Since ancient times humans have been devising ways to automate laborious and repetitive tasks. There are various examples ranging from ancient history to modern times including water mills for grinding grains, automatic fountains, Johannes Gutenberg’s printing press, James Watt’s steam engine, Ford’s moving assembly line and the Robotic Process Automation. While there exists various types of automated technologies, there is one specific type of automation which has revolutionized our lives i.e a programmed automation. We got the power to instruct the machines for doing a specific task. One of the pioneers was Joseph Marie Jacquard who used punched cards to automate pattern weaving. Since then inventions and innovations have taken place in various sectors.
One sector which adopted this kind of automation is the manufacturing sector. They used Numerical Control to automate the machining process. The instructions are provided to the machines in the form of numbers, letters and symbols. A punched card contains these numbers, letters and symbols. The punched card is inserted into the machine, then the control unit reads and converts the instructions into electric signals. The electric signal is then sent to drive motors which converts these signals into mechanical motion of tool and/or workpiece to perform machining operations. A feedback unit is present in the machine which feeds back the actual movement data to the control unit for correcting errors.
After developments in computer technology, the NC machining process got upgraded to CNC machining process. CNC stands for Computer Numeric Control. CNC machining was developed more than 50 years ago and is used by manufacturers till date.
CNC Machining is a process wherein we instruct the plant machinery and tools to perform machining operations in a specific sequence. We provide the instructions through a computer program. This process is a successor to NC Machining wherein we provide instructions through punched cards or magnetic tapes. CNC Machining process involves subtractive manufacturing in which the layers of material are removed from blank/workpiece to produce customized parts.
Framework of the process
How do we achieve this process ?
The framework of this process involves two steps :
- Developing the Computer Program : We need to prepare a set of instructions for the machine. Languages understood by machine are G-Code and M-code.
- Inserting the Program in CNC Machine : CNC Machine reads the instructions from left to right and from top to bottom and then manufactures the product.
Let us understand each step in detail. We will start with the first step.
What is G-Code and M-Code ?
G-Code and M-Codes are AlphaNumeric in nature.
G stands for Geometry. G-Code covers the Geometric and Cutting aspect for the workpiece. G-code tells how the tool/workpiece will perform motion, where it will move. By using G-Code we can specify coordinate systems, we can tell the machine which units to use i.e. English or Metric, we can specify the positioning system i.e. Absolute or Incremental, etc.
By using G-Code, we can achieve the desired geometry from a workpiece.
M stands for Miscellaneous / Machine. M-Code instructs machines to perform Non-Cutting / Non-Geometric operations like – Coolant ON/OFF, Tool Change, Spindle rotation CW/CCW, etc.
Other AlphaNumerals used in CNC Program : G-Code also includes alphanumerals that start with alphabets apart from G. You can find the list here.
Example of the Computer Program :
Let us take an example of drilling a hole. The workpiece is of square shape with dimensions 100 mm x 100 mm x 5mm.As shown in Fig 1. a hole of diameter 10 mm has to be drilled at the center of the workpiece. The coordinates of the workpiece and tool are shown in Fig 1. The workpiece and the tool are at the same height Z=0.
Codes that will be used in program:
The following codes have been taken from Siemens Sinumerik 802d Milling Manual
G71 – Metric dimension data input
G90 – Absolute dimension data input
G94 – Feed in mm/min
M6 – Tool change
G0 – Linear interpolation with rapid traverse
G17 – Selecting X/Y plane
M3 – Rotate spindle clockwise
G1 – Linear interpolation at Feedrate
M2 – End of main program with return to beginning of program
M8 – Start the coolant flow
M9 – Stop the coolant flow
M5 – Stop moving the spindle
|N010 G71 G90 G94
|This statement tells the machine that we are going to specify all dimensions in mm, we will use absolute positioning and will specify feed rate in mm/min
|N020 M6 T01
|It tells the machine that we are going to select tool 01
|N030 G0 X150 Y50 Z 50
|It tells the tool to travel in a linear manner with the fastest speed to the target coordinates
|N040 G0 Z20
|It tells the machine that we are going to perform drilling in X/Y plane
|N050 M8 M3 S400
|It tells the machine to switch on the coolant, tells the spindle of tool to rotate clockwise with a speed of 400 rpm
|N060 G1 Z-60 F15
|It tells the tool to travel in linear manner at a rate of 15mm/min to the target coordinates
|N070 G0 Z20
|N080 M9 M5 M2
|It tells machine to switch off the coolant, stop the rotation of spindle and end the program
Programming Methods :
1. Manual Programming :
The programmer has to visualize the machining operations that will be carried out on the workpiece in a sequence. Then the programmer has to manually develop the program i.e. without taking help from the computer.
2. Conversational Programming :
Conversational Programming allows operators to generate programs on a CNC machine control. The operator answers a series of displayed questions about the intended workpiece. The questions include type of material, OD/ID dimensions, part lengths,etc. After the questions are answered, the control generates the program. Conversational Programming can be done either on a shop floor or on a personal computer.
3. Use of CAD/CAM systems:
The programmer uses CAD (Computer-Aided Design) software and CAM (Computer-Aided Manufacturing) software in a sequence.
First, the programmer creates a CAD model of the part that has to be manufactured. Then the programmer has to transfer this model to the CAM software. If the programmer has CAD and CAM as different packages then the programmer has to import CAD files into the CAM software. If the programmer has CAD and CAM integrated in a single package then there is no need to import or convert CAD files.
Second, the programmer has to enter the details of machining operations, select tools and enter tool data in CAM in order to generate a toolpath. Toolpath is the path that cutting tool will follow to machine the part. Once the toolpath is generated, the programmer can run the simulation to do collision checks. Once the toolpath is finalized, the programmer uses a Post Processor to generate the program. The role of the post processor is to read the toolpath data and convert it into a program that can be read by a machine controller.
