CNC USB controller ( www.cnczone1.blogspot.com ) .flv

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CNC Milling Machine Buying Tips

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CNC stand for Computer Numerical Control, and refers specifically to the computer control of machine tools. The main purpose of CNC Milling Machines is to repeatedly manufacture complex parts in metal as well as other materials, using a specially coded program. This specially coded program that is used by CNC Milling machines is written in a notation called G-code. G-codes represent specific CNC Milling functions in alphanumeric format. CNC Milling was developed in the late 1940's and early 1950's by the MIT Servomechanism Laboratory.

1. About CNC

- Computer Numerical Control (CNC) Milling is the most common form of CNC - CNC mills can perform the functions of drilling and often turning - CNC Milling machines are classified according to the number of axes that they possess - Axes are labeled as x and y for horizontal movement, and z for vertical movement - The evolution of CNC milling machines drastically changed the manufacturing industry - Curves are as easy to cut as straight lines, complex 3-D structures are relatively easy to produce, and the number of machining steps that required human action is way down.

2. The Fabrication Process

With the use of CNC milling machine the fabrication process of the materials have been trimmed down to just a couple of steps. CNC Milling machines now days are driven directly from computer softwares crated by CAD software packages. With the use CNC Milling machines the assembly of parts can go from brief designs without any intermediate paper drawing works being required. In one sense, with the use of CNC milling machines industrials tasks are done must easier and much faster and the production cost of the company is also lessening out. CNC machines may be said to represent special industrial robot systems, as they are programmable to perform any kind of machining operation, within certain physical limits, like other robotic systems.

3. Buying Tips

Before buying a CNC milling machine it is a must that you should have knowledge about the CNC milling machines basic parts. A CNC milling machine is basically composed of a Safety shield that is usually a clear plastic cover that cover and protects the cutting area. The Tool bit, this part of the CNC milling machines is the one that do the cutting. Spindle Shaft, is the part that holds the tool bit. Spindle Motor, is the part of the CNC milling machine that drives the cutter. The Vertical Column, the part that holds the spindle and all of its part. The Cross Side, a moveable support where the work piece is being cut. The axis motors, which moves the cross side into different axis and the Controller box.

When purchasing your milling machine make sure to check that you have all of this part intact on your CNC milling machine, for if one of this parts is not there it will not surely work or will produce an undesirable end product. Also see to it to check out for safety features, never buy a CNC milling machine without an emergency stop button, this button automatically stops machining when it is pressed. Human, hardware or software errors could mean big losses if the CNC cannot be stopped quickly enough to correct the problem. Also check out the control panel part, it is advisable to buy one with a big control guide sticker so you can clearly see it.

Also check out the screws and tools with long overhangs and adapters, be more observant about cracks and breaks on this CNC milling tools. Make sure that the plastic shield that you are purchasing with your CNC milling machine is made up of high impact polycarbonate plastic. An insert break loose from a 35 mm diameter CNC milling cutter at a spindle speed of 45,000 rpm will be thrown out at a speed of 90 meters per second - equivalent to a bullet that is being shot out of a pistol!

All About Cnc Router

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CNC may be the acronym of 'computer control numeric' and it relates to numerous functions implemented for manufacturing. CNC router is usually a wood-cutting unit entirely managed and governed by a laptop or computer. CNC router is also chosen to cut plastic and even metal. Though the usage of CNC Router is still at a pretty early stage, the handful of consumers who are applying a CNC router are reaping helpful benefits greatly in conditions of price usefulness, top quality and productiveness.
Router bits are wood functioning routers are diverse CNC router products.

If a carpenter takes complete advantage of the CNC router, enormous added benefits could be purchased.

CNC routers are very much effortless to run in comparison to lathes and milling models.

CNC routers is often implemented constantly and should be switched off only occasionally for the sake of maintenance. CNC routers not only lower waste; these also minimize the variety of errors along with the times necessary to manufacture any item.
The design program of CNC router is such that countless comparable solutions might be designed out of it. The CNC router designed partsare all the same.

Updating CNC router is rather convenient using the guide of software program betterment. Consequently there's no really need to invest in a prototype. Given that handbook labor shouldn't be necessary for operating CNC router, a reduced amount of skilled and also unskilled individuals can operate with these equipments.

Virtual computer software provides coaching on the use of CNC routers. It can be pretty simple for a single individual to supervise several CNC routers at a time for the reason that as soon as programmed, these units maintain on working with no any manual aid.

Still, CNC routers have specific disadvantages as well. Compared to other manually functioned equipments, CNC router bits and CNC routers are a great deal alot more high-priced.

Only simple instruction periods can permit an person to run CNC devices successfully. Therefore the yearlong knowledge and expertise of engineers are under challenge. CNC routers are effective in mass production. Considering the fact that these are computerized, a reduced amount of quantity of many people is essential to operate these. Thereby CNC routers really encourage unemployment.

Used optimally, a CNC router can very easily take the location of your skillful carpenter. Although use of this machine is not yet in complete swing, the price tag of those equipment is reducing which in turn would produce higher demand.

Wider use of CNC routers and slipping rates of computer systems will shortly lead to further slash inside selling price of those units making popular using every one of the a lot more.

Programming 101: CNC

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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, here’s 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 doesn’t 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 don’t 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

Data Transfer of CNC

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A CNC machine cannot function without a program. And a program cannot make its way to the machine without an effective data transfer system. So, what are the methods of data transfer and how effective are they in conveying data from one point to the next?



Punched tape

The first data transfer method is the punched tape. It consists of a long strip of paper with holes punched in it to store data. The holes represent a set of data that tells the machine how to move and what to do.

This method has proven to be very versatile and very useful. It has proven to withstand the test of time as numerous magnetic storage devices have deteriorated over time even to the extent of being unreadable while punched tape has been shown to be fine decades and perhaps even centuries later. Repair is also not a problem as specially designed splices can put two end together virtually unchanged. Furthermore, punched tape can be visually decoded should the need arise. This means that human accessibility is also not a problem.

Floppy Disk

While punched tape is quite a long roll of paper, a floppy disk is a small magnetic storage device that is more space efficient than punched tape. It can also be used to store simple programs.

Floppy disks virtually revolutionized the way data could be stored and transferred from one point to another. It allowed users to store and transfer data faster than punched tape allowed. Furthermore, the data within a floppy could be easily edited at any point as long as you have the proper program to read it. However, this method has proven to be quite problematic in the long run as floppies have a tendency to degrade alarmingly fast. A floppy could be unreadable after only 3 years.

RS232

This method is actually a set of standards for serial binary signals that connects between computers, terminals, and modems. This is a fast and efficient way to transfer data.

This cable connects a CNC machine to a computer that has floppy disk support thus eliminating the need for punched tape. This allows the operator to input data remotely and even while accomplishing other tasks. However, it need to be used in conjunction with an effective data storage device so as to have backups in case of emergencies.

Networks

Networks are a set of computers that are linked together to make data sharing easier. In an industrial scenario, networks allow a number of different users to individually create a program for the machine to run on.

This method allows multiple users to access and transfer data remotely. This allows for a faster and more efficient check-and-balance system for the programmer and the data verifier. Furthermore, different parts of the program can be completed by different programmers and then compiled by one user. This makes program creation a fast and easy process.

Manual Data Input (MDI)

MDI allows users to input commands directly into the CNC machine’s memory. This may seem to be an effective way of telling the machine what to do but it actually has a lot of drawbacks to it.

Despite it being the fastest way of telling the machine what to do, it is also a very risky and tedious operation as it requires the use of the machine’s terminal. Furthermore, the construction of a program is not as fast as opposed to the network method. It only allows one user to access the machine thus making it a long and drawn-out process.

