CNC Machine Tool
What is a CNC Machine Tool?
CNC Machine Tool, an acronym for Computer Numerical Control, refers to implementing computer technology in controlling machine tools, transforming them into highly sophisticated CNC machines.
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Running on a set of prescribed digital instructions, CNC machines use computer files to execute a project. These digital instructions are created in either Computer Aided Design (CAD) or Computer Aided Manufacturing (CAM) files.
Once the program is uploaded, an operator runs a test program, often referred to as “cutting air.” This trial run is an important first step to verifying both speed and tool position because any discrepancies can result in damage to the machine or the part being created.
To maximize efficiency, CNC machines combine multiple tools into common cells or units. They produce the desired end product by removing material from the original stock source. This results in a stronger, more durable finished product.
Advantages :
They can run for 24 hours a day.
They can product jobs with higher accuracy and precision than other manual machines.
Operators can make changes easily, which reduces the delay time.
Fewer workers are needed to operate these machines, which saves labor costs.
CNC machines have the capability to create complex designs with high accuracy in a short amount of time.
The modern design software for CNC machines removes the need of producing a prototype or model before executing a project, which saves money and time in the long run.
What are the Different Types of CNC Machines?
There are countless different types of CNC machines today. CNC machines are machine tools that cut or move material as programmed on the controller, as described above. The type of cutting can vary from plasma cutting to laser cutting, milling, routing, and lathes. CNC machines can even pick up and move items on an assembly line.
Below are basic types of CNC machines:
Lathes: This type of CNC turns the workpiece and moves the cutting tool to the workpiece. A basic lathe is 2-axis, but many more axes can be added to increase the complexity of cut possible. The material rotates on a spindle and is pressed against a grinding or carving tool that makes the desired shape. Lathes are used to make symmetrical objects like spheres, cones, or cylinders. Many CNC machines are multi-function and combine all types of cutting.
Routers: CNC routers are usually used to cut large dimensions in wood, metal, sheets, and plastics. Standard routers operate on 3-axis coordinate, so they can cut in three dimensions. However, you can also buy 4,5 and 6-axis machines for prototype models and complex shapes.
Milling: Manual milling machines use handwheels and lead screws to articulate a cutting tool onto a workpiece. In a CNC mill, the CNC moves high accuracy ball screws to the exact coordinates programmed instead. Milling CNC machines come in a wide array of sizes and types and can run on multiple axes.
Plasma Cutters: The CNC plasma cutter uses a powerful laser to cut. Most plasma cutters cut programmed shapes out of sheet or plate.
3D Printer: A 3D printer uses the program to tell it where to lay down small bits of material to build the desired shape. 3D parts are built layer by layer with a laser to solidify the liquid or power as the layers grow.
Pick and Place Machine: A CNC "pick and place” machine works similar to a CNC router, but instead of cutting material, the machine has many small nozzles which pick up components using a vacuum, move them to the desired location and put them down. These are used to make tables, computer motherboards and other electrical assemblies (among other things.)
CNC Machines can do many things. Today computer technology can be put on just about machine imaginable. The CNC replaces the human interface needed to move machine parts to get the desired result. Today's CNC's are capable of starting with raw material, like a block of steel, and making a very complex part with precise tolerances and amazing repeatability.
What are the Materials Used in CNC Machining?
CNC machines are used on a vast array of materials. Each material has its own optimal set of machining parameters (speeds and feeds) to successfully machine the material. The most common materials are:
Metal
Meal is easily the most commonly used material in CNC machining. CNC machines can cut almost any type of metal from free-machining brass to nickel superalloys like Inconel. Metal machining covers a range of applications from injection molds to shafts and gears.
01
Plastic
While the vast majority of plastic parts are manufactured using injection molding, CNC machining may be used to produce certain plastic components. Typical materials can include ABS (acrylonitrile butadiene styrene), nylon, and polycarbonate. Plastic machining applications can include valve bodies, bushings, and injection molding prototypes to check the overall function of the part before investing in expensive molding tools.
02
Wood
CNC routers are most often used to cut wood and are generally cheaper than standard metal cutting CNC machines. CNC machining of wood is most commonly done for decorative purposes. Common applications include furniture, window frames, and ornamental panels.
03
Foam
Polyurethane foam (either closed or open-cell) is commonly used in CNC machining applications. Foam blocks can be cut into snug packaging for high-value products using a CNC router. One example is the foam used in toolboxes to keep the tools secure during transport.