The program can be transferred to a CNC machine controller using data carriers such as a USB.
To see Pros and Cons of each method, visit What CNC programming style best suits your operations?
Let us understand the elements of a CNC machine and how it works.
Elements of a CNC machine :
The main components of CNC machine are:
1. Input Devices:
The below devices are used to transfer programs to the CNC machine.
- Floppy Disk: It is a small magnetic storage device. Floppies are sensitive to large magnetic fields, dust and scratches. Floppies can degrade fast and might be unreadable after only 3 years.
- USB flash drive: It is a removable and rewritable hard drive. It is portable and compact in nature and has more storage size than a floppy disk.
- Serial communication: The data transfer can be accomplished through a serial communication port. The port is built on RS-232 standard.
- Ethernet: The program can be transferred from the computer to CNC machine via ethernet communication cable. Most companies built LAN as their infrastructure.
- Wireless: The program can be transferred to a CNC machine via Wi-Fi.
2. Machine Tool
A machine which satisfies below conditions is known as a machine tool.
- It is power driven
- It is non-portable
- It has sufficient value in terms of capability and performance
- It has a cutting tool that performs machining operation on workpiece
- It can perform more than one type of machining operations
It is a place where a workpiece is converted into a finished product.
Examples of machine tools include lathe machines, milling machines, etc.
Machine tool consists of a worktable, spindle, motors, cutting tools, work fixtures and other equipment that assist in machining operation.
3. Drive System
The drive system is used to provide controlled motion to elements of CNC machine tools such as work-table, tool spindle, etc. The drive systems used in CNC machine are:
a. Feed Drive:
Feed Drive is used to control the position and velocity of the slide or table of a CNC machine. Feed Drive is used to provide linear motion to a workpiece or tool.
Feed Drive consists of a motor coupled with a mechanism. Motor provides rotary motion and the mechanism converts rotary motion into linear motion. An example for the motor is a servo motor and for the mechanism is a ball lead screw. A schematic of Feed Drive is shown below
b. Spindle Drive:
Spindle Drive provides cutting power that is required for machining the workpiece. The cutting power is generated through angular motion of the workpiece or tool.
Spindle Drive consists of a spindle motor which provides angular motion to the spindle. Spindle transfers angular motion to the workpiece or tool as they are attached to the spindle. A schematic of Spindle Drive is shown in Fig 4.
4. Feedback System
It is used in closed loop CNC machines. This system is used to send actual position and actual velocity data to the MCU. The data is used to correct the error between the specified value and actual value.
The devices that can be used to measure position are encoders and linear transducers. The device that can be used to measure velocity is the tachometer.
5. Machine Control Unit (MCU)
6. Display Unit
It is an interactive device between operator and machine. It displays data such as position status, spindle rpm, feed rate, part programs, etc.
How does a CNC machine work?
MCU converts the entered program into electrical signals and sends it to the amplifier to drive the motor. The motor operates the machine tool components to perform the cutting actions and other auxiliary functions. Feedback systems monitor the actual output and it sends the data to MCU. MCU calculates the error. If there is any error, MCU generates electrical signals for the motor and eliminates the error.
Materials that can be used for CNC Machining
Below is a list of some of the metals and some of the variants which can be machined on CNC.
Ceramics like zirconia can be CNC machined for dental applications.
Operations like engraving, bevelling, grinding, drilling, milling and polishing can be done on glass using CNC. The Optical Industry has used CNC for machining glass.
Machining plastics is not the same as machining metals. One of the challenges is heat buildup. Machining involves friction and thus heat is generated. If the heat is not controlled during the machining process it can cause changes in tolerances, can reach a softening point of plastic and in case of thermosets it can burn the surface. Another challenge is performing milling operations on plastic. The vibration of the component during operation can leave chatter marks on the component. CNC routers have vacuum chuck as a workholding device.
Using machining operations for plastic has advantages. CNC Machining eliminates the need for mold and thus it reduces cost and startup times. Some materials such as PTFE and UHMW are not possible to mold and require machining.
Plastics that can be used for CNC machining are Acrylic, PVC, PMMA, Nylon, ABS, POM, PTFE, HDPE and PEEK.
Composites can be machined on CNC. The nature of composite materials poses a challenge for machining operations. Composites are made up of matrix and fibre. The matrix has low thermal conductivity and the fibres are abrasive. This poses a challenge in tool design. Heat is not transported away from the cutting edge and fibres can cause rapid tool wear. Cutting performance depends on both tool geometry and tool material. Selection of improper tools can cause delamination, inconsistent cut geometry, hole exit deburring and rapid tool wear.
To tackle the challenge, three different materials can be used for composite tools. They are Carbide, Coated Carbide and Polycrystalline Diamond (PCD). The tools used for composites are often custom products.
The machine tool required to produce contoured shape on composite material is generally a 5-axis machine tool.
The most widely used material is CFRP (Carbon Fiber Reinforced Plastic). Panels made up of aluminum composites like Dibond can be used for CNC Machining.
Factors affecting cost of CNC Machining
Cost will depend on:
- Raw materials: It includes the cost of raw material itself. The availability of raw material is also a factor that affects cost. Hard to find materials will be more expensive than materials that are easily available. Machinists buy material in blocks and they will charge for the whole use of a block. Customers must try to fit as many parts as they can in a block. Use of fewer blocks can save money in the long run.
- Machinability: Materials that have low machinability will take more time and effort to machine. Apart from time and effort, these materials also consume cutting fluids, electricity and cutting tools. Materials that have high machinability can be machined faster.
Additional measures: If the material poses some hazard, then additional measures will be taken. An example is machining of composites. During machining, plenty of dust is raised. The dust can pose health hazards and can damage machine controllers and equipment. To control this dust a suitable cartridge style dust collector is installed. Such additional measures will add to the cost.
