When To Shove People Out To Make Way For CNC
When To Shove People Out To Make Way For CNC
The normal businessmans mind is always geared towards profit, profit, profit. No matter how much the company spends, at the end of the day, the revenues should exceed the expenses (including tax). Although innovation is a major requirement to a business’ growth, many small-time businesses just lie back in comfort. They think that as long as they’re earning and they have a steady market, its all right.
This holds true for businessmen who are contented with being small-time (though it’s hard to find one). However, for businesses that are aggressive towards getting ahead, acquiring a CNC machine seems to top their list of priorities.
CNC stands for Computer Numerical Control. A CNC machine is a computer “director” which is composed of machine tools that read a specific set of instructions (in G-code) and is able to direct certain manufacturing tasks repetitively. The top industries that use the CNC technology are the Metal and Woodworking industries.
If you are a regular member of a techie forum for entrepreneurs, CNC may be showered with praises because of its performance. Most businessmen also swear by saving a lot of money and time when they started employing CNC technology in their production processes. However, if you are still considering CNC at the expense of the jobs of your employees, it is best that you prefer CNC at two levels: the logical level and the emotional level.
LOGIC-WISE
CNC machines do specific instructions. They will never assume anything, nor rebel against the program loaded to them. Imagine the security of knowing that you will “reap” exactly what you “sowed”. Let’s say, something goes wrong during the process. Assuming the machine is in perfect condition, you CANNOT put the blame on it because it just performed what you told it to do so.
Secondly, there is the blanket of consistency. It provides a certain level of safety and ease to the head supervisor. If you have overseen the operations today, most likely, it will be exactly the same tomorrow. The feeling of knowing what to expect is always a good thing, especially when there’s money involved.
Lastly, there’s speed. CNC machines do not stop to think. After you do the thinking, they do the power-jobs that they need to do. Its that simple. There is a minimized set-up time and back-job time pocket.
What you will find a flaw about CNC though, is that logic-wise, CNC machines cannot think of better ways to perform a task (IF there is a better way). A CNC machine is purely mechanical; when it was sold to you; the salesmen never mentioned the word creative or “innovative”. I hope you did not miss that.
EMOTION-WISE
CNC machines are also assets of the company. When assets like this are purchased, there is little or no emotional investment that goes with it. You won’t even train it! It is expected to do certain tasks and thats saving you a lot of time from all the explaining, demonstration and reminding.
Also, when a CNC machine is performing its task, it is void of any emotion. So no matter how hot the weather is, or how noisy the workplace is, the CNC machine will do its job just like any other day. It is different as compared to people – who have the tendency to space-out when doing very mechanical and tedious jobs.
Although the CNC may want to, it also cannot complain. That’s really convenient. What you will need to note now is your electric bill. Beware, for when getting CNC machines, it may betray you in the form of lofty bills. All the emotions youve saved might just be unleashed.
This day in history…
Powered By Resell Rights .us
This day in history...
Powered By Resell Rights .us
What It Takes to be a CNC Operator
Being a CNC operator may seem a little too easy but take a look at the requirements from companies and you’ll think twice about the difficulty level of being a CNC operator.
Being a CNC operator takes a lot more than just being able to handle long hours of staring at the monitor or creating an input stack for the programs. What it means is that you have to have outstanding programming capabilities and at least basic machining knowledge.
Job Requirements
A CNC operator has to be knowledgeable about blueprint reading. This is because, basic design concepts and construction is hinged heavily on blueprints. Furthermore, the components that are being manufactured by companies that have CNC machines are based on blueprints of a whole structure. Therefore, if you do not know how to read blueprints, you won’t know what to program the machine to do.
Another thing that a CNC operator has to have is familiarization with machine operations. If the operator does not know which machine tools are for which job, or how fast the machine can work, or what the rate of feed is for the machine, or even the depth of the cut needed for the operation, then you wouldn’t be productive and the operation would be a failure.
The most obvious thing that an operator would have to know would be the general operating characteristics of the machine. He/she would have to know what the machine runs ontape, network data input, or floppy. Furthermore, proper data input procedures have to be observed to lower the error ratio. A faulty data input procedure could cause the entire cycle to collapse therefore lowering the level of efficiency.