Another disadvantage that comes with MDI is that it limits the operator to only one task at a time. However, MDI allows the most control over the machine compared to other methods

CNC Programming Tips

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When a program is completed and sent to the Computer Numerical Control Machine, the programming process is over. All calculations were made and the algorithm fully written. But the question is the programmer’s job really finished? When is the programmer’s responsibility really over? And how can we evaluate the type of program that the Computer Numerical Control Machine programmer did?

The fairest and reasonable answer to those questions would basically when a part has been machined under the most optimized working conditions. Therefore the Programmer’s responsibility does not end after he or she finishes the program. We could say that the program at this stage is still very much in the development process, because most of the programming considerations were based on certain assumptions and there are a lot of external factors that may affect the outcome of the product.

Every Computer Numerical Control programmer should have an effort to be in the touch with the actual production. In the field of software development, Constant communication with your colleagues as well as actual machine operators of the CNC will help you to improve your own program. Because most of the time the CNC machine operators are a good source of constructive ideas, improvements and suggestions.

A good CNC programmer should talk, ask questions to them and most importantly listen to what they have to say. Programmers who never put their foot in the actual machining process and think they are always right are all on the wrong track. Exchanging ideas with CNC machine operators, asking questions and seeking answers is the only way to be fully aware of what is going on in the machine.

Whenever you start a Computer Numerical Control Program the first time it is important to check its Program Integrity. A new and unproved program is a potential source of problems. During Manual Programming in CNC, mistakes are more common than when the program is made in a CAM program.

A good way to look at a new program is through the machine operator’s perspective. Experienced Machine Operators take a direct approach when running a program for the first time. That means that they wont take any chances of mistakes with the actual running of a program therefore a good programmer must take note of any comments that the Machine operator will say about the program.

What does an experienced Machine Operator look for in a new part of a program? Most of the Machine operators would say that the first and most important thing to be checked on a Computer Numerical Control Program is its consistency. Therefore a machine operator looks at how a CNC programmer does its own programming, is the way you create your own algorithms the same as the other ones. Machine Operators take note with this kind of Information.

Upgrading your CNC Program

Whenever you upgrade your own program, it means that you are strengthening or enriching it, therefore making it better than it was before. Upgrading would be based on this standard, It is to decrease the production cost without compromising the quality of the part being manufactured or the safety of the Computer Numerical Control Machine Operator.

One of the Most Common forms of Program Optimization is doing some minor changes to the spindle as well as the feed rates of the machines. This process is called cycle time optimization, slightly increasing the spindle speed and feed rates of these machines will decrease the time it takes to finish the part.

And when we compare it to mass production, saving one second for each part in a batch of 3600 pieces would mean an hour saved. Efficiency in the rate of production is a very important aspect in Mass Production.

5 axis cnc head porting maching.mp4

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CNC Programming

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By Brent Cohagan
CNC programming is beneficial in that it provides enhanced automation to the manufacturing process. With this programming process, the need for an individual operator can be eliminated altogether, as the programmer can in fact be the machine operator as well. The computer program, once started, can actually run with no human intervention in the entire process until it has been completed. The end result of the process is less error and higher precision levels in the final product. The final outcome once the process is complete is predictable, and in fact, the process can be repeated time and again and still end up with the same end result.
CNC simply stands for computer control. The machine essentially creates the final product based on geometrical output. The result is a part or other object that is as nearly as identical as that which it is modeled after, generally within 100 microns of the specification. Basically, once the object has been programmed, the machine can cut one right after the other, nonstop and each will be the same as the last. Once the program has been created, there is no need to program it again, and you can come back perhaps 6 months later, or even more, load the program, and get the same thing once again.
Another great benefit of the programming process is flexibility in the tools that may be used to complete the process. The machines themselves run on specific CNC programs, so producing the other work pieces will only require that the appropriate program and same machine be utilized for producing the other types of work required. The end result with this type of setup however is that the change-over from one part or object to another is relatively fast. You can be in the middle of a large run, or say, 100 pieces, and have an emergency project come in that interrupts your current run. You can install the program to run the emergency project, run it and get it done, then go right back to the original project without much lost time except the time required to produce the emergency work. This would not be possible in the old standard method of machining without costing a lot of production time.
Overall, the basic function of the machines that are run by CNC remains fairly consistent. The motion involved is automatic and precise. Rather than having to resort back to the use of manual tools that activate the motion as required in traditional machining processes, the CNC method provides this control in a manner that is innovative, and the same in the case of repetitive processes. There are at least 2 directions of motion with the majority of them, which as they are known as axes. These axes will from back and forth, up and down, side to side or whatever other way the machine is constructed, and it will create your work on the level of precision standard for the machine.
These will be most commonly rotary, or linear in nature, again, depending on the needs. For more information on how cnc programming can assist your manufacturing requirements, visit http://www.internetmachineshop.com
Brent Cohagan
President
Cohagan Engineering, Inc.
http://www.CohaganEngineering.com
Article Source: http://EzineArticles.com/?expert=Brent_Cohaga

CNC Lathe Machines

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By Ivan Irons

CNC lathe machines are computer controlled just like any other CNC machine. It can be programmed to do a variety of different things such as sanding, cutting and drilling. CNC lathe machines will work for wood or metals, depending upon the project that you are doing. This machine can help cut your production time down and increase the profitability of your business in the end.
The wood lathe can not only be used for wood but also for materials such as brass and aluminum. Metalworking lathes or milling machines are available for other materials. The variety that is offered offers you limitless possibilities in creativity. So, what direction will you be taking your business in next?
From small shops to large companies, there is a lathe that is available for anyone. Whether you need a portable machine or a stationary machine, the choice is yours. Small shops are able to use the CNC machine to make precise, intricate cuts as in developing stair railings, table legs, chair legs, and so on. When you are done, the product will be beautiful, symmetrical and worth it in the end.
The process is called turning. Turning of the material allows for many shapes and cuts to be made while keeping the end product symmetrical. Perfect diameter from top to bottom will be cut to the specifications desired. Never has it been any easier to achieve this level of design and end product production as it is now.
Metal fabrication is another possibility with the CNC lathe machine. Do you need to create a part that needs to have a circular motion? If so, the CNC lathe machine is the perfect machine to allow you to produce that certain part. Any material can be used. The material, however, has to be able to stand up to the turning process as the computer software program continues its rotation through until the end.
All the operator has to do is program the machine to the specifications that are required to produce the product that is desired and load the material into the machine. The machine does the rest. The machine operates on the X and Y axis. It is great to use if you want to several identical products of the same size and shape without a whole lot of decoration. The computer software program will continue to operate the machine, making in turn rotation after rotation, until the desired specifications have been reached.
From tapered ends to contoured shapes, this machine can do it all. CNC lathe machines can offer your business that special touch, extra technology and time saving steps that you are looking for. Remember, no matter what type of material you are working with, the CNC lathe machine can work with it, as long as it stands up to the rotation process.
If you have any further questions about the CNC lathe machine and what it can do for you, contact a dealer who offers this technology. They will be able to further answer any questions that you have and guide you in the right direction.
Go to CNC Machining Zone to get your free ebook on CNC Machining at CNC Lathe Machine. CNC Machining Zone also has CNC Machining Information, and forums and blogs all about Machining. Visit CNC Machining Zone today to sign up for free and get your free ebook on CNC Machining.