2. Manufacturing equipment
Shops set an hourly rate for running the machine. This rate depends on:
- The number of axes.
- Operations to be performed. Ex: drilling, milling, etc.
- The number of machines used i.e one or more than one.
- Capability and size of the equipment.
- Cost of cutting tools.
Tighter tolerances can add up to the cost of CNC machining. Tighter tolerance requires more time and more effort to produce the part. It also demands better quality control equipment for inspections. Tighter tolerance will decide which tools, machines and cutting techniques to be used for manufacturing the part.
Tolerance must be provided for appropriate features only. Ex: mating areas. If tolerance is provided to every dimension, cost will increase due to increase in setup time, modification in computer programs and due to scraps and rework.
4. Quantity of parts
The operator requires time to set-up the machine for manufacturing the part. This setup cost will be fixed irrespective of quantity. Same setup cost can be assigned to single quantity as well as bulk quantity. If we order in bulk, the overall cost will increase but the cost per part will reduce. Also, if we order in bulk, the machine shop can buy bulk raw materials at a better price.
Though CNC is automated, manual intervention is required for below tasks.
- Design: Labour cost is involved if we outsource the task of preparing 3D models or CAD files of the part. This cost can be eliminated by preparing the CAD file on our own.
- Programming: The manufacturing engineer checks the design and gives suggestions. Then the programmer prepares the computer program.
- Setup: The operator has to load tools into the tool changer, set up the machine and the workpiece.
- Post processing: It involves cleaning, support removal and assembly of parts.
Complex features such as non-standard hole sizes, lettering and thin walls can add up to the cost of CNC machining. Complex features take more programming time, demand specialized tools and multiple setups to manufacture a part. Increase in runtime will increase cost.
By eliminating unnecessary features, we can simplify the design. Wherever possible, we can choose recessed texts instead of raised texts. For thin walls, a good rule of thumb is a width-to-height ratio of 3:1. Machining for walls can be made easier by adding a draft of angle 1, 2 and 3 degrees.
7. Additional treatments
These treatments include surface finish operations that will be performed on the machined part. A number of finishing operations can be used to improve surface roughness, aesthetics and wear resistance.
Some of the finishing operations are:
- As machined: This finish can have minor visible tool marks. The part is provided with a specific surface roughness value. These values are planned in advance and are regulated by industry standards. The values typically specified for CNC machining are 3.2 μm Ra, 1.6 μm Ra, 0.8 μm Ra and 0.4 μm Ra. The lower the Ra value more effort and quality control is required and hence the cost will increase. As machined parts have tighter dimensional tolerances.
- Bead Blasting: It provides uniform matte surface finish to the machined surface. Bead blasting is a manual process. It can be used in applications where dimensional tolerance is not a key concern.
- Anodizing: Anodizing type II is used for making aesthetically pleasing surfaces. Anodizing type III produces thick coatings that provide excellent corrosion and wear resistance. Type III requires closer process control. Hence the cost is higher than type II.
- Powder Coating: It is used for applications where high impact strength is required. These additional treatments will also add up to the overall cost
List of leading CNC machine tool manufacturers
- Okuma Corporation
- Haas Automation Inc
- DMG MORI
- Yamazaki Mazak Corporation
- Doosan Machine Tools
- Chiron Group
List of CNC machine tools
- Lathe Tool
- Milling machine
- Swiss style turning tool
- Turn-Mill Centers
- Plasma Cutter
- Electric Discharge Machine
- Laser Cutter
- Water Jet
Benefits of using a CNC Machine
1. Quality of parts
Since CNC is computerized, human error is eliminated. CNC machines manufacture parts with high precision and accuracy. The two copies of a part will be virtually identical with an average variation of 0.020mm. That means CNC can replicate products with uniformity.
The operator is at a safer distance from the machine. The machines work behind a guard or a closed transparent safety door.
3. Less material waste
It uses as much raw material as necessary. Hence, waste can be reduced.
4. Lowers the cost of production
One trained worker can monitor the output of several CNC machines. Thus the amount of labour is reduced. Also, CNC machines can work faster and operate 24/7 as opposed to traditional machining where operators can develop fatigue. CNC machines are stopped only for maintenance purposes.
5. Complex Shapes
CNC machines enable production of complex shapes that were earlier not possible to produce using traditional methods.
CNC machining has advantages over traditional machining. Manufacturers who are still using traditional machining can think of using CNC machining to increase their productivity.
Alternatives to CNC Machining
Every application is different. There are alternatives to CNC machining which may prove more economical for specific applications.
1. Additive Manufacturing
It is an opposite process to CNC machining. The process takes a layer-by-layer approach where the successive layers of material are added to create the required object. Within additive manufacturing, seven different technologies are available to manufacture a product
2. Molding and Casting
If we want to replicate an object, mold and cast can be used.
Mold: A mold is an impression of an object. The mold is hollow in nature. The process of preparing mold is known as molding.
Cast: After the mold is prepared, a material (in liquid form) is poured into the hollow cavity of the mold. The liquid is allowed to solidify. Upon solidification, the material becomes a replica of the object. This process is known as casting.
3. Forming Process
In this process, the workpiece/raw material is converted into a desired product by changing the shape/form of the workpiece. The shape can be changed by applying stresses such as tensile, compressive, bending, shear, etc. During this process material doesn’t lose its mass but only its form.
Forming Process includes sheet metal fabrication, forging, pressing and extrusion.
4. Joining Process
This process is used to join two or more parts. Joining process can be used to create assemblies.
Joining process includes mechanical fastening, welding, brazing, soldering and adhesive bonding.
Karkhana.io – Your Ally for On-demand, CNC Manufacturing
Karkhana.io is India’s foremost on-demand manufacturing company. We partner with start-ups, small & medium enterprises and large businesses, and address their prototyping and mass production requirements. We have a large number of trusted vendors with manufacturing capabilities spanning 3D printing services, vacuum casting, sheet metal fabrication, CNC machining, and injection molding.
