Information from these measurements can help you better predict when your machines will need maintenance or adjustments to improve performance.
Benefits of improving the positioning accuracy of CNC machines
By improving your equipment, you gain many things. The benefits your company will gain from these changes will depend on current workloads and upgrades to existing equipment. With upgrades, you will be able to catch up as both technology and demand drive the development of more precise parts.
Key criteria for precision CNC machining
CNC programming is the most basic machining task. An experienced programmer can skillfully use an in-house program, reducing cumulative system errors while providing full flexibility within the main program and subprogram. In complex CNC operations, we generally use multi-part mold machining. If there are several identical shapes, a relationship between the main program and the subprogram should be used, where the latter should be used repeatedly in the base program until processing is completed, thus ensuring consistency in processing volume and improving efficiency. The incremental calculation, also known as delta calculation, is a software function that, by recalculating only those results that depend on changing data, attempts to save time with each such change. Many programs use just such calculations, ensuring stable machine operation.
Test cutting
Make it by adjusting the blade extension to the material, using such raw materials as included in the design. We often use it for the production of small batches of single pieces.
Adjustment method
Size can be found by adjusting the relative positions of the machine tool, chuck, workpiece, and tool. This method is often used for mass production.
Reduce measurement error
Choose from precision cylindrical roller bearings, oil-rich wedge bearings and hydrostatic bearings to improve bearing rotation accuracy.
Improve the precision of bearing parts
Improve machining accuracy of the case support hole and spindle journal. Measure and adjust the radial runout range of related parts to reduce errors.
Reduce tool wear
Sharpen your tools to extend their life. Use special cutting oil to ensure proper lubrication. Choose the right turning tool for the correct machining.
Reduce thermal distortion of the process system
The thermal error of a machine tool depends on cutting speed, feed rate, machining time and ambient temperature.
Assembly process
When preparing the machine for operation, use a tool adjuster to make the work more precise. These add-ons measure tool placement accuracy in less than a minute. In contrast, it takes a mechanic more than an hour to set up fifteen tools for a project with probes. Using locators also improves accuracy, as the system can more precisely determine the position of a tool for finer cuts. With tool positioning, work will be able to handle errors during manual setup. Although tool pre-fabrication is only a concept for larger operations, any workplace where tools are changed frequently can save time with such applications. In addition to precision tooling, it is also necessary to ensure that the workpiece does not fall or slip during machining. A work chuck prevents accidents, and if you have a piece of metal, you can use permanent electromagnets for this purpose. U.S. processors have been using these devices for nearly 25 years since their introduction, and they remain a popular choice today. Using electroactive magnets to hold metal parts is a clever idea for thin parts that may move or bend during cutting or milling. The activity becomes more precise with a chuck because the parts do not move during machining. Ordinary clamps can also be used for this purpose. The important point is that any work chuck that improves part stability is better than none, especially for smaller parts that tend to move more during the machining process.
Machining process
Machining processes can be improved in several ways. First, think about your employees. If they are disorganized when operating the machine, they may save time and make mistakes. When updating the software, make sure that all employees are fully trained in its use. Failure to enter information into the system will result in further machine errors due to erroneous data. The advantages of CNC machining are certainly high precision, low production costs (if you have the right personnel and equipment), and the ability to create products from plastic, or metal. Almost any type of material can be machined. Nevertheless, a properly established program can also demonstrate the accuracy of machining.
The right program
Updating software and hardware to accommodate higher levels of precision will also improve the process. Upgrading to new software improves the machines’ ability to see further than before, and because the computer can predict where the tool will need to be placed in the future, it becomes more efficient and accurate throughout the machining process.
Navigation system
Another way to improve equipment for greater accuracy is to replace the navigation system. The accuracy of a guidance system depends on how well it smooths out roll, pitch, and yaw – movements around the X, Y, and Z axes, respectively. Precision guidance systems with tight tolerances for height, width, and parallelism will cost more and more as the tolerance decreases. However, the lower it is, the higher the device’s precision. If your budget does not allow for an ultra-precise guidance system for your equipment, consider outsourcing the task.
Proper support
The quality of the machine bed support will also affect the accuracy of precision CNC machining equipment. The bed supports the machine’s moving parts and ensures CNC accuracy, so you must have a flat, thermally stable, and rigid substrate that absorbs vibration. To achieve these properties, you may need to grind the surface on which the hardware rails are mounted. The interaction between the bed and the foundation affects the accuracy of the equipment. If your machine has an area of one square meter and a very solid bed, you only need three connection points. The placement of the bed frame at the connection point is crucial to reduce distortion. Even the most formidable bed can deflect imperceptibly between the points. To achieve perfect alignment, the spacing of the bed’s feet should be about 60% of its length. These are Airy points – points of support that help minimize bed flexing. Place the third support between the other two. Reduced bed deflection ensures precision during machining.
Reduce tool wear and deformation
When your tools are in excellent condition, they become more durable and efficient. Dull or worn-out ones need to be replaced frequently, which takes time with projects. Several ways to reduce wear and avoid unexpected CNC machining tool failures exist. More than forty percent of downtime cases were caused by equipment failure. Unplanned downtime is ten times more expensive than planned maintenance downtime. Keeping up with equipment repair and improvement can prevent many of these problems. First, opt for preventive maintenance. Unlike scheduled maintenance, it uses data to determine when to perform maintenance tasks best. Anticipating when CNC machining equipment will require them reduces unnecessary activities while preventing unplanned downtime due to machine failure. Suppose you don’t have the data to predict the best time to service your equipment; at least follow the manufacturer’s guidelines for a preventive maintenance schedule. When performing scheduled maintenance, check the tools, filters, and spindle condition. If you use your machine frequently, these parts may need to be replaced frequently. Making sure your machine has quality parts will help you get the most out of it. Another way is to use harder tools when machining your part. Frequent use of less durable material often accelerates its wear and tear.
While the most durable tools are comparably priced, you’ll get more precise machining solutions while maintaining sharpness. No matter how precise you set up your machine, dull, worn tools cannot achieve high precision.
Finally, if you have a project requiring a highly durable tool that you want to avoid investing in, consider outsourcing the work. You don’t have to choose an outside machine shop for all work, but for very delicate parts or parts that require special tooling, having someone else do the work can help prevent wear and tear on plant equipment. CNC (Computerized Numerical Control) machining and its widely used manufacturing process.