Working with CNC machines means that you will also be dealing with a lot of computer work. This means that you have to be familiar with basic computer operations. In addition to that, you will have to know how to interpret data in the program output stack.
The company’s requirements and the benefits.
some companies require a lot more than what is written above. Oftentimes, they require applicants to be familiar with the system that they use. Other times, they want the applicants to have no less than five years of experience working in a factory or at least working with a CNC machine. Also, some companies require applicants to undertake a specific training program to ensure the employers that the material they are getting is worth the money they will be shelling out.
However, the benefits that can be reaped is quite solid. Salaries and insurances are often negotiable. Working hours are also a snap! All you would have to do is initiate the cycle and then sit back and occasionally check for glitches. Furthermore, these companies often takes care of their operators as there is always a shortage of skilled enough people to take hold of the position.
So, what does it take to be a CNC operator? To synthesize the requirements, you have to be amazingly determined to pass the requirements of the company you are applying for. And then, you have to be able to quickly restructure the program in case of any glitch that the computer might encounter during the process.
The benefits are solid, but passing the requirements is like surviving the gauntlet. Think about this career.
This day in history…
Powered By Resell Rights .us
This day in history...
Powered By Resell Rights .us
Weighing Technology’s Offers: The Pros and Cons of a CNC
Weighing Technology’s Offers: The Pros and Cons of a CNC Job
Are you good with computers and looking for a job? Well then, consider being a CNC machine operator. Its usually easy, full-time and the name isnt intimidating, right?
If you think that being a Computer Numerical Control (CNC) machine operator may be a bit out of your reach, think again. You dont have to be a math wizard or a programming genius to get that position. But dont jump in just yet! There are a few things that you have to know (and consider! ) before applying for the job.
The first thing that you have to understand is the abbreviation CNC. According to an online encyclopedia, CNC stands for Computer Numerical Control, and refers specifically to a computer controller that reads G-code instructions and drives a machine tool, a powered mechanical device typically used to fabricate components by the selective removal of material. CNC does numerically directed interpolation of a cutting tool in the work envelope of a machine. The operating parameters of the CNC can be altered via a software load program.
THE PROS
The good thing about being in this job is that the workload is actually light. Operators even complain of boredom because the cycles of CNC machines are all automated. All they have to do is initiate the sequence, sit back, watch for malfunctions, adjust the performance of each machine, and turn them off. If your boss is kind enough to let you use an MP3 player while working, then you sure are lucky.
Another good thing about this job is that job openings for this position will always rise. Technology is moving forward. CNC machining will certainly lead the demand because in CNC, a group of machines can be controlled at the same time. That is exactly what big-time companies want, right? To reduced manual overseeing and just leave it to the machines.
Advantage in this job arena is easy too. Statistics show that you will need only a high school diploma and (more importantly) an experience in CNC operations to gain an edge.
THE CONS
The thing is, when youre in this line of work, it is repetitive. One gets bored after doing the same mechanical thing over and over again. As time withers, you will reach a point where you will breathlessly wait for the next paycheck and not actually care about the job. Its emotionally exhausting. Furthermore, programming and operating these machines can be tedious. So, add that up to boredom and you get disproductivity.
Another thing that you should think about is the work environment. Youre going to be working in a factory. And factories are located away from town. If youre not comfortable with being away from the hustle and bustle of the city, this might not be for you.
It can get pretty dangerous. Reports show that although most CNC operators work in a well-lit and smoothly ventilated environment, the high-power machinery poses dangers for them in the form of flying particles of metal and plastic. Also, though most modern machines produce less noise, ear plugs are still recommended by experts.
Lastly, this may not sound like a biggie, but most CNC operators are on their feet all day. They can only sit when the programs are being loaded into the computer. Its pretty comforting that they receive salaries waaaay bigger than those salesladies.
This day in history…
Powered By Resell Rights .us
This day in history...
Powered By Resell Rights .us
Understanding CNC
Have you ever asked yourself how machines in a factory know exactly when to stop making the parts theyre supposed to make? Well, this is all because of Computer Numerical Control (CNC). But to understand CNC, you have to know what Numerical Control (NC) is.