CNC Plasma

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here are many different CNC plasma plans and kits that are available on the market. If you are planning on trying to build your own CNC plasma cutting machine, then this could be the way for you to go. You will first want to search and find the plans that you could possibly work with.
Once you locate the right CNC plasma plans for you, make sure you purchase several different plans. Study those plans closely and then you will see which one works best for you and that you are capable of building and that the end product that is created will perform the jobs that you are wanting it to do.
Decide whether you need a larger machine or a smaller one. This can help you in your decision making process in relation to the plans that are right for you. You have to know exactly what you want the machine to do. You don't want to spend the time building your own custom CNC plasma cutting machine and in the end realize that it cannot do what you need it to do.
Next, make tweaks to the plans. Do you want to incorporate something different into the design element of the CNC plasma machine that you want to build? Or, will it work the way it is for you? These are very important questions that you will need to know the answer to.
Do not give up. Start to build your unique machine. It may be difficult and it may take some considerable time to complete, but at least start on the project. As you begin to see the project develop right in front of your eyes, you will begin to have the inspiration to finish it. Most people end up giving up after they view the plans. They never even begin to build a machine. Do not let that happen to you. Imagine the possibilities that a machine like this can create for you. Find that inspiration that will help you to keep this project on the front burner up until completion.
CNC plasma plans are like blueprints that tell you what the specifics are of the design and how it all works, the mechanics of the machine any way. You will want to have some kind of knowledge on how to read plans in order for you to go completely through with the project. If not, someone who can read the plans who can help you out is advisable. Experience in this type of work can also help you in the long run. Viewing plans of this magnitude can become overwhelming. Just remember, do not give up. It is definitely not going to be easy, no one ever said that it would; however, it can be done.
To learn more about CNC plasma plans, search the internet. You will be able to find several different companies who offer plans for purchase. They may even be able to help you in finding the plan that is right for you.

5 Axis CNC Machine

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By Ivan Irons

The 5 axis CNC machine offers more intricate and precise cutting abilities. This machine does not operate around the normal 3 axes of movement: X, Y and Z. Instead it works around 5 different axes of movement which makes it harder for the programming; however, the type of work that can be performed is limitless with the 5 axis CNC machine.
There are several different companies that offer a 5 axis CNC machine. When trying to decide on whether to purchase a 5 axis CNC machine or not, it may be best to consult with a salesman from any of the companies. Comparison shopping would work best here. What specifically would you like to achieve from your machine? What are you looking for? What software programs work best for this type of machine? How much space will this machine take up? Can adjustments be made easily? These are all legitimate questions that you must first ask yourself before purchasing a machine of this caliber.
This type of machining is most typically used in the Aerospace Industry. It enables them to craft airframe components that have draft surfaces, impellers and turbine engine components. Now, different industries are taking advantage of this technology.
Justifying the cost of a machine of this caliber is very important. 5 axis CNC machines are not cheap. If you currently have a 3D CNC machine and are considering a 5 axis for your business, you must ask yourself why. Why do you need a 5 axis? Can you use your current 3D CNC machine to achieve what you are wanting? It could be that you need a different program or just make some simple adjustments.
New 5 axis CNC machines can allow one to cut just about anything that they want. Cutting simultaneously on both sides, offers more efficiency in the workplace. CNC machines can pretty much operate on their own just by programming the software to do what is needed. Man power can be used to oversee a group of machines. With the PRS (personal robotics system) that is offered on these machines, manual operation is no longer needed.
Cutting, machining or creating a particular part that is complex and incorporates different angles and tough geometrics, is difficult. 5 axis CNC machines offer a solution to this. That's why the Aerospace Industry has been using this technology for some time now. Usually the first to take advantage of technology, the Aerospace Industry requires dependable, reliable and efficient tools and technology that will allow them to be one step ahead of the rest. 5 axis CNC machines allow them to do this and this is not new technology for them.
If you have any questions about 5 axis CNC machining there are several blogs and forums that are located across the internet that you can become a part of and stay up to date with the latest from this industry. Ask any question and you will be able to receive a response that is to your liking. Machinists from all over will over you their expertise and knowledge.
Go to CNC Machining Zone to get your free ebook on CNC Machining at 5 Axis CNC Machine. CNC Machining Zone also has 5 Axis CNC Machine Information, and forums and blogs all about Machining. Visit CNC Machining Zone today to sign up for free and get your free ebook on CNC Machining.

Getting Timely Help in the CNC Plasma Cutter Zone

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By Ivan Irons

With increased automation, processes that were too hazardous for workers in the long run have been replaced with computer controlled machines. The CNC plasma cutter is one such machine that can cut various metals to the desired shape as the operator supervises the entire operation. This new CNC zone allows fellow users to meet up and exchange invaluable ideas that lead to increased productivity at lower costs.
Workings of a CNC Machine for Plasma
Plasma cutters use a combination of ionized gas at very high temperature along with high pressure and an arc to cut through various metals of varying thickness. While the gas allows electricity to pass through and cut the metal with the help of the arc, the high pressure ensures that debris is blown away from the cut, thereby ensuring a clean cut. Other than the conventional gas plasma cutters there are different types of cutters that can cut metal such as air plasma and water shield plasma, among many others.
Features of a CNC Machine for Plasma
There are various metals that can be easily cut with the help of the right CNC Machine for Plasma. Some of these metals are:
o Aluminum
o Steel Alloys
o Mild steels, etc
As compared to other metal cutters, plasma cutters hardly leave behind any burrs after the component has been cut and this reduces the time taken for finishing the component for the next process. A CNC plasma cutter can make several cuts such as interrupted cuts and bevel cuts depending on its design and the requirements of the user. Most cutters are also compatible with G code software and along with the right type of controllers can quickly cut through the thickest material with perfect consistency. People that want to buy such machines should choose ones with an emergency override switch to retain control in case of any unforeseen problem. Most cutter manufacturers can work in tandem with potential buyers so as to suggest the most suitable machine for the buyer's needs.
Advantages of lounging online in the CNC plasma cutter zone
Earlier, people that had problems related to their particular CNC Machines could not get timely help but with the advent of the Internet they can now visit an online zone and get all the information that they need at the click of a mouse. An online CNC plasma cutter zone can enable buyers of new and used machines to meet potential sellers. People that have problems in finding spares for their machines can also get helpful advice and links from fellow members. The blog at these sites allows members to express their thoughts and experiences in using different plasma cutters while the forum can help like-minded people mingle with each other to share thoughts and new ideas. Help is also provided by such sites in the form of e-books, videos, tips and articles that enable a viewer or member to increase his or her knowledge about this vast industry.
As newer techniques keep on appearing in the CNC plasma cutting field, it pays for buyers, sellers and users to remain abreast of the latest happenings in the industry. The best method to do so is for people to immerse themselves in the CNC plasma cutter zone and absorb the wealth of knowledge so as to enhance their own skills.
Go to CNC Plasma Cutter to get free information on this product. This website will give you all of the information you need on CNC Plasma Cutter along with a lot of other free information. Don't miss out on this new website if you are looking for more information. Find us at http://cncplasmacutterzone.com/

CNC Lathe Turning - AIT

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Advanced Integrated Technologies (AIT) offers CNC lathe
turning services for both short and long run production, for
customers all over the world. AIT utilizes 5 axis multi-purpose
machines which allow us to both turn and mill features into a part,
all within the same machine.

Our Daewoo lathes are precision
machine tools that are designed for versatility and speed. We turn
almost any material, but the vast majority of our CNC lathe turning
is done in aluminum and stainless steel. If you need lathe turning or
milling services, AIT is your provider.