Our network of CNC machining facilities can produce complex prototypes and low-volume production as well as high-volume production runs of precision machined parts. We help clients with selecting the right material and providing the best way to optimize the design. We work with a large network of manufacturers that together have over 100+ professional machines. Therefore, we can fulfill both high-volume and low-volume production requirements, and we offer competitive pricing.
Hence, if you are searching for a partner to help you with your CNC machining requirements, reach out to us!
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Tangu nyakati za kale wanadamu wamekuwa wakibuni njia za kufanya kazi ngumu na zinazorudiwa-rudiwa ziwe za kiotomatiki. Kuna mifano mbalimbali kuanzia historia ya kale hadi nyakati za kisasa ikiwa ni pamoja na watermills kwa ajili ya kusaga nafaka, chemchemi moja kwa moja, Johannes Gutenberg's kuchapisha vyombo vya habari, James Watt's injini ya mvuke, Ford's kusonga mstari wa mkutano na Robotic Process Automation. Ingawa kuna aina mbalimbali za teknolojia za kiotomatiki, kuna aina moja maalum ya kiotomatiki ambayo imebadilisha maisha yetu yaani programu ya kiotomatiki. Tuna uwezo wa kuelekeza mashine kufanya kazi fulani hususa. Mmoja wa waanzilishi alikuwa Joseph Marie Jacquard ambaye alitumia kadi za punch ili kuendesha utengenezaji wa mifumo. Tangu wakati huo uvumbuzi na uvumbuzi umefanyika katika sekta mbalimbali. Sekta moja ambayo ilipitisha aina hii ya automatisering ni sekta ya utengenezaji. Walitumia Udhibiti wa Hesabu ili kuendesha utaratibu wa kutengeneza mashine. Maagizo hutolewa kwa mashine katika fomu ya tarakimu, herufi na alama. Kadi iliyochongwa ina namba, herufi, na alama hizo. Kadi hiyo huingizwa ndani ya mashine, kisha kitengo cha kudhibiti husoma na kubadilisha maagizo hayo kuwa ishara za umeme. Kisha ishara ya umeme ni kutumwa kuendesha motors ambayo hubadilisha ishara hizi katika harakati ya mitambo ya chombo na au workpiece kufanya kazi machining. Kitengo cha maoni ni sasa katika mashine ambayo feeds nyuma data halisi harakati kwa kitengo cha kudhibiti kwa ajili ya kurekebisha makosa. Baada ya maendeleo katika teknolojia ya kompyuta, mchakato wa machining wa NC uliboreshwa kuwa mchakato wa machining wa CNC. CNC ni kifupi cha Computer Numeric Control. CNC machining ni mbinu ya kiufundi ambayo imetengenezwa na wazalishaji wa vifaa vya umeme zaidi ya miaka 50 iliyopita na bado inatumika katika viwanda vya umeme. CNC machining ni mchakato ambapo sisi kuagiza mashine ya kiwanda na zana kufanya shughuli machining katika mfululizo maalum. Tunatoa maagizo kupitia programu ya kompyuta. Utaratibu huu ni mrithi wa CNC Machining ambapo tunatoa maelekezo kupitia kadi za punched au mkanda wa sumaku. CNC machining ni mchakato wa utengenezaji wa subtractive ambapo tabaka za nyenzo huondolewa kutoka kwa sehemu tupu ili kutengeneza sehemu zilizoboreshwa. Mfumo wa mchakato Jinsi ya kufikia mchakato huu? Mfumo wa mchakato huu unahusisha hatua mbili: - Kuendeleza Programu ya Kompyuta: Tunahitaji kuandaa seti ya maelekezo kwa mashine. Lugha zinazoeleweka na mashine ni G-Code na M-code. - Kuingiza Programu katika CNC Machine: CNC Machine husoma maelekezo kutoka kushoto kwenda kulia na kutoka juu kwenda chini na kisha hutengeneza bidhaa. Hebu tuelewe kila hatua kwa undani. Tutaanza na hatua ya kwanza. G-Code na M-Code ni nini? G-Code na M-Codes ni AlphaNumeric katika asili. G inasimama kwa Geometry. G-Code inashughulikia kipengele cha Geometric na Kukata kwa workpiece. G-nambari inaambia jinsi chombo / workpiece itafanya mwendo, ambapo itaenda. Kwa kutumia G-Code tunaweza kutaja mifumo ya kuratibu, tunaweza kumwambia mashine ambayo vitengo kutumia yaani. Metric au Kiingereza, tunaweza kutaja mfumo wa nafasi yaani Absolute au Incremental, nk. Kwa kutumia G-Code, tunaweza kufikia jiometri inayotakiwa kutoka kwa kipande cha kazi. M inasimama kwa Mashine Miscellaneous. M-Code anaagiza mashine kufanya Non-Kukata Non-Geometric shughuli kama vile <unk> Coolant ON / OFF, Tool Change, Spindle mzunguko CW / CCW, nk. "Alphanumerals kutumika katika CNC programu: G-Code pia ni pamoja na alphanumerals kwamba kuanza na alfabeti mbali na G. Unaweza kupata orodha hapa.""" Mfano wa Programu ya Kompyuta: Hebu tuchukue mfano wa kuchimba shimo. Workpiece ni ya umbo la mraba na vipimo 100mm x 100mm x 5mm, kama inavyoonyeshwa katika Picha ya kwanza, shimo la kipenyo cha 10mm lazima kufungwa katikati ya workpiece. Mipangilio ya kipande cha kazi na chombo inaonyeshwa katika Picha ya 1. Chombo cha kazi na chombo ni juu sawa Z = 0. "Kama ilivyoelezwa katika ""Siemens Sinumeri 802d"" (Manual ya Milling) ya Siemens, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G90, G9 Programu ya mwongozo: Programu lazima kuonekana shughuli machining ambayo itafanywa juu ya workpiece katika mfululizo. Kisha programu ina manually kuendeleza programu yaani bila ya kuchukua msaada kutoka kwa kompyuta. 