HISTORY
NC machines were first introduced after the 2nd world war as mass production became the trend. These machines were given a set of instructions in punched cards. However, these machines were hard-wired and their parameters were difficult to change.
These NC machines still required a great deal of human intervention. To illustrate this point, try to take a look at a drill press. A lot of actions have to be taken in order to manufacture a product. The process is actually so complicated that a person has to do something almost every step of the production process. This created an avenue for errors to take place as the likelihood of fatigue increased with the quantity growth.
CNC then came into the picture when computers were introduced. Punched cards were replaced by floppy disks, cables, and other software transfer media. This made it easier to manage and edit data.
Production and manufacturing were revolutionized by the increased automation of CNC machines. These machines allowed a degree of added control over the quality and consistency of the components that were manufactured without any additional strain on the operators. This reduced the frequency of errors and allowed the operators time to perform additional tasks. Furthermore, this automation allowed a greater degree of flexibility in the way components are held in the manufacturing process.
With the advent of Computer Aided Manufacturing (CAM), even programming CNC machines is a snap. These programs actually take the bulk of the programming process to make the operation less tedious. However, to be an effective programmer of CNC machines, you have to know what the machine youre working on will be doing. That is why machinists are often the best people for the job.
The ease that the machines provide is hinged heavily on the quality of the machine. Low-cost CNC machines oftentimes have many functions that have to be manually activated. High-cost machines, however, are almost fully automated. The operator only has to load or unload workpieces. Once the cycle has been initiated, the operator just has to sit back and watch for any malfunctions. The stress on the operator is so low that some even complain of boredom in the middle of a cycle.
CODING
The programming language that CNC uses is called a G-Code. These codes actually position the parts and do the work. To be able to have a machine work properly, you have to input the correct variables such as axes, reference points, the machine accessories, and whatnot. Every machine has a different set of variables so you have to be careful to take note of the differences.
Aside from the G-Code, logical commands or parametric programming can be used to make the process more time-efficient. This type of programming language shortens lengthy programs with incremental passes. A loop can also be programmed thereby removing the need for coding repetitions.
Because of these features, parametric programming is more efficient than CAM. It allows users to directly and efficiently make performance adjustments. It also allows extensions to the functionality of the machine it is running on.
And that makes CNC.
This day in history…
Powered By Resell Rights .us
This day in history...
Powered By Resell Rights .us
The Different CNC Machines
CNC has different applications depending on the machines that operate on it. So if you’re a budding operator, you should know the most common machines that can operate on CNC.
Milling
Milling machines are common CNC machines. These devices are used in the shaping of metal and other solid materials. It is basically a rotating cutter and a table. Milling machines are capable of complex toolpaths as the cutter is not limited to a sideways movement but allows for an in and out motion. This movement is precisely controlled by moving the table and the cutter relative to each other. Cutting fluid is then pumped in to lubricate and cool the cut and to remove any swarth that is generated by the cut.
Lathes
Lathes are machines that perform different operations such as sanding, cutting, knurling, deformation, or even drilling. These machines work by spinning various solid objects and then using tools that are symmetric to the axis of rotation. A lathe machine has a single tool in which the workpiece is worked against the tool. The tool is then worked alongside or into the workpiece in order to generate the feed.
Lathes can be used for different operations.
Machining Centers
These are more complex CNC machines that combine milling and turning. As milling was described earlier, turning will be the focus of this section.
Turning is the process by which a central lathe is used in conjunction with the rotation of the material to be turned. The cutting tool is then moved along the two axes of motions to produce accurate dimensions.
Combining turning and milling can produce extremely precise components. And that is what these machines are used for. However, due to the complexity of these machines, operators have to be specialists in order to be able to operate with maximum efficiency.
Electrical discharge machine
An electrical discharge machine (EDM) creates cavities in metals by emitting electric sparks. This process requires an electrode, coolant, a power source, and a tank. The cycle is accomplished by connecting the workpiece to one side of the power supply and then placing it in the tank. An electrode (made in the shape of the cavity required) is then connected to the other side of the power supply.