Lathe turning is the process of shaping material by spinning the raw material and then bringing a cutting tool into contact with the spinning raw material. Many people’s first exposure to this process is with a wood lathe, where wood is spun and then shaped by a person using a sharp chisel like tool. As the cutting tool touches the raw material, it essentially “peels” the material away. CNC lathe turning is simply doing this with a lathe that is computer numeric controlled (CNC), or in other words, controlled by a computer program and servo motors.

CNC lathe turning has come a long way since the early days. The essence of the CNC lathe turning process hasn’t changed that much, but the details are far advanced. Today’s machines use indexable replaceable carbide or diamond insert cutters to reduce tooling cost, improve consistency, and speed up tool change over. Also most machines today run fully enclosed, and force high pressure coolant into the cutting zone to keep material and cutting tools cool, and to flush away the chips that are peeled off the raw stock. These and other advances have brought CNC lathe turning into the twenty-first century.







CNC lathe turning is divided into several broad categories. At one end of the spectrum is screw machine work, which is a multi-spindle high production machine. These typically produce simpler parts, like a bushing for example, but in very high volume. This keeps the per part cost very low. At the opposite end of the spectrum are 5 axis live tool machines. These can produce highly complex geometry by combining lathe turning with milling capability, all within the same machine. This often eliminates second milling operations, and thus helps in keeping the final part price low. AIT utilizes 5 axis live tool machines for our CNC lathe turning services, in order to be very flexible with short run production.
Email or Call 870-269-4367 to request a quote
Find CNC Machine Shops and CNC Milling Turning at A-I-T.Com.

CNC Machine Shops - A Great Contribution in the Business World

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By John Balentine
The word 'machine' is derived from a Latin word 'machina'. A machine is a device that is used to perform any task. It is a device with some parts attached to it that perform or directs in performing a particular task. A person who is an expert in machines is known as a machinist. A place, room or building where machining is done is known as machine shops. Latest trends and technology has also brought about a drastic change in controlling machines. Earlier machines were controlled by human labor by now it is controlled by computer numerical control which is an abbreviation of CNC.
Nowadays large numbers of machine shops have switched to CNC machine shops. Some shops are specialized in producing only one type of products whereas; others accommodate for mass production like aerospace industry, automotive industry and furniture making etc.
CNC machine shops have allowed businesses to expand and provide services which they could never think of before the introduction of CNC machine. The biggest advantage of these shops is that they are precise and provide multiple shapes with minimum wastage.
It is always better to seek services from a CNC shop then to invest in establishing your own CNC milling department. This will be cost effective since you will be saving a whole bundle of money which you would have spent in buying and owing your own CNC shop. It is always better to take advantage from CNC machine shops available as they have already invested a lot of money in buying the desired equipments.
Another advantage of getting your work done from CNC shops is that your department will not have to sit idle when there is no work regarding such machines. This will be a waste of money since your employees will not be working on a daily basis but you will have to pay them salary for the entire month.
Even though the machines are self controlled, safety measures must be taken seriously to avoid any accidents or mishaps. These machines do not produce a lot of noise and wastage but even then the operators are advised to wear safety goggles and earplugs.
CNC machine shops require expert operators to control the machine. These operators usually have a desk job, they write programs which help the machine to operate effectively and efficiently. Any mistake in the program will result in producing defective products.
Even though the machines are self controlled they still need a set of instructions to work effectively, appropriate tools to produce the desired outcome, placement of raw material is very essential to obtain the desired outcome and last but not the least an operator to push the start button to start the machine.
In a CNC machine shop it is very important to make sure that the employees are trained and up to date with the latest technologies. Each employee must meet the standards of the company in order to ensure that the products that are produced are of high quality.
CNC machine shops provide their clients with unique services which no other machine shop can offer unless they have the same equipment and tools.
Find CNC Machine Shops and CNC Milling Turning at A-I-T.Com.

6 Important Things to Consider Before Buying a New CNC Milling Machine

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By Jimmy Dales

In today's industrial mechanical business industry, traditional milling machines have become obsolete ever since the innovation of Computer Numerical Control (CNC) milling machines which have helped many companies to produce wide spectrum of components on a large scale without neglecting precision and accuracy. It has proven that these machines have the ability to boost one's productivity and profitability. As a result of technology advancement, this explains CNC machining centers are capable to perform complex milling operations which subsequently enables companies fabricate more useful components.
If you are a business owner who has a few older CNC machining centers - you might be having difficulties whether you should a newer version or remain the old ones. Here are several things that you need to consider before buying a new CNC milling machine:
1. The size of your components produced - For instance, if your business requires machines which are capable to fabricate large or small components - ideally, you would need a larger milling machine to manufacture large components and smaller machines vice versa. If there is no change of the component size, it is not necessary to change your old CNC machining centers.
2. The complexities of the component design - Basically, newer models usually have its own distinctive number of axes - which represents its simultaneous movement of the cutting tools, for instance, 4-axis and 5-axis machines. If you are planning to perform positioning work on complex multi-parts over a long period of time, then you need to have advanced machining centers to perform intricate parts production operations. If your business only requires 3-axis CNC milling machines, it means that you are only capable to produce low difficulty components.
3. The actual condition of the machine used - If your current machining centers have been frequently sent for maintenance, you are required to bear the high maintenance cost over the long term. When it comes to a situation where it is worth to invest in CNC milling machines rather than spending on the maintenance, it is wisely that you consider purchasing new models to replace the older machines.
4. The actual productivity of the machine - You would need to buy new CNC machining centers if you want to offer fast turnaround time to your clients. Newer models have updated integrated control software which can hasten repetitive high precision milling operations. If you have productivity problems with your old machining centers, it will affect your turnaround time and subsequently it will affect your reputation over the long term.
5. Dealing with the precision issue - If your CNC milling machines have precision issues - for instance, the components produced are far from the precision range, it will affect the quality of components and you will likely to receive complaints from your clients. In order to avoid this problem, you need to find CNC machining centers which are capable to perform high precision cutting and drilling operations effectively.
6. The machine cleanup cost - Newer models have efficient chip management feature that can keep the chips out and the internal cutting tools clean. If you are not experiencing cleanup cost problems - stick with the old CNC milling machines to perform milling operations as usual.
Hope that you can make a wise decision whether you should buy a new CNC milling machine by considering several things as mentioned above.
If you think that it's not necessary to buy any machining centers at this moment - why not try outsourcing your CNC milling task now! See how it can boost your productivity and profitability of your business.
Searching for companies which provide high quality and affordable CNC milling service can be indeed a time-consuming process.
To speed up the search process - If you are looking for high quality parts production service, try out Abtech's professional precision engineering services - For more information about it - CLICK HERE.
If you have a new project or an existing project that needs a new approach which requires CNC milling solutions, please visit this website - ABTech-Precision-Engineering.com

CNC Vedio NMV5000 - 5 Axis Simultaneous Machining

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CNC Machine Auction

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By David Karlson

Are you looking to save money on your CNC purchase? One of the best places to look is a CNC machine auction. Before wasting your time, do some research on the exact type of machine you need. Then, if possible attend the previewing of the auction items. This way you can look over the items before bidding on anything.
There could be a variety of different CNC machines available at a CNC machine auction. Which type do you need? Is it a milling machine or a tube bending machine? These are important points to note before any bidding begins.
What type of auction should you attend? You have several otpions, one is an auction for a manufacturing facility that is going out of business and needs to liquidate it's assets. Another, is an auction house that is auctioning off items for a specific client. There are websites that cater specifically to machines and CNC machine auctions.
Sometimes a CNC machine auction may allow you to inspect the merchandise prior to any bidding. In other cases, you are not allowed to carefully inspect the machines. As in the case with any type of auction, it is buyer beware. It is much better for you if you have some experience with these types of mashines. In addition, try to bid on a machine that appears to be rarely used.
Some people even have had some luck on ebay when searching for a good CNC machine auction. The reason why more people are turning to auctions for CNC machines is because of the popularity of these machines these days and the downturn in the economy. Companies are looking at cheaper ways to upgrade their current machinery and to reduce costs to compete in todays economic uncertainty.
A CNC machine auction is similar to any other auction in that you must know the item you are bidding on. Do your homework and there is a good chance that you will get yourself a bargain.
We have combined a great deal of information into one complete site about CNC or computer numerical control. Visit our site today for all your CNC related inquiries including CNC motion control
http://www.computer-numericalcontrol.com/
By D. Karlson
 