2. Uwezekano wa kupata Programu ya Mazungumzo: Programu ya Mazungumzo inaruhusu waendeshaji kuzalisha programu kwenye udhibiti wa mashine ya CNC. Opereta anajibu mfululizo wa maswali yaliyoonyeshwa kuhusu workpiece inayokusudiwa. Swali ni pamoja na aina ya vifaa, OD, ID, vipimo, urefu sehemu, na kadhalika. Baada ya maswali kujibiwa, udhibiti hutokeza programu. Majadiliano ya Programu inaweza kufanyika ama juu ya sakafu ya duka au kwenye kompyuta ya kibinafsi. 3. Uwe na mtazamo wa kweli Programu ya CAD (Computer Aided Design) na programu ya CAD (Computer Aided Manufacturing) Kwanza, programu huunda mfano wa CAD wa sehemu inayopaswa kutengenezwa. Kisha programu lazima kuhamisha mtindo huu kwa programu CAM. Kama programu ina CAD na CAM kama vifurushi tofauti, programu lazima kuagiza faili CAD katika programu CAM. Kama programu ina CAD na CAM jumuishi katika mfuko mmoja basi hakuna haja ya kuagiza au kubadilisha faili CAD. Kwa mfano, programu ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine ya mashine. Toolpath ni njia kwamba kukata chombo itafuata mashine sehemu. Mara baada ya toolpath ni yanayotokana, programu inaweza kukimbia simulation kufanya kukutana ukaguzi. Mara baada ya toolpath ni kukamilika, programu hutumia Post Processor kuzalisha programu. Jukumu la baada ya processor ni kusoma data toolpath na kugeuza katika programu ambayo inaweza kusoma na mtawala mashine. Programu inaweza kuhamishwa kwa CNC mashine controller kutumia wachukuaji wa data kama vile USB. Kuona Faida na Hasara za kila njia, tembelea Nini CNC programu style bora suits shughuli yako? Hebu tuelewe vipengele vya mashine ya CNC na jinsi inafanya kazi. Sehemu za msingi za CNC: Sehemu za msingi za CNC ni: Vifaa vya kuingiza: Vifaa vya chini hutumiwa kuhamisha programu kwa mashine ya CNC. - Floppy Disk: Ni kifaa kidogo cha kuhifadhi cha sumaku. Floppy ni nyeti kwa mashamba makubwa ya sumaku, vumbi na scratches. Floppy inaweza kuharibika haraka na inaweza kuwa haiwezi kusomeka baada ya miaka mitatu tu. - USB flash drive: Ni removable na rewritable diski ngumu. Ni portable na compact katika asili na ina ukubwa wa kuhifadhi zaidi kuliko diski floppy. - Serial mawasiliano: uhamisho wa data inaweza kufanyika kupitia bandari ya mawasiliano ya mfululizo. Bandari ni kujengwa juu ya RS-232 kiwango. -: Programu inaweza kuhamishwa kutoka kwa kompyuta kwa mashine ya CNC kupitia kebo ya mawasiliano ya ethernet. Kampuni nyingi zilijenga LAN kama miundombinu yao. - Wireless: Programu inaweza kuhamishwa kwa mashine ya CNC kupitia Wi-Fi. 2. Uwezekano wa kupata Mashine chombo mashine ambayo inakidhi chini ya masharti inajulikana kama chombo cha mashine. - Ni nguvu kuendeshwa - Ni non-portable - Ina thamani ya kutosha katika suala la uwezo na utendaji - Ina kifaa cha kukata kwamba hufanya kazi machining juu ya workpiece - Inaweza kufanya zaidi ya aina moja ya kazi machining. Mifano ya mashine zana ni pamoja na mashine lathe, mashine milling, nk. Mashine ya zana inajumuisha meza ya kazi, spindle, motors, zana za kukata, vifaa vya kazi na vifaa vingine ambavyo husaidia katika operesheni ya usindikaji. 3. Uwe na mtazamo wa kweli Mfumo wa kuendesha gari hutumiwa kutoa mwendo uliodhibitiwa kwa vipengele vya zana za mashine za CNC kama vile meza ya kazi, spindle ya zana, nk. Mifumo ya kuendesha inayotumiwa katika mashine ya CNC ni: a. Feed Drive: Feed Drive ni kutumika kudhibiti nafasi na kasi ya slide au meza ya mashine CNC. Drive kulisha ni kutumika kutoa mwendo linear kwa workpiece au chombo. Feed drive inajumuisha motor pamoja na utaratibu. Motor hutoa mwendo wa mzunguko na utaratibu hubadilisha mwendo wa mzunguko kuwa mwendo wa mstari. Mfano kwa ajili ya motor ni servo motor na kwa ajili ya utaratibu ni mpira kuongoza screw. Spindle Drive: Spindle Drive hutoa nguvu ya kukata ambayo inahitajika kwa machining workpiece. nguvu ya kukata ni zinazozalishwa kwa njia ya mwendo angular ya workpiece au chombo. Spindle Drive inajumuisha spindle motor ambayo hutoa mwendo angular kwa spindle. Spindle uhamisho mwendo angular kwa workpiece au chombo kama wao ni kushikamana na spindle. Mfano wa Spindle Drive unaonyeshwa katika Picha 4. 