When issues arise with your CNC machine, what course of action is best? Should you attempt repairs yourself, contact the supplier, or search online?
As a business providing CNC machining for over a decade, we’ve encountered numerous common problems during the process. Through experience, we understand these issues and how to address them. Challenges range from burned surfaces to power failures to parts getting stuck or machining inaccuracies.
In this article, we outline some frequent CNC machining problems and preliminary solutions. Our goal is to help you determine the most appropriate first steps when difficulties occur.When issues arise with your CNC machine, what course of action is best?
#1 Using the wrong cutting tools/settings
Using inappropriate cutting tools or settings for a given machining task is a common issue that can arise in CNC operations. Selecting tools that do not suit the specific job requirements all too often results in subpar surface quality on the finished workpiece material. Deficiencies in the material surface finish manifest in various ways such as rough, uneven edges along cut lines, visible knife marks or streaks imprinted onto exposed surfaces, and prominently raised blemishes or burn marks appearing at corners and edges. Employing tools that do not match the material or machining process can also lead to significantly accelerated wear and potential damage to the tools themselves over repeated use.
Poor surface finish outcomes may additionally stem from using dull, worn-down cutting tools that have lost their sharp, precise edges due to overuse without proper sharpening or replacement. Setting an unsuitable feed rate ratio when programming the CNC machine is another potential cause, as pushing material through at the wrong speed relative to the tool rotation can degrade the quality of the finished surfaces. Even when using adequately sharp tools, choosing ones that are the wrong size, made from subpar quality material, or simply an improper match for the job at hand and workpiece material composition can result in a less-than-ideal finish.
To effectively address issues stemming from the selection and use of inappropriate or mismatched tools and settings, it is imperative to exercise great care in choosing tools, inserts, and machining parameters that are optimally suited for each specific job and material being cut or shaped. Proactively selecting the proper tools and setting the correct speeds and feeds based on an understanding of tool and material properties helps avoid many surface quality complaints and also protects against premature wear of expensive cutting tools that can drive up costs if replaced too frequently. Thoroughly vetting and testing tool-material-process combinations for each application is key to attaining quality results.
#2 Programming Errors
A significant source of problems that can arise when utilizing computer numerical control machines for manufacturing stems from flaws and mistakes made during the programming phase of operations. As CNC systems rely on coded computer instructions to precisely maneuver cutting tools and other machine components through complex patterns and motions, errors in the programming code itself can easily lead to all manner of issues. Programming errors may come about due to an incomplete or incorrect understanding of the various G and M code commands used by the machine controller to designate functions and sequences. Mistakes could also manifest from inputting the wrong parameter settings into the controller or entering invalid variable data values.
To help address programming mistakes that may occur, it is crucial that new operators receive thorough training on the proper techniques for developing CNC machine programs. The machine supplier or experienced personnel already working on the manufacturing floor should provide newcomers with an in-depth programming manual covering all code functions as well as motion planning and machine operation. Hands-on instruction should be given that allows trainees to gain comprehensive knowledge of how to author code that will efficiently direct the machine through necessary toolpaths and procedures without flaws. Only with a comprehensive education on programming language and methods can operators begin crafting error-free programs capable of smoothly manufacturing high-quality parts with minimal wasted time, material, or machine runs. Reducing programming mistakes through training ultimately serves to help optimize productivity and part quality.
#3 Chuck and Clamp Clamping/Unclamping Problems
Holding workpieces firmly during machining prevents defects and injuries. To fix clamping issues, check:
1. Check part placement for full surface contact grip.
2. Check hydraulic pressure and pump settings provide tight holding.
3. Inspect jaws sizes and positions secure material properly.
4. Help troubleshoot stuck chucks – check foot switch wires and clean inside.
5. Check enough lubricant where needed and movable parts work smoothly.
6. Check chuck responds correctly to commands.
7. Inspect valves and connectors allow clamping to function.
8. Check hydraulic lines work and aren’t loose.
Clamping correctly is important for safety during outputs and equipment life. Thoroughly address all clamping problems. Together ensure components stay securely clamped.
#4 Workers Lack Needed Skills
Modern computer-controlled machines are getting more advanced. CNC operators now need different skills. Experienced machinists used to mostly rely on what they learned on the job. Now these complex computer machines require much more knowledge.
Operators must understand programming to plan each manufacturing step from start to finish. They must pick the best tools and sequences to exactly meet the product designs. Even experienced workers won’t get these powerful machines to work as well without the right organizing abilities and technical know-how to make detailed programs mapping out how each part is produced.
To fix this problem, companies must hire people with the skills needed. It’s not enough for candidates to only know machining. They must also be able to visualize complex manufacturing processes from beginning to end. Good hires will have strong problem-solving abilities to handle any issues. Most importantly, employers need people highly skilled in computer languages to write the unique instructions for each job. Only by developing these advanced planning, programming and other skills across all employees can companies be sure workflows use the machines in the most effective ways possible. Retraining current staff is another way to reach this goal.
Post time: Dec-06-2023