Thermwood - 5 Axis CNC Router at John Cox's Creature Workshop

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Concept car CAD/CAM- CNC 5 axis machining

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New CNC Machine = lASMC-510P Super Maxi VERTICAL MACHINING CENTER

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Acra ASMC-510P Super Maxi Vertical Machining Center



 


Acra Model ASMC-510P Super Maxi VERTICAL MACHINING CENTER
Specifications: ASMC-510P Super Maxi Specifications: ASMC-510P Super Maxi
Travel, X (Long.) 20" Travel, Y (Cross) 16"
Travel, Z (Vert.) 18" Table size 23.5x14.9"
Spindle speeds 8,000 ATC type Carousel, 16
CNC control Mitsubishi 64M Rapids 1181XY,789Z
Spindle HP 10 Spindle taper, drive BT40(CT opt)
Spindle nose to table 3.5-21.65" Table load capacity (lbs) 500
Servo drives 1.3 HP AC Type of ways Recirc. Linear
Rigid tapping Yes Accuracy +/-0.0002"/12"
Repeatability +/-0.0001" Net weight (lbs) 5,500
Country of origin Taiwan
ACRA VERTICAL MACHINING CENTER MODEL ASMC-510P SUPER MAXI CENTER
Three Free and Easy Services: Click here.
 MITSUBISHI 64M CONTROL Featuring
  • Ballscrews are double nuit designed, anchored at both ends

  • Ribbed Meehanite cast iron

  • Minimal operator lean-in for easy loading 
    Specification:
  • Longitudinal travel (X-axis) - 20"

  • Cross travel (Y-axis) - 16"

  • Vertical travel of head (Z-axis) - 18"

  • Table work area - 23.5 x 14.9"

  • Distance table surface to spindle nose - max./min. - 3.5"/21.6"

  • Spindle speed range - 8,000 RPM

  • Spindle drive motor - 10 HP

  • Spindle taper - BT40 (CT40 optional)

  • Rapid traverse rate: - X and Y-axis - 1181 IPM, Z-axis 789 IPM

  • Table lod capacity - 500 lbs.

  • Cutting feedrate - 0.04 to 196 IPM


  • Tool magazine capacity - Carousel, 16 (20 opt.)

  • Max. tool dia. - 3.15"

  • Max. tool length - 9.8"

  • Tool selection system - Bi-directional

  • Tool weight, maximum - 15.4 lbs.

  • Distance spindle center to column face - 14.6"

  • Overall machine height - 97

  • Required floor space - 90" x 90"

  • Net weight – approximately - 5,500 lbs.

  • Machine accuracy Positioning +/-0.0002"/12", Repeatability +/-0.0001"

  • Mitsubishi AC servo motor 1.3 HP

  • Air required - 80 psi

  • Standard Mitsubishi 64M CNC control features:


  • Program storage - 600 m

  • Tool length compensation

  • Cutter compensation

  • Tool offsets, 200 sets

  • Inch/Metric conversion

  • Workpiece coordinate, 54 sets

  • RS232C interface

  • Least input increment 0.001 mm (0.0001")
    Standard machine items:
  • MPG Handwheel

  • Heat Exchanger for NC cabinet

  • Air blow system

  • Auto Way Lube





  • Work Light

  • Pilot Lamp

  • Leveling bolts and pads

  • Manuals and toolbox 








  • AMADA WASINO DV-1 CNC FORM GRINDER

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    Grinders
    State New
    ID Number
    Make AMADA WASINO DV-1 CNC FORM GRINDER
    Description THE ULTIMATE IN CNC FORM GRINDING WITH CCD IMAGE MEASUREMENT.
    Revolution in Optical Profile Grinding technology with the profile grinding centre fitted with up to 7 contolled axis
    Automatic operation for grinding profile shapes in parts as fine profile punches, including rotation, side clearences, front clearence with full automation of measurement of workpiece by CCD and automatic correction/compensation to sub-micron accuracy.
    100mm diameter rotary table.
    Table travel 300/250/80mm.
    Wheelhead reciprocation slide 80mm.
    Reciprocation speeds 30-400/min.
    Wheel speed 2,000-20,000rpm.
    Available with 10 pallet auto-loader
    Email: enquiries@colingladwell.com

    New CNC Machine

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    Hardinge CNC Lathes...

    Talent - Universal Bar & Chucking. 45-78mm Bar
    Elite - Bar & Chucking with C-Axis & live tooling
    Quest GT – Super Precision Gang slide
    Quest – High performance, Multi Tasking & SP
       

    Bridgeport Mills & Machining Centres...

    Series 1 – Manual Turret Mills, with CNC option
    XP – Low cost range of VMC’s
    P3 – Range of VMC’s from 450 to 1500
    XP3 – High performance VMC’s from 600 to 1500
    HSC500 – High speed VMC, 40,000rpm
    5AX – High performance full 5-Axis
    480 – High speed Drilling, Tapping Milling VMC’s
    APC – Auto pallet changer VMC's 480, 700 & 1000
    HMC700 – Twin pallet Horizontal, 4-Axis
       

    Grinding Machines...

    Kellenberger – Manual & CNC Cylindrical Grinders
    Bridgeport FGS - 5-Axis Viper Grinding technology
    Hauser – Jig Grinders
    Tschudin – High production Cylindrical Grinders
    Tripet – CNC Internal & OD Grinders

    Machine Tool

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    According to USMTC, machine tool sales in December 2010 were 75.2% (units) and 113.8% (real dollars) more than in December 2009. Since January 2004, there have been only 11 months that have recorded higher unit sales than December 2010. Over the same time period, there have been only seven months that have recorded higher real dollar sales than December 2010. Given the sales of not just December but the last four months of 2010, it is fair to say that machine tool sales have returned to normal. In fact, orders for machine tools are so strong that deliveries are being pushed out. Machine tool components, such as ball screws and controllers, are in short supply, making it even more difficult for builders to meet demand. In 2010, machine tool sales were 61.1% higher than in 2009, almost certainly a record. I look for the peak annual growth rate to reach the low 70% range around the March-April time frame. Since machine tool sales are as strong as they have been in quite some time, I expect the annual growth rate to start slowing down after the first quarter of 2011. For more on machine tool sales and the leading indicators, go here.

    Knowing Machining in Japan

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    DMG/Mori Seiki’s Greg Hyatt, who heads the company’s Machining Technology Laboratory, offers a booth tour for editors during JIMTOF 2010.


    In late October/early November, DMG/Mori Seiki hosted a press junket to Japan to visit Mori’s Iga and Nara manufacturing campuses as well the 25th edition of JIMTOF, the Japan International Machine Tool Fair. This is the first JIMTOF since the business collaboration between Mori Seiki and DMG was established. Their joint JIMTOF booth featured 15 new models among the 34 machines on display. The show also marked the introduction of the company’s X-Class machines to the Japanese market (these machines were introduced to the U.S. market at IMTS). The X-Class is a machine line engineered to offer rigid, stable machining as well as lower energy consumption and an attractive price point. Here’s some detail about that new line.