4. Uwe na uhakika Mfumo wa maoni Inatumiwa katika mashine za CNC za mzunguko uliofungwa. Mfumo huu hutumiwa kutuma nafasi halisi na data ya kasi halisi kwa MCU. Takwimu ni kutumika kurekebisha makosa kati ya thamani maalum na thamani halisi. Vifaa ambavyo vinaweza kutumiwa kupima nafasi ni encoders na transducers linear. Kifaa kinachoweza kutumiwa kupima mwendo ni tachometer. 5. Uwe na mtazamo mzuri. Mashine Control Unit (MCU) Display Unit Ni kifaa maingiliano kati ya operator na mashine. Inaonyesha data kama vile hali ya nafasi, spindle rpm, kiwango cha kulisha, programu sehemu, nk. Jinsi gani mashine ya CNC inafanya kazi? MCU hubadilisha programu iliyoingizwa kuwa ishara za umeme na kuituma kwa amplifier kuendesha motor. Motor inafanya kazi sehemu za chombo cha mashine kufanya vitendo vya kukata na kazi nyingine za msaidizi. Mfumo wa maoni hufuatilia pato halisi na hutuma data kwa MCU. MCU ni moja ya njia za kuamua makosa. Ikiwa kuna kosa lolote, MCU hutengeneza ishara za umeme kwa motor na kuondoa kosa. Vifaa vya CNC: Vifaa vya CNC vinaweza kutumika kwa mashine ya CNC, lakini kuna aina kadhaa za vifaa vya CNC vinaweza kutumika kwa mashine ya CNC. Kwa mfano, zirconia inaweza kutengenezwa kwa CNC kwa ajili ya matumizi ya meno. Kazi kama vile kuchonga, beveling, kusaga, kuchimba visima, kusaga na polishing inaweza kufanyika juu ya kioo kutumia CNC. Viwanda vya macho vimetumia CNC kwa mashine ya kioo. Kutengeneza plastiki si sawa na kutengeneza metali. Mojawapo ya magumu ni kuongezeka kwa joto. Utaratibu wa kutengeneza mashine huhusisha msuguano na hivyo joto hutokezwa. Kama joto si kudhibitiwa wakati wa mchakato wa machining inaweza kusababisha mabadiliko katika uvumilivu, inaweza kufikia hatua ya laini ya plastiki na katika kesi ya thermosets inaweza kuchoma uso. Tatizo jingine ni kufanya kazi za kusaga plastiki. Mtetemeko wa sehemu wakati wa operesheni inaweza kuacha alama chatter juu ya sehemu. CNC routers kuwa na utupu chuck kama kifaa workholding. Kutumia shughuli za usindikaji kwa ajili ya plastiki ina faida. CNC machining huondoa haja ya mold na hivyo hupunguza gharama na nyakati za kuanza. Vifaa vingine kama vile PTFE na UHMW haziwezi kufanyizwa na zinahitaji mashine. Plastiki zinazotumiwa kwa CNC ni Acrylic, PVC, PMMA, Nylon, ABS, POM, PTFE, HDPE na PEEK. Composites inaweza kuwa machined juu ya CNC. Asili ya vifaa composite ina changamoto kwa ajili ya shughuli za machining. Vifaa vilivyofanyizwa hutengenezwa kwa matrix na nyuzi. Matrix ina conductivity chini ya joto na nyuzi ni abrasive. Jambo hilo hutokeza tatizo katika kubuni vifaa. Joto si kusafirishwa mbali na makali ya kukata na nyuzi inaweza kusababisha haraka chombo kuvaa. Kukata utendaji inategemea wote chombo jiometri na chombo nyenzo. Uchaguzi wa zana zisizo sahihi inaweza kusababisha delamination, kutofautiana kukata jiometri, shimo exit deburring na haraka chombo kuvaa. Ili kukabiliana na tatizo hilo, vifaa vitatu tofauti vinaweza kutumiwa kutengeneza vifaa vya mchanganyiko. Ni Carbide, Coated Carbide na Polycrystalline Diamond (PCD). Vifaa vinavyotumiwa kutengeneza vifaa vilivyotengenezwa kwa vifaa vilivyotengenezwa kwa njia tofauti-tofauti mara nyingi hutengenezwa kwa ajili ya watu binafsi. Mashine ya kutengeneza nyuzi za kuunganisha nyuzi za kuunganisha nyuzi za kuunganisha nyuzi za kuunganisha nyuzi za kuunganisha nyuzi za kuunganisha nyuzi za kuunganisha nyuzi za kuunganisha nyuzi za kuunganisha nyuzi za kuunganisha nyuzi. Vifaa vinavyotumiwa sana ni CFRP (Carbon Fiber Reinforced Plastic). Paneli zilizotengenezwa kwa mchanganyiko wa alumini kama Dibond zinaweza kutumika kwa CNC Machining. Vipengele vinavyoathiri gharama ya CNC Machining gharama itategemea: - malighafi: Ni pamoja na gharama ya malighafi yenyewe. Upatikanaji wa malighafi pia ni jambo linaloathiri gharama. Vifaa ambavyo ni vigumu kupata vitakuwa ghali zaidi kuliko vifaa ambavyo vinapatikana kwa urahisi. Machinists kununua vifaa katika vitalu na wao itabidi malipo kwa ajili ya matumizi yote ya vitalu. Wateja wanapaswa kujaribu kuweka sehemu nyingi kadiri wawezavyo katika kiunzi. Kutumia vitalu vichache kunaweza kuokoa pesa kwa muda mrefu. - Machinability: Vifaa ambavyo vina machinability ya chini itachukua muda zaidi na juhudi ya mashine. Mbali na wakati na juhudi, vifaa hivi pia hutumia umajimaji wa kukata, umeme na zana za kukata. Vifaa ambavyo vina uwezo mkubwa wa kutengenezwa vinaweza kutengenezwa haraka zaidi. Hatua za ziada: Ikiwa nyenzo hiyo ni hatari, basi hatua za ziada zitachukuliwa. Mfano ni machining ya composites. Wakati wa kutengeneza mashine, vumbi nyingi huinuliwa. Vumbi hilo linaweza kuhatarisha afya na kuharibu vifaa vya kudhibiti mashine. Ili kudhibiti vumbi hili sahihi cartridge style vumbi mkusanyaji ni imewekwa. Hatua hizo za ziada zitaongeza gharama. 