The tanks is then filled with coolant and the electrode is lowered until a spark jumps between the work and the electrode. As the coolant is a dielectric substance (resists electric currents), it requires a smaller difference in distance in order for a spark to jump through. This means that when the spark appears, the dielectric property has been overcome. The spark then dislodges material thereby creating a cavity in the shape of the electrode.
CNC systems
CNC systems are complex machines that transfer and store data regarding the operation mechanism of the machines. Motion programs include point to point control, straight cut control, and contouring control.
Point to point control means the control of the tools from one point to another in the coordinate plane. This method of control is commonly used in drilling and boring operations.
Straight cut control is the method by which a tool is moved in all axes of the machine. The tool also has the ability to move in a 45 degree angle.
Contouring control is the means to create a toolpath. It moves the tools by interpolating points or coordinates that make up the path for the tool to follow.
This day in history…
Powered By Resell Rights .us
This day in history...
Powered By Resell Rights .us
The CNC Family
You might have not heard of the CNC before, or what it does, or how it makes lofty manufacturing operations a lot easier. However, CNC machining is dubbed as one of the most important factors of most production processes. The common tasks CNCs machines usually perform are drilling holes, tool changing, cooling and lubrication of separate factory machines at the same time.
Lets start with a brief introduction. CNC stands for Computer Numerical Control and it has been around since the early 1970s. Before it was christened CNC, it was called NC, for Numerical Control. When computers were introduced during 1070s, the name changed. It has stroked almost all manufacturing forms in almost all stages of production. CNC machines either substitute some existing manufacturing processes or combine work with them.
A CNC program is just any other set of instructions. Its written like a sentence and the order of operation is chronological. The machine will then execute that set of instructions step-by-step. A special series of CNC words/codes are used to relay what the machine is supposed to do. CNC codes begin with letter addresses (like S for spindle speed, and X, Y & Z for common linear axis motions).
When certain codes are arranged together in a coherent method, this group of CNC codes create a command that is like a sentence. A common CNC machine will only be needing around 40-50 words/codes to program different commands. See, its not very difficult to learn.
Although CNC sounds very independent and do-it-all, there are a few words that you need to know to fully understand CNC operations.
THE CAM
CAM stands for Computer Aided Manufacturing. It simplifies the programming processes which are new, and added to the CNC program regularly. Of course, the easy applications can be programmed with only the simplest machines around: the pen, paper and calculator. However, more complex programs are vital regularly. It is when composing these programs become much more tricky and (worse) tedious.
The CAM is a program that runs on a computer that aids the CNC programmer with the programming. It also works hand-in-hand with the CAD (Computer Aided Design) design drawing (those designs engineers compose/nurture). With the CAM helping, redefinition of the work-piece configuration is not needed. What the CNC programmer is left to do is just to specify the machine operations to be executed and the CAM system will compose the CNC program automatically. Thanks to CAM, programming tediousness will not be a problem to the CNC programmer again.
THE DNC SYSTEM
DNC stands for Distributive Numerical Control. It is a computer that is connected with one or more CNC machines, forming a network. When a program is manually composed and ready to be loaded to the CNC control, it is being typed right into the control. However, this is like using the CNC machine as a luxurious keyboard.
Moreover, if the CNC program is achieved with the help of CAM, it is already in text form and ready to be loaded to the CNC control. The DNC simply distributes the CNC program to more than one CNC machine. Lately, the newest controls are more advanced in terms of networking capabilities and can be networked with, say, the Ethernet.
If its your first time to read and learn about the CNC, it may sound so mighty and ubiquitous. Its about time you learn they also need help from some programming friends such as the CAM and the DNC. No man is an island; but hey, neither are CNC machines.
This day in history…
Powered By Resell Rights .us
This day in history...
Powered By Resell Rights .us
Programming CNC Machines With G-Codes
Ever since the industrial revolution started, the demand to create precise instruments and products is an important factor in large scale manufacturing. Belts, screws, Drills and all movable parts needed to create other products in the assembly line must all be exact and compatible, thus extra care must be taken in order to ensure that all moving parts match perfectly. Computer Numerical Controlled programming has become an extremely important part of this process.