    The company’s booth also displayed a number of interesting machined parts, including winning entries to the company’s Cutting Dream contest. This contest is open to manufacturing companies, schools and research institutions engaged in machining in Japan. Check out this slideshow of those winning entries.

    JIMTOF is held at Tokyo’s Big Sight complex located on a man-made island filled with buildings sporting very interesting (i.e. non-traditional, sorta “out there”) architecture. Nearly 115,000 visitors attended the show despite the rainy weather (there was a typhoon in the area at that time). I managed to snap photos of a handful of interesting technologies that caught my eye at the show and you can see them in this slideshow.

    Thanks to all at DMG/Mori Seiki for hosting such an interesting, informative and fun trip to the Land of the Rising Sun. Domo arigato!

    CNC Machine Controls

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    The CNC (computer numerical control) system of a machine tool includes the control unit itself, as well as less visible parts of the motion-control system such as the servomotors, drives and axis positioning devices. These components are part of any CNC machine tool, but they might be bought separately and retrofitted later on older machines that are upgraded or refurbished. Also part of the control system are sensors that may allow the control to make certain real-time decisions during unattended or lightly attended machining processes. These can include probes for measuring the position of the part or machined features, as well as monitoring systems for detecting the presence of the tool or the force that is being exerted in the cut.

    Knowing your machine

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    A CNC operator MUST understand the makeup of the CNC machine tool being utilized. While this may sound like a basic statement, a CNC user must be able to view the machine from two distinctly different perspectives. Here in key concept number two, we will be viewing the machine from a programmer’s perspective. Much later, in key concept number seven, we will look at the machine from an operator’s viewpoint.

    Basic machining practice – the key to success with any CNC machine
    Many forms of CNC machines are designed to enhance or replace what is currently being done with more conventional machines. The first goal of any CNC beginner should be to understand the basic machining practice that goes into using the CNC machine tool. The more the beginning CNC user knows about basic machining practice, the easier it will be to adapt to CNC.
    Think of it this way. If you already know basic machining practice as it relates to the CNC machine you will be working with, you already know what it is you want the machine to do. It will be a relatively simple matter of learning how to tell the CNC machine what it is you want it to do (learning to program). This is why machinists make the best CNC programmers, operators, and setup personnel. Machinists already know what it is the machine will be doing. It will be a relatively simple matter of adapting what they already know to the CNC machine.
    For example, a beginner to CNC turning centers should understand the basic machining practice related to turning operations like rough and finish turning, rough and finish boring, grooving, threading, and necking. Since this form of CNC machine can perform multiple operations in a single program (as many CNC machines can), the beginner should also know the basics of how to process workpieces machined by turning so a sequence of machining operations can be developed for workpieces to be machined.
    This point cannot be overstressed. Trying to learn about a particular CNC machine without understanding the basic machining practice related to the machine would be like trying to learn how to fly an airplane without understanding the basics of aerodynamics and flight. Just as a beginning pilot will be in for a great number of problems without understanding aerodynamics, so is the beginning CNC user have difficulty learning how to utilize CNC equipment without an understanding of basic machining practice.
    Learning about a new CNC machine – the key points
    From a programmer’s standpoint, as you begin to learn about any new CNC machine, you should concentrate on four basic areas. First, you should understand the machine’s most basic components. Second, you should become comfortable with your machine’s directions of motion (axes). Third, you should become familiar with any accessories equipped with the machine. And fourth, you should find out what programmable functions are included with the machine and learn how they are programmed.
    Machine components
    While you do not have to be a machine designer to work with CNC equipment, it is important to know how your CNC machine is constructed. Understanding your machine’s construction will help you to gauge the limits of what is possible with your machine. Just as the race car driver should understand the basics of suspension systems, breaking systems, and the workings of internal combustion engines (among other things) in order to get the most out of a given car, so must the CNC programmer understand the basic workings of the CNC machine in order to get the most from the CNC machine tool.
    For a universal style slant bed turning center, for example, the programmer should know the most basic machine components, including bed, way system, headstock & spindle, turret construction, tailstock, and work holding device. Information regarding the machine’s construction including assembly drawings is usually published right in the machine tool builder’s manual. As you read the machine tool builder’s manual, here are some of the machine capacity and construction questions to which you should find answers.
    What is the machine’s maximum RPM? How many spindle ranges does the machine have (and what are the cut-off points for each range? What is the spindle and axis drive motor horsepower? What is the maximum travel distance in each axis? How many tools can the machine hold? What way construction does the machine incorporate (usually square ways, dovetail, and/or linear bearing ways)? What is the machine’s rapid rate (fastest traverse rate)? What is the machine’s fastest cutting feedrate?
    These are but a few of the questions you should be asking yourself as you begin working with any new CNC machine. Truly, the more you know about your machine’s capacity and construction, the easier it will be to get comfortable with the machine.
    Directions of motion (axes)
    The CNC programmer MUST know the programmable motion directions (axes) available for the CNC machine tool. The axes names will vary from one machine tool type to the next. They are always referred to with a letter address. Common axis names are X, Y, Z, U, V, and W for linear axes and A, C, and C for rotary axes. However, the beginning programmer should confirm these axis designations and directions (plus and minus) in the machine tool builder’s manual since not all machine tool builders conform to the axis names we show.
    As discussed in key concept number one, whenever a programmer wishes to command movement in one or more axes, the letter address corresponding to the moving axes as well as the destination in each axis are specified. X3.5, for example tells the machine to move the X axis to a position of 3.5 inches from the program zero point in X (assuming the absolute mode of programming is used.
    The reference point for each axis
    Most CNC machines utilize a very accurate position along each axis as a starting point or reference point for the axis. Some control manufacturers call this position the zero return position. Others call it the grid zero position. Yet others call it the home position. Regardless of what it is called, the reference position is required by many controls to give the control an accurate point of reference. CNC controls that utilize a reference point for each axis require that the machine be manually sent to its reference point in each axis as part of the power up procedure. Once this is completed, the control will be in sync with the machine’s position.
    Accessories to the machine
    The third area a beginning CNC user should address is related to other possible additions to the basic machine tool itself. Many CNC machine tools are equipped with accessories designed to enhance what the basic machine tool can do. Some of these accessories may be made and supported by the machine tool builder. These accessories should be well documented in the machine tool builder’s manual. Other accessories may be made by an after-market manufacturer, in which case a separate manual may be involved.
    Examples of CNC accessories include probing systems, tool length measuring devices, post process gauging systems, automatic pallet changers, adaptive control systems, bar feeders for turning centers, live tooling and C axis for turning centers, and automation systems. Truly, the list of potential accessory devices goes on and on.
    Programmable functions
    The programmer must also know what functions of the CNC machine are programmable (as well as the commands related to programmable functions). With low cost CNC equipment, often times many machine functions must be manually activated. With some CNC milling machines, for example, about the only programmable function is axis motion. Just about everything else may have to be activated by the operator. With this type of machine, the spindle speed and direction, coolant and tool changes may have to be activated manually by the operator.
    With full blown CNC equipment, on the other hand, almost everything is programmable and the operator may only be required to load and remove workpieces. Once the cycle is activated, the operator may be freed to do other company functions.
    Reference the machine tool builder’s manual to find out what functions of your machine are programmable. To give you some examples of how many programmable functions are handled, here is a list a few of the most common programmable functions along with their related programming words.
    Spindle control
    An "S" word is used to specify the spindle speed (in RPM for machining centers). An M03 is used to turn the spindle on in a clockwise (forward) manner. M04 turns the spindle on in a counter clockwise manner. M05 turns the spindle off. Note that turning centers also have a feature called constant surface speed which allows spindle speed to also be specified in surface feet per minute (or meters per minute)
    Automatic tool changer (machining center)
    A "T" word is used to tell the machine which tool station is to be placed in the spindle. On most machines, an M06 tells the machine to actually make the tool change. Tool change (on turning centers) A four digit "T" word is used to command tool changes on most turning centers. The first two digits of the T word specify the turret station number and the second two digits specify the offset number to be used with the tool. T0101, for example specifies tool station number one with offset number one.
    Coolant control
    M08 is used to turn on flood coolant. If available M07 is used to turn on mist coolant. M09 turns off the coolant.
    Automatic pallet changer
    An M60 command is commonly used to make pallet changes.
    Other programmable features to look into
    An M60 command is commonly used to make pallet changes.
    As stated, programmable functions will vary dramatically from one machine to the next. The actual programming commands needed will also vary from builder to builder. Be sure to check the M codes list (miscellaneous functions) given in the machine tool builder’s manual to find out more about what other functions may be programmable on your particular machine. M codes are commonly used by the machine tool builder to give the user programmable ON/OFF switches for machine functions. In any case, you must know what you have available for activating within your CNC programs.
    For turning centers, for example, you may find that the tailstock and tailstock quill is programmable. The chuck jaw open and close may be programmable. If the machine has more than one spindle range, commonly the spindle range selection is programmable. And if the machine has a bar feeder, it will be programmable. You may even find that your machine’s chip conveyor can be turned on and off through programmed commands. All of this, of course, is important information to the CNC programmer.