2. Uwezekano wa kupata Vifaa vya utengenezaji Maduka huweka kiwango cha saa kwa kuendesha mashine. Kiwango hiki inategemea: - Idadi ya mhimili. - Upasuaji unaopaswa kufanywa. Mfano: kuchimba visima, kusaga, nk. - idadi ya mashine kutumika i.e moja au zaidi ya moja. - Uwezo na ukubwa wa vifaa. - Gharama ya vifaa vya kukata. Vipimo vya chini vya kutofautiana vinaweza kuongeza gharama ya usindikaji wa CNC. Uvumilivu mkali zaidi huhitaji wakati mwingi na jitihada nyingi zaidi za kutengeneza sehemu hiyo. Pia inahitaji vifaa bora vya kudhibiti ubora kwa ajili ya ukaguzi. Uvumilivu tight zaidi itaamua ambayo zana, mashine na mbinu za kukata kutumika kwa ajili ya utengenezaji wa sehemu. Uvumilivu lazima utolewe kwa vipengele vinavyofaa tu. Kwa mfano: maeneo ya kuoa. Ikiwa uvumilivu hutolewa kwa kila kipimo, gharama itaongezeka kwa sababu ya kuongezeka kwa muda wa kuanzisha, marekebisho katika programu za kompyuta na kwa sababu ya scraps na rework. 4. Uwe na uhakika Idadi ya sehemu Opereta inahitaji muda wa kuanzisha mashine kwa ajili ya utengenezaji wa sehemu. Gharama hii ya kuanzisha itakuwa fasta bila kujali wingi. Gharama sawa ya kuanzisha inaweza kupewa kiasi kimoja na vilevile kiasi kikubwa. Kama sisi amri kwa wingi, gharama ya jumla itaongezeka lakini gharama kwa kila sehemu itapungua. Pia, ikiwa tunagiza kwa wingi, duka la mashine linaweza kununua malighafi kwa wingi kwa bei bora. Ingawa CNC ni automatiska, uingiliaji wa mwongozo inahitajika kwa kazi chini. Kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano, kwa mfano. Kwa hivyo, gharama hii inaweza kuondolewa kwa kuandaa faili ya CAD. - Programu: Mhandisi wa utengenezaji hukagua muundo na kutoa mapendekezo. Kisha programu hiyo hutayarishwa na programu ya kompyuta. - Kuanzisha: Opereta ana kupakia zana katika chombo cha kubadilisha zana, kuanzisha mashine na workpiece. - Post usindikaji: Ni inahusisha kusafisha, kuondoa msaada na kusanyiko la sehemu. Vipengele vya hali ya juu kama vile ukubwa wa shimo lisilo la kawaida, maandishi na kuta nyembamba zinaweza kuongeza gharama ya usindikaji wa CNC. Vipengele tata huchukua muda zaidi wa programu, huhitaji vifaa maalumu na miundo mingi ili kutengeneza sehemu. Ongezeko la muda wa kukimbia itaongeza gharama. Kwa kuondoa mambo yasiyo ya lazima, tunaweza kurahisisha muundo. Kila inapowezekana, tunaweza kuchagua maandishi yaliyochongwa badala ya maandishi yaliyoinuliwa. Kwa kuta nyembamba, kanuni nzuri ni uwiano wa upana-kwa-urefu wa 3:1. Mashine ya kuchora inaweza kuundwa kwa kuongeza mwelekeo wa pembe 1, 2 na 3 7. Uwe na mtazamo gani? Matibabu ya ziada Matibabu haya ni pamoja na shughuli za kumaliza uso ambazo zitafanywa kwenye sehemu ya mashine. Idadi ya shughuli za kumaliza inaweza kutumika kuboresha roughness uso, aesthetics na kuvunja upinzani. Baadhi ya shughuli za kumaliza ni: - Kama machined: Hii kumaliza inaweza kuwa ndogo inayoonekana chombo alama. Sehemu ni zinazotolewa na thamani maalum ya roughness uso. Thamani hizi zimepangwa mapema na zinadhibitiwa na viwango vya tasnia. Kwa mfano, kwa mashine ya CNC, kiwango cha juu cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango cha kiwango. Chini ya Ra thamani zaidi juhudi na kudhibiti ubora inahitajika na kwa hiyo gharama itaongezeka. Kama sehemu machined kuwa na tolerance tightest kipimo. - Bead Blasting: Ni hutoa sare matte uso kumaliza kwa uso machined. Kupiga risasi kwa shanga ni mchakato wa mikono. Inaweza kutumika katika maombi ambapo uvumilivu wa kipimo si wasiwasi muhimu. - Anodizing: Anodizing aina II ni kutumika kwa ajili ya kufanya aesthetically pleasing nyuso. Anodizing aina III inazalisha mipako nene ambayo kutoa excellent kutu na kuvaa upinzani. Aina ya tatu inahitaji udhibiti wa mchakato wa karibu. Kwa hiyo gharama ni ya juu kuliko aina ya pili. - Powder Coating: Ni kutumika kwa ajili ya maombi ambapo