The 4th Industrial Revolution is currently in full swing, and manufacturers will need to automate if they hope to keep up with foreign and domestic competitors. One of the most accessible and impactful forms of automation is a CNC machine. A CNC machine can significantly increase overall productivity and profitability. This article will list some of the more important factors to consider when selecting CNC machines.
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The type of CNC machine required depends heavily on the nature of the work being undertaken. If parts are simple then a 3-axis milling machine or CNC lathe may be good enough. However, as complexity increases, it becomes more cost-effective to have equipment that can machine most parts in one setup. Five-axis CNC machines are best suited to this type of work. Other classes of products require specialized CNC machines. For example, if thousands of small, complex, cylindrical parts are required, a purpose-built Swiss lathe might be a better option.
Cost is often the most important consideration when selecting CNC machines. CNC machines are generally significantly more expensive than manual machines. In addition to this, the cost of CNCs varies significantly depending on a number of factors. These factors can include the cost of tooling, cooling systems, chip conveyors, bar feeders, and automatic tool changers. Make sure that only the required add-ons are purchased. For example, a chip conveyor is not necessary if only small amounts of material are being removed.
Like any machine, CNC machines need to be maintained regularly to ensure that they operate optimally. For this reason, it is important to select a machine that has, at the very least, a local technical support division that stocks the spare parts most typically needed. This is even more critical if the machine breaks down, as every hour of downtime results in a loss of income. Competent and easily accessible technical support is also extremely valuable. Some companies charge extra for their technicians to be on call. This is well worth the cost when selecting CNC machines.
CNC machines take up significant amounts of space, especially if accessories like chip conveyors and tool changers are added to the machine, so it is necessary to plan ahead. Another factor to consider is machine weight. Large CNC machines are surprisingly heavy and require a concrete floor that is designed to support their weight. It is definitely worth the effort to pull up the factory plans to confirm that the foundation is sufficiently strong when selecting CNC machines.
CNC machines are power-hungry and often run on 3-phase power. It is important to ensure that enough power is supplied to the building to serve the new equipment. It is also worth the effort to confirm current power consumption. There may be enough power supplied to the building when all the existing machines are running, but adding a new CNC might push consumption above the available level.
If multi-feature, complex parts are being machined it may be beneficial to add an automatic tool changer to the machine. This allows for continuous machining without operator intervention. For example, when the CNC is done machining a feature that requires one tool, it can be programmed to quickly retrieve the tool needed for the next process on its own instead of waiting for an operator.
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Most CNC machines require clean and dry pressurized air, typically around 90 PSI. Therefore, it is important to have a reliable supply of compressed air in a factory. If more machines are expected in the near future it may be worthwhile to size the compressor and the pressure lines to the machine accordingly in order to account for this future expansion. Consider installing a compressor with a larger air tank to allow for multiple machines to operate at once. A small tank will quickly be depleted if, for example, multiple machines perform a tool change at once. Think of future expansion and rather place the compressor in an area where it will not become a nuisance and pipe the compressed air to where it is needed.
The types of materials being machined are important factors when selecting CNC machines. Hard superalloys like Inconel require advanced machines with sufficient stiffness to machine accurate parts. If softer materials like aluminum or mild steel are being machined, cheaper machines can be considered that will still be able to maintain the required tolerances.
When selecting CNC machines, it is important to understand the implications of choosing one control system over another. CNC machines come with factory-installed controlled systems for example Fanuc, Haas, Heidenhain, etc. In most cases, the machine manufacturers will determine the control system but there are some manufacturers that give a few options regarding this. Haas control is known as being one of the easiest to use whereas Fanuc is more difficult but is packed with more features.
It is important to ensure that existing operators are trained to use the specific type of CNC machine and its control system. If this is not possible, additional operators may need to be hired. Some machine suppliers will offer free training on their machines. Even if it is not free, it is well worth the cost.
Selecting CNC machines is a serious financial commitment. However, the overall benefits that can be expected in terms of improved productivity, profitability, and increased product quality are well worth the investment. Manual machining is no longer relevant in modern manufacturing and as such consider re-tooling to CNC machines to be part of the exciting future of automated manufacture.
Thank you so much everyone, this was my first post on the site and am feeling very lucky to have found such a helpful group. I am sorry for that image, I swapped it out for another image that is smaller so it doesn't wreck havoc on the siteSo space wise I am very open ended at least at this point. I am moving and hoping to either get a two story garage, or a detached workshop and so can make most any machine work. I don't expect to have three phase in the beginning, but do expect to get some light industrial property someday as I come up with new ideas and need more space (or someone complains about noise / smells[including my wife]).I would have to say that yes, the 4th axis is going to be a must, I would like to be able to repair / replace anything that breaks in addition to making new things and being able to cut screw feed drives, gears and such is very appealing. I could be wrong, but I think it also reduces the number of times I have to set something up in a jig. If I am working as a dentist, it would be great if I can hit "Run" before leaving to work and coming back with some real progress being made and not having to rotate it so many times to reach each side.The drip feed system sounds interesting, I have been looking online and have been surprised that even the $60,000 machines on ebay sometimes only have 1MB ram on it and a floppy drive.... It seems odd to me, but I have been in computers for the last 24 years so expected manufactures to jump on some easy current tech like USB or network connections.Material by volume will be aluminum, but I will probably do my fair share of stainless as well.From all the comments it sounds as though the older machines are still working just fine for those that know how to use them and can overcome challenges associated with limited support and or parts availability.Here is an example of what I am interested in making, I realize there are going to be more machines and processes I need to work out but think it will be fun and rewarding. The instruments in the bottom left are called elevators and run $100-200 the ones on top are about $15-30 each. I would like to work out the process, make a few myself and then outsource mass production, I have a way of directly contacting graduating dentists and would like to drastically reduce what they are spending on hand instruments.I have some experience with hydraulics having made an extrusion press and imagine I will be making quite a few presses and stamps to get the right shapes. I would like to learn more about electro-polishing and using liquid nitrogen for treating the metals after processing. Between Liquid Nitrogen, Anodizing, hydraulics, mills, injection molding, and things I don't even know about yet, I have my hands fullI love to tinker and also find ways to help out in my community which ATM is comprised of a bunch of students overloaded with debt trying to start a practice, i have been fortunate enough to have a little cash that I can use to maybe help them out while doing something I love.
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