Computer Numerical Controlled Machines are useless without any programming. CNCs rely on pure hard codes in order to execute commands that the Machine Operator wants to do, therefore not only is it needed to learn the mechanics of the whole Computer Numerical Controlled Machine but it is also at the utmost importance that the Machine operator knows how to communicate with the machine, and that is by using G-codes.
Preparatory code/ functions or much commonly called as G-codes are functions in the Computer Numerical Control programming language. The G-codes job is to manage the position of the tool as well as control the step by step commands during the actual work. Basically the G-codes are the most important part of the Computer Numerical Control Programming algorithm.
There are other codes involved in the programming of CNCs such as M-codes that manages the machine, T-codes for managing the tools, and F-codes for the tool feed and tool speed controls. All of these codes are created in a Computer Aided Manufacturing (CAM) software.
G codes as well as the others use the RS-274D as the recommended standard for the Computer Numerical Controlled Machines. This standard was developed by the Electronic Industry association during the 1960s. These standards provide a basis for the creation of Computer Numerical Controlled Programs.
First designs of these standards came from punched paper tapes as the medium standard for data interchange, but now ASCII character bit patterns are the standard for the representation.
G-Codes
Lets discuss the g-codes further, as what I have said earlier G- codes constitute only a part of the Computer Numerical Control Program, in the whole programming algorithm, they are denoted by the letter G, Basically it is a code telling the machine what kinds of actions to perform in a step by step basis, examples of these actions would be rapid move, controlled feed moves that would bore holes, a work piece cut routed to a specific dimension, change a pallet, and set a tool information such as offset.
After creating each part of the codes, the algorithm is compiled in the Computer Aided Manufacturing (CAM) software. The CAM software basically use translators called post processors to output the code optimized for a certain machine type. Often times, post-processors are often used to allow users to enable further customization.
G-codes can also be used to create outputs for Computer Aided Design systems used to design printed circuit boards (PCB). Any software must be customized for each type of machine tool that it will be used to program. Some G-codes are written by hand for volume production jobs.
Some Computer Numerical Controlled machines use conversational programming. Conversational programming is an easier way to program CNC machines because it is more user friendly because it uses a wizard like program that hides the G-codes into plain view. Some Popular examples of this kind of CNC machines are the Southwestern Industries Proto TRAK, Mazaks Mazatrol, and Mori Seikis CAPS conversational software.
Conclusion
With these kinds of further sophistication in programming Computer Numerical Controlled Machines, it is expected in the future that programming would be much easier for its machine operators.
This day in history…
Powered By Resell Rights .us
This day in history...
Powered By Resell Rights .us
Programming 101: CNC
After World War II, people realized that they have to manufacture goods at a faster rate and at a lower cost. Hence, mass production trending came to be. Those events led to the development of the Numerical Control (NC) machines which in turn led to the Computer Numerical Control (CNC).
HOW TO PROGRAM A CNC MACHINE
CNC programming uses a code similar in structure to BASIC. So, if you know how to construct a simple counting program, chances are, you already know what a G-Code looks like. However, there a few other things you have to consider before you start encoding instructions.
The first thing that you have to do is to assign values for each of the variables. These variables include the programmable motion directions (axes), and the reference point for the axes. The values that you assign to these variables dictate the movement of the machine.
The next thing that you have to do is to take into account the accessories of the machine. Many machines have accessories that are designed to enhance the capabilities of the basic device. However, using these accessories requires you to include them in the coding system. This means that if you want a more efficient machine, you will have to know the machine inside out.
READING CODES
After those steps, you have to create a subprogram that will deal with the math. This step will then allow your machine to compute the necessary variables and effectively operate without stopping to ask the operator what the limitations are.