    The Basics Of Computer Numerical Control

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    Fundamentals Of CNC
    While the specific intention and application for CNC machines vary from one machine type to another, all forms of CNC have common benefits. Though the thrust of this presentation is to teach you CNC usage, it helps to understand why these sophisticated machines have become so popular. Here are but a few of the more important benefits offered by CNC equipment.


    The first benefit offered by all forms of CNC machine tools is improved automation. The operator intervention related to producing workpieces can be reduced or eliminated. Many CNC machines can run unattended during their entire machining cycle, freeing the operator to do other tasks. This gives the CNC user several side benefits including reduced operator fatigue, fewer mistakes caused by human error, and consistent and predictable machining time for each workpiece. Since the machine will be running under program control, the skill level required of the CNC operator (related to basic machining practice) is also reduced as compared to a machinist producing workpieces with conventional machine tools.
    The second major benefit of CNC technology is consistent and accurate workpieces. Today’s CNC machines boast almost unbelievable accuracy and repeatability specifications. This means that once a program is verified, two, ten, or one thousand identical workpieces can be easily produced with precision and consistency.
    A third benefit offered by most forms of CNC machine tools is flexibility. Since these machines are run from programs, running a different workpiece is almost as easy as loading a different program. Once a program has been verified and executed for one production run, it can be easily recalled the next time the workpiece is to be run. This leads to yet another benefit, fast change-overs. Since these machines are very easy to setup and run, and since programs can be easily loaded, they allow very short setup time. This is imperative with today’s Just-In-Time product requirements.
    Motion control – the heart of CNC
    The most basic function of any CNC machine is automatic, precise, and consistent motion control. Rather than applying completely mechanical devices to cause motion as is required on most conventional machine tools, CNC machines allow motion control in a revolutionary manner. All forms of CNC equipment have two or more directions of motion, called axes. These axes can be precisely and automatically positioned along their lengths of travel. The two most common axis types are linear (driven along a straight path) and rotary (driven along a circular path).
    Instead of causing motion by turning cranks and handwheels as is required on conventional machine tools, CNC machines allow motions to be commanded through programmed commands. Generally speaking, the motion type (rapid, linear, and circular), the axes to move, the amount of motion and the motion rate (feedrate) are programmable with almost all CNC machine tools.
    Accurate positioning is accomplished by the operator counting the number of revolutions made on the handwheel plus the graduations on the dial. The drive motor is rotated a corresponding amount, which in turn drives the ball screw, causing linear motion of the axis. A feedback device confirms that the proper amount of ball screw revolutions have occurred.
    A CNC command executed within the control (commonly through a program) tells the drive motor to rotate a precise number of times. The rotation of the drive motor in turn rotates the ball screw. And the ball screw causes drives the linear axis. A feedback device at the opposite end of the ball screw allows the control to confirm that the commanded number of rotations has taken place.
    Though a rather crude analogy, the same basic linear motion can be found on a common table vise. As you rotate the vise crank, you rotate a lead screw that, in turn, drives the movable jaw on the vise. By comparison, a linear axis on a CNC machine tool is extremely precise. The number of revolutions of the axis drive motor precisely controls the amount of linear motion along the axis.
    How axis motion is commanded – understanding coordinate systems It would be infeasible for the CNC user to cause axis motion by trying to tell each axis drive motor how many times to rotate in order to command a given linear motion amount. (This would be like having to figure out how many turns of the handle on a table vise will cause the movable jaw to move exactly one inch!) Instead, all CNC controls allow axis motion to be commanded in a much simpler and more logical way by utilizing some form of coordinate system. The two most popular coordinate systems used with CNC machines are the rectangular coordinate system and the polar coordinate system. By far, the most popular of these two is the rectangular coordinate system, and we’ll use it for all discussions made during this presentation.
    One very common application for the rectangular coordinate system is graphing. Almost everyone has had to make or interpret a graph. Since the need to utilize graphs is so commonplace, and since it closely resembles what is required to cause axis motion on a CNC machine, let’s review the basics of graphing.
    As with any two dimensional graph, this graph has two base lines. Each base line is used to represent something. What the base line represents is broken into increments. Also, each base line has limits. In our productivity example, the horizontal base line is being used to represent time. For this base line, the time increment is in months. Remember this base line has limits – it starts at January and end with December. The vertical base line is representing productivity. Productivity is broken into ten percent increments and starts at zero percent productivity and ends with one hundred percent productivity.
    The person making the graph would look up the company’s productivity for January of last year and at the productivity position on the graph for January, a point is plotted. This would then be repeated for February, March, and each month of the year. Once all points are plotted, a line or curve can be drawn through each of the points to make it more clear as to how the company did last year.
    Let’s take what we now know about graphs and relate it to CNC axis motion. Instead of plotting theoretical points to represent conceptual ideas, the CNC programmer is going to be plotting physical end points for axis motions. Each linear axis of the machine tool can be thought of as like a base line of the graph. Like graph base lines, axes are broken into increments. But instead of being broken into increments of conceptual ideas like time and productivity, each linear axis of a CNC machine’s rectangular coordinate system is broken into increments of measurement. In the inch mode, the smallest increment is usually 0.0001 inch. In the metric mode, the smallest increment is 0.001 millimeter. (By the way, for rotary axes the increment is 0.001 degrees.)
    Just like the graph, each axis within the CNC machine’s coordinate system must start somewhere. With the graph, the horizontal baseline started at January and the vertical base line started at zero percent productivity. This place where the vertical and horizontal base lines come together is called the origin point of the graph. For CNC purposes, this origin point is commonly called the program zero point (also called work zero, part zero, and program origin).
    For this example, the two axes we happen to be showing are labeled as X and Y but keep in mine that program zero can be applied to any axis. Though the names of each axes will change from one CNC machine type to another (other common names include Z, A, B, C, U, V, and W), this example should work nicely to show you how axis motion can be commanded.
    The program zero point establishes the point of reference for motion commands in a CNC program. This allows the programmer to specify movements from a common location. If program zero is chosen wisely, usually coordinates needed for the program can be taken directly from the print.
    With this technique, if the programmer wishes the tool to be sent to a position one inch to the right of the program zero point, X1.0 is commanded. If the programmer wishes the tool to move to a position one inch above the program zero point, Y1.0 is commanded. The control will automatically determine how many times to rotate each axis drive motor and ball screw to make the axis reach the commanded destination point. This lets the programmer command axis motion in a very logical manner.
    With the examples given so far, all points happened to be up and to the right of the program zero point. This area up and to the right of the program zero point is called a quadrant (in this case, quadrant number one). It is not uncommon on CNC machines that end points needed within the program fall in other quadrants. When this happens, at least one of the coordinates must be specified as minus.
    Understanding absolute versus incremental motion