04
Composites
CNC machines are regularly used when processing composite parts. Composites can include anything from aramid to fiberglass to carbon fiber. These materials are extremely abrasive to cutting tools. Aerospace and marine composite components are machined to add fastener holes and for general trimming after the molding process.
05
How To Set up a 5-Axis Cnc Machine?
One of the advantages of a 5-axis Machining Centre is that no complex clamping systems or fixtures are required to hold the part being machined. Hence, it is rather easy to set-up a work piece on such a machine.
The holding equipment or work piece part should preferably be mounted at the machine table center. The holding equipment can either be a zero clamp vice, a hydraulic clamp or just a block where the part to be machined is mounted securely.
More importantly, the part should be freely accessed by the cutting tool from all 5-sides and securely fixed such that it cannot move or vibrate. The cutting tools and tool holder need to then be prepared, measured and loaded into the machine's Automatic Tool Changer (ATC) magazine.
An essential point often overlooked is the calibration of the entire machine before production starts. This calibration requires a very specific software and an automatic measuring probe (operated either by infrared or radio). The entire calibration function may take about 45-seconds (in the case of Hwacheon) or a maximum of 2-3 minutes, depending on the machine brand and type.
By running such a calibration cycle, the machine is freshly and correctly calibrated on all axes and no tolerances are accumulated between each axis. This should be done at least once a month (preferably once a week), and definitely before each production run.
Many 5-axis Machining Centers are sold, unfortunately, without this function and the equipment necessary for it — mainly to save money. While initial sums of money may be saved, it comes at the cost of accuracy. Over time, such costs will be amplified, resulting in sub-standard machining. This is certainly not part of the industry's best practices.
Another important point to note is to carefully check if there are any potential collision areas prior to pushing the cycle start button. Thereafter, allow the whole program to run, step-by-step, to ensure that every position is correct, and that every tool changed is the right one.
Without spending some time on checking, a crash may occur. This not only costs a substantial amount of time to fix, but may result in very expensive repairs as well as the need the for realignment of all axes.
Difference Between 3-Axis and 5-Axis Machining
To better support the increasingly sophisticated needs of advanced industries like aerospace engineering, medical, defence, robotics and automotive manufacturing, CNC machine tool makers have constantly innovated in developing newer, more complex and at the same time more powerful machine tools.
One of the major milestones in this area is the development of 5-axis Machining Centers. The capability and flexibility of such machines are far superior to standard 3-axis Machining Centers. Some of the key points can be seen in the table below:
|
Difference |
3-axis |
5-axis |
|
1. |
Materials are fed and worked on only 3-axis – Axis X, Y & Z. |
Materials are fed and worked on 5-axis – Axis X ,Y, Z, A & B / C. |
|
2. |
Difficult to handle complex parts in one setting as well as workpieces that have deep and narrow cavities or shapes. Limitation due to the 3D-axis movement. For more complex operations, parts need to be repositioned and clamped in custom made fixtures. |
Built for complex parts with highly accurate machined results. Can use shorter cutting tools with faster tool speeds at a lower vibration level. This greatly saves time and effort in machining while allowing for more sophisticated parts to be made. Capable of reaching 5-sides on any part to achieve complex contours. E.g. Impeller, Tire Mold, 3D shaped parts. |
|
3. |
To achieve quality surface finishes, parts may need to be repositioned. Not only will this take additional time but the possibility for errors is high. |
5-axis CNC Machines are able to position the parts to the cutting tool in an optimum position to each other (90 degree). At the same time, all 5 sides of a part can be reached. Even the most complex contours and shapes can be machined by simultaneously utilizing all 5-Axis. |
|
4. |
Fewer axes make programming simpler with faster preparation and turnaround time. |
CAD/CAM systems are used to easily programme complex operations. |
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Guangdong Anda Automation Solutions Co.,Ltd. is a smart equipment and system manufacturer providing vertical integration of research & development, manufacturing, sales and service to fluid applications, and intelligent automation systems. Anda's main product lines include high precision dispensing machines, conformal coating systems, plasma treatment equipment, curing systems, multi-functional assembly systems, semiconductor manufacturing equipment, medical electronic dispensing and assembly machines, and smart manufacturing system solutions. Anda equipment covers the application of consumer electronics, automotive electronics, communication electronics, instrument equipment, electric appliances, new energy, power supply, LED, military electronics, medical electronics, semiconductor and other industries.
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