We are a leading producer of CNC machine tools in Asia, therefore we are aware of the typical difficulties that can occur during milling. These include the entire gamut, ranging from burn marks on the surfaces of machined parts to issues with the power supply, the jamming of various moving parts, and improperly made parts.
We’ll try to address some of the most typical problems and challenges with CNC machining in this article and provide answers. CNC controllers are a great invention of modern technology, but the more you rely on them, the more issues you’ll have. If you require CNC controller repair, contact us.
The Big Four CNC Machine Tool Mistakes
Our observations show that machinists encounter four main challenges while using CNC lathes, milling machines, and multi-axis machining centers.
1. Using incorrect cutting equipment or settings
Choosing the wrong cutting tool for the job is typically the cause of low-quality material finishes. This may show up on the material’s corners or edges as jagged edges, surface cutter markings, raised marks, or burn marks. This error could result in considerable tool wear.
An ineffective feed speed ratio or a dull tool may be to blame for poor material finishes. Another possible cause could be incorrect tool dimensions in terms of size, quality, or compatibility with the material.
This can be solved by choosing the right tool and environment for the task and material.
2 programming errors
Since CNC machines are highly complex pieces of equipment, programming is frequently to blame for many of the issues that arise during CNC milling. These could be the result of poor setup, wrong data variables being entered into the CNC controller, or a lack of knowledge of the different G and M codes used by the controller.
In order to fix these issues, it’s essential that new operators receive adequate training in the different ways that CNC machines can be programmed. New operators should receive complete training on machine operation, motion sequencing, and other topics from seasoned operators on the shop floor.
3 Negligent maintenance of CNC machines
CNC machine tools are intricate, constantly moving machines that need frequent upkeep to operate at their peak efficiency.
If dirt, materials, and other debris are not removed, a buildup may develop over time and result in machine malfunctions or imprecise machining.
In order to prevent this, machine operators must follow a detailed maintenance programme for the tools they are utilizing. They should also regularly check the levels of coolants or airflow, for example, air filters, to ensure that operations continue to run smoothly and without interruption.
Be aware that an overheated spindle could result from a blocked air filter in your cooling system.
4 Poor Worker Skill and Training
Today’s CNC machine tool operators need a specific set of skills due to the expanding usage of computing and programming. Workers lack the planning, organizing, and programming skills required to maximize the production of these machines, even if they are skilled in machining and have experience with older models of equipment.
If you want to be sure that this problem is resolved, hire the correct machine operators who can envision and plan the machining process, select the proper tools and sequences for the work, and build the programme.
5 Power Supply Problems
On rare occasions, issues with the power supply could make the display or other parts of the CNC machine tool inoperative. Verify that the input side of the power and supply is receiving the proper voltage and power to resolve the issue. The secondary side, or output, should then be checked to ensure correct operation.
It is advised that you allow a qualified individual to conduct the examination.
Consider detaching the output connections when the power is off, resuming the device, and then retesting the output side if there is no power or a low voltage reading. Additionally, you can look at the fuses to see if they are blown and the machines’ LEDs to see if they are on. For more information on ASCO Solenoid Valves. get in touch.
6 Automatic tool changers: Problems
You could occasionally experience issues with the automatic tool changeover on your CNC machine tool. To solve this problem, it would be helpful to analyze each step of the tool-changing process and what went wrong.
Check to see sure the base, gripper arm, tool holder, support arm, and tool magazines are all functioning properly. Alternately, see if the swiveling and mechanical arm action work as intended. Keep coolant and chips away from the tool holders and the automatic tool changer.
7 Chatter and vibration from machinery
When your CNC machine vibrates while it is operating, your tool’s life may be significantly decreased, its durability may be impaired, and the quality of your machined product may suffer. This can be found out by simply listening to the noise that is made, which can occasionally be rather loud.
To solve the issue, you must identify whether the chatter is coming from the tool or the workpiece. Additionally, you can alter the RPM of your machining process so that the frequencies of the operation and the material are not synchronized.
Occasionally, overheating can occur during time-consuming, high-volume milling procedures. Your CNC machine tool may be capable of producing internal temperatures of 150 degrees or higher. The results of your machining project, the tool utilized, and the CNC machine itself may suffer as a result.
To avoid this, be sure to regularly empty all channels and clean the machine to remove all dirt, soil, and debris. Schedule the removal of any metal shavings and cutting fluids.
Prolonged operation at maximum rpm is the primary cause of a machine spindle overheating. A grease-lubricated spindle cannot maintain full speed for extended periods of time. A spindle with air-oil lubrication is preferred, however an oil-jet lubricated spindle, like the one used by Hwacheon, can run for long periods of time even at maximum rpm.
Alterations in the ambient temperature of the workshop have an impact on machine overheating as well. Wind and air draughts entering through open windows or doors might affect the accuracy of your precision machine equipment.
10. Unreliable CNC Tool Partners
Choosing the right CNC machine tool partner is perhaps the most important step in reducing the possibility of machine problems and human errors.
Errors and defects with machine tools may have significant long-term expenses for your company. To guarantee that issues are kept to a minimum, work with reliable and skilled CNC machine tool vendors who provide a comprehensive after-sales maintenance, training, and servicing package. Contact us to find out more about our inverter repair services.