To show you what these codes look like, heres an example from Wikipedia:
#100=3 (bolt circle radius)
#101=10 (how many holes)
#102=0 (x position of ctr of bolthole)
#103=0 (y position of ctr of bolthole)
#104=0 (angle of first hole
Tool call,
spindle speed,and offset pickup,etc
G43 in some cases (tool length pickup)
G81(drill cycle)
call sub program
N50
G80
M30
Subprogram
N100
#105=((COS#104)*#100) (x location)
#106=((SIN#104)*#100) (y location)
x#105 y#106 (remember your G81 code is modal)
If #100 GT 360 goto N50
#100=(#100+(360/#101))
Goto 100
In the code above, the machine is a drill. The operator utilized a loop in order to keep the machine from stopping. The subprogram then governs the cycle of the machine. This code is still quite a simple code. Other machines require the inclusion of the maximum RPM in the coding.
An easier way of programming CNC machines would be the use of Computer Aided Manufacturing (CAM). This system takes on the brunt of programming so that it doesnt seem so tedious and frustrating. It is still similar to BASIC.
Another programming enhancement that was developed was the parametric programs or the logical commands. These programs were designed to shorten lengthy codes in order to make them user friendly. However, these codes do not always use the same language with every machine. The language and sequence often varies depending on the typ of machine you will be working on.
The operator has to know what the machine can do or what it was made to do before attempting to program it. You should be able to visualize the machine doing what you want it to do.
But, you dont have to be a math wizard or a programming genius. You just have to know what your machine does and what you want it to do.
This day in history…
Powered By Resell Rights .us
This day in history...
Powered By Resell Rights .us
Practical Applications of CNC
Manufacturing anything that requires exact measurements requires cutting edge precision and nimbleness from the worker. Most of the time manufacturing these kinds of products requires weeks or months to finish therefore slowing down productivity as well as consistency of the manufacturers.
Computer Numerical Control or more commonly called as CNCs are the new trend in machine shop manufacturing and practice. Any manufacturing environment owns one or is basically acquainted to this kind of device because of its capability to increase productivity as well as consistency on the products being produced.
Benchmarked from Numerical Control (NC) during the late 50s, Computer Numerical Control incorporate the functionality of a Programmable Logic Controller (PLC), meaning you could program it to execute different functions depending on the type of manufacturing that the industry needs.
Given this kind of quality what does the Computer Numerical Control do in the practical application concept? CNC can do a variety of things depending on how the machine operator would program the system. The more acquainted the machine operator is to the CNC machine the more complex applications as well as programming can be made. Practical applications of CNC range from drilling, lathes, multi-axis spindles, milling machines, laser cutting machines, and wire electrical discharge machines.
Lets discuss some of these common applications further. In Metal fabrication, Computer Numerical controlled Lathes are used to fabricate metal sheet by shearing, flame or plasma cutting, punching, laser cutting, forming and welding. Most CNC Lathes are used for designing modern carbide tooling. The design could be created with the Computer Aided Manufacturing (CAM) process, and when done, the CNC could start creating the product automatically with little supervision from the machine operator.
Electrical discharge machining (EDM) is the process of removing metal with the use of electrical sparks to take away the metal. These Electrical Discharge Machine has two types, the vertical EDM and wire EDM. Vertical EDM uses an electrode that is the shape of the cavity to be machined into a work piece. Wire EDM is used to create punch and die combinations in the fabrication industry. Computer Numerical Control EDMs are not usually known because it is mostly incorporated to other CNC process.
Drilling is the most common machine process. Computer Numerical Controlled Drilling is used to create precise right circular cylinders over a certain material, the CNC could be programmed to create holes on different standards, most of the time this is the gaps between these holes. Drilling is commonly used in wood working manufacturing process in which other process is also involved such as milling, turning and grinding.
Several tools for creating holes with CNCs involve varied hole sizes as well as drill press for creating different depths on its holes. CNC drills are equipped depending on the type of hole that the machine operator is drilling.
Applications stated above are just a few examples on what the Computer Numerical Control could execute. Depending on how you want it to perform, more complex designs can be made and a lot of things can be made in a shorter period of time, therefore the key concept for the proper use of CNCs is that the machine operator must know what he or she wants to do.
This makes the CNC an indispensable tool for the Manufacturing Industry nowadays.
This day in history…
Powered By Resell Rights .us
This day in history...
Powered By Resell Rights .us
Recent Comments