nguvu ya juu ya athari inahitajika. "Kama ilivyoelezwa hapo juu, ""Mashine za CNC"" ni mashine za CNC zinazotumiwa na kampuni ya Okuma Corporation, Haas Automation, DMG, Mori, Yamazaki, Mazaki, na Mashine za CNC zinazotumiwa na kampuni ya Doosan, na ""Mashine za CNC zinazotumiwa na kampuni ya Chiron"" ni mashine za CNC zinazotumiwa na mashine ya CNC." Ubora wa sehemu Kwa kuwa CNC ni kompyuta, kosa la kibinadamu huondolewa. CNC mashine kutengeneza sehemu kwa usahihi wa juu. Nakala mbili za sehemu itakuwa karibu sawa na tofauti ya wastani ya 0.020mm. CNC inaweza kuunda bidhaa kwa usawa. Mfanyakazi yuko mbali zaidi na mashine hiyo. Mashine hufanya kazi nyuma ya mlinzi au mlango wa usalama uliofungwa ulio wazi. 3. Uwe na mtazamo wa kweli Matumizi ya chini ya vifaa Inatumia malighafi nyingi kama inahitajika. Kwa hiyo, taka zaweza kupunguzwa. 4. Uwe na uhakika Kwa sababu ya gharama ya uzalishaji, wafanyakazi mmoja wa CNC anaweza kusimamia uzalishaji wa mashine kadhaa za CNC. Hivyo kiasi cha kazi hupunguzwa. CNC mashine inaweza kufanya kazi kwa kasi zaidi na kufanya kazi 24 7 tofauti na machining ya jadi ambapo waendeshaji wanaweza kupata uchovu. CNC mashine ni kusimamishwa tu kwa ajili ya matengenezo. 5. Uwe na mtazamo mzuri. Mashine za CNC zinatoa uwezo wa kutengeneza maumbo magumu ambayo hapo awali hayakuweza kutengenezwa kwa kutumia mbinu za jadi. CNC machining ina faida juu ya machining jadi. Watengenezaji ambao bado wanatumia mashine za jadi wanaweza kufikiria kutumia mashine za CNC ili kuongeza uzalishaji wao. Njia mbadala za CNC Machining Kila maombi ni tofauti. Kuna mbadala kwa CNC machining ambayo inaweza kuthibitisha kiuchumi zaidi kwa ajili ya maombi maalum. 1. Uwe na mtazamo wa kweli Additive viwanda ni mchakato kinyume na CNC machining. Utaratibu inachukua tabaka kwa tabaka mbinu ambapo tabaka mfululizo wa nyenzo ni aliongeza kuunda kitu required. Katika utengenezaji wa nyongeza, teknolojia saba tofauti zinapatikana kutengeneza bidhaa 2. Kuunda na Kutengeneza Ikiwa tunataka kuiga kitu, muundo na kutengeneza inaweza kutumika. Mfano: Mfano ni hisia ya kitu fulani. Aina hiyo ya ukungu ni ya kawaida. Utaratibu wa kutayarisha ukungu unajulikana kama ukungu. Baada ya kufanyizwa, kitu fulani (katika umbo la kioevu) hutiririka ndani ya shimo hilo. Kioevu huruhusiwa kuimarika. Baada ya kufanyizwa kuwa imara, nyenzo hiyo inakuwa nakala ya kitu hicho. Utaratibu huo unaitwa kutengeneza chuma. 3. Uwe na mtazamo wa kweli Katika mchakato huu, workpiece ni kubadilishwa katika bidhaa inayotakiwa kwa kubadilisha umbo la workpiece. Umbo inaweza kubadilishwa kwa kutumia mkazo kama vile tensile, compressive, bending, shear, nk. Wakati wa mchakato huu nyenzo haina kupoteza wingi wake lakini tu fomu yake. Utaratibu wa kuunda ni pamoja na utengenezaji wa karatasi ya chuma, kufanyiza, kushinikiza na extrusion. 4. Uwe na uhakika Kujiunga mchakato Utaratibu huu hutumiwa kuungana sehemu mbili au zaidi. Kujiunga mchakato inaweza kutumika kuunda makusanyiko. Kujiunga mchakato ni pamoja na mechanical fastening, kulehemu, brazing, soldering na adhesive bonding. Karkhana.io <unk> Mshirika wako kwa On-Demand, CNC Manufacturing Karkhana.io ni India <unk>s mbele juu ya mahitaji ya kampuni ya utengenezaji. Sisi kushirikiana na startups, makampuni madogo na ya kati na biashara kubwa, na kushughulikia prototyping yao na mahitaji ya uzalishaji wa wingi. Tuna idadi kubwa ya wauzaji wa kuaminika na uwezo wa utengenezaji unaozunguka huduma za uchapishaji wa 3D, kutupwa kwa utupu, utengenezaji wa karatasi, usindikaji wa CNC, na kutengeneza sindano. Mtandao wetu wa vifaa vya CNC unaweza kutengeneza prototypes ngumu na uzalishaji wa kiasi kidogo, pamoja na uzalishaji wa kiasi kikubwa cha vipande vya usahihi. Sisi kusaidia wateja na kuchagua vifaa sahihi na kutoa njia bora ya kuboresha kubuni. Sisi ni kampuni ya kuvutia ya kuajiri na pamoja na kampuni yetu ya kuajiri, tuna zaidi ya 100+ mashine za kitaalamu. Kwa hiyo, tunaweza kutimiza mahitaji ya uzalishaji wa kiasi kikubwa na kiasi kidogo, na tunatoa bei ya ushindani. Kwa hiyo, kama wewe ni kuangalia kwa mpenzi kukusaidia na mahitaji yako CNC machining, kuwasiliana na sisi! "Picha ya ""Mwanzoni"" ya ""Mwanzoni"" ya ""Mwanzoni"" ya ""Mwanzoni"" ya ""Mwanzoni"" ya ""Mwanzoni"" ya ""Mwanzoni"" ya ""Mwanzoni"" ya ""Mwanzoni"" ya ""Mwanzoni"" ya ""Mwanzoni"" ya ""Mwanzoni"" ya ""Mwanzoni"" ya ""Mwanzoni"" ya ""Mwanzoni"" ya ""Mwanzoni"" ya ""Mwanzoni"""