    All discussions to this point assume that the absolute mode of programming is used. The most common CNC word used to designate the absolute mode is G90. In the absolute mode, the end points for all motions will be specified from the program zero point. For beginners, this is usually the best and easiest method of specifying end points for motion commands. However, there is another way of specifying end points for axis motion.
    In the incremental mode (commonly specified by G91), end points for motions are specified from the tool’s current position, not from program zero. With this method of commanding motion, the programmer must always be asking "How far should I move the tool?" While there are times when the incremental mode can be very helpful, generally speaking, this is the more cumbersome and difficult method of specifying motion and beginners should concentrate on using the absolute mode.
    Be careful when making motion commands. Beginners have the tendency to think incrementally. If working in the absolute mode (as beginners should), the programmer should always be asking "To what position should the tool be moved?" This position is relative to program zero, NOT from the tools current position.
    Aside from making it very easy to determine the current position for any command, another benefit of working in the absolute mode has to do with mistakes made during motion commands. In the absolute mode, if a motion mistake is made in one command of the program, only one movement will be incorrect. On the other hand, if a mistake is made during incremental movements, all motions from the point of the mistake will also be incorrect.
    Assigning program zero
    Keep in mind that the CNC control must be told the location of the program zero point by one means or another. How this is done varies dramatically from one CNC machine and control to another. One (older) method is to assign program zero in the program. With this method, the programmer tells the control how far it is from the program zero point to the starting position of the machine. This is commonly done with a G92 (or G50) command at least at the beginning of the program and possibly at the beginning of each tool.
    Another, newer and better way to assign program zero is through some form of offset. Commonly machining center control manufacturers call offsets used to assign program zero fixture offsets. Turning center manufacturers commonly call offsets used to assign program zero for each tool geometry offsets. More on how program zero can be assigned will be presented during key concept number four.
    Other points about axis motion
    To this point, our primary concern has been to show you how to determine the end point of each motion command. As you have seen, doing this requires an understanding of the rectangular coordinate system. However, there are other concerns about how a motion will take place. Fore example, the type of motion (rapid, straight line, circular, etc.), and motion rate (feedrate), will also be of concern to the programmer. We’ll discuss these other considerations during key concept number three.
    Telling the machine what to do – the CNC program
    Almost all current CNC controls use a word address format for programming. (The only exceptions to this are certain conversational controls.) By word address format, we mean that the CNC program is made up of sentence-like commands. Each command is made up of CNC words. Each CNC word has a letter address and a numerical value. The letter address (X, Y, Z, etc.) tells the control the kind of word and the numerical value tells the control the value of the word. Used like words and sentences in the English language, words in a CNC command tell the CNC machine what it is we wish to do at the present time.
    One very good analogy to what happens in a CNC program is found in any set of step by step instructions. Say for example, you have some visitors coming in from out of town to visit your company. You need to write down instructions to get from the local airport to your company. To do so, you must first be able to visualize the path from the airport to your company. You will then, in sequential order, write down one instruction at a time. The person following your instructions will perform the first step and then go on to the next until he or she reaches your facility.
    In similar manner, a manual CNC programmer must be able to visualize the machining operations that are to be performed during the execution of the program. Then, in step by step order, the programmer will give a set of commands that makes the machine behave accordingly.
    Though slightly off the subject at hand, we wish to make a strong point about visualization. Just as the person developing travel directions MUST be able to visualize the path taken, so MUST the CNC programmer be able to visualize the movements the CNC machine will be making BEFORE a program can be successfully developed. Without this visualization ability, the programmer will not be able to develop the movements in the program correctly. This is one reason why machinists make the best CNC users. An experienced machinist should be able to easily visualize any machining operation taking place.
    Just as each concise travel instruction will be made up of one sentence, so will each instruction given within a CNC program be made up of one command. Just as the travel instruction sentence is made up of words (in English), so is the CNC command made up of CNC words (in CNC language).
    The person following your set of travel instructions will execute them explicitly. If you make a mistake with your set of instructions, the person will get lost on the way to your company. In similar fashion, the CNC machine will execute a CNC program explicitly. If there is a mistake in the program, the CNC machine will not behave correctly.
    Program: O0001 (Program number) N005 G54 G90 S400 M03 (Select coordinate system, absolute mode, and turn spindle on CW at 400 RPM) N010 G00 X1. Y1. (Rapid to XY location of first hole) N015 G43 H01 Z.1 M08 (Instate tool length compensation, rapid in Z to clearance position above surface to drill, turn on coolant) N020 G01 Z-1.25 F3.5 (Feed into first hole at 3.5 inches per minute) N025 G00 Z.1 (Rapid back out of hole) N030 X2. (Rapid to second hole) N035 G01 Z-1.25 (Feed into second hole) N040 G00 Z.1 M09 (Rapid out of second hole, turn off coolant) N045 G91 G28 Z0 (Return to reference position in Z) N050 M30 (End of program command)
    While the words and commands in this program probably do not make much sense to you (yet), remember that we are stressing the sequential order by which the CNC program will be executed. The control will first read, interpret and execute the very first command in the program. Only then will it go on to the next command. Read, interpret, execute. Then on to the next command. The control will continue to execute the program in sequential order for the balance of the program. Again, notice the similarity to giving any set of step by step instructions.
    Other notes about program makeup
    As stated programs are made up of commands and commands are made up of word. Each word has a letter address and a numerical value. The letter address tells the control the word type. CNC control manufacturers do vary with regard to how they determine word names (letter addresses) and their meanings. The beginning CNC programmer must reference the control manufacturer’s programming manual to determine the word names and meanings. Here is a brief list of some of the word types and their common letter address specifications.
    O – Program number (Used for program identification) N – Sequence number (Used for line identification) G – Preparatory function X – X axis designation Y – Y axis designation Z – Z axis designation R – Radius designation F – Feedrate designation S – Spindle speed designation H – Tool length offset designation D – Tool radius offset designation T – Tool Designation M – Miscellaneous function (See below) </LI>
    As you can see, many of the letter addresses are chosen in a rather logical manner (T for tool, S for spindle, F for feedrate, etc.). A few require memorizing.
    There are two letter addresses (G and M) which allow special functions to be designated. The preparatory function (G) specifies is commonly used to set modes. We already introduced absolute mode, specified by G90 and incremental mode, specified by G91. These are but two of the preparatory functions used. You must reference your control manufacturer’s manual to find the list of preparatory functions for your particular machine.
    Like preparatory functions, miscellaneous functions (M words) allow a variety of special functions. Miscellaneous functions are typically used as programmable switches (like spindle on/off, coolant on/off, and so on). They are also used to allow programming of many other programmable functions of the CNC machine tool.
    To a beginner, all of this may seem like CNC programming requires a great deal of memorization. But rest assured that there are only about 30-40 different words used with CNC programming. If you can think of learning CNC manual programming as like learning a foreign language that has only 40 words, it shouldn’t seem too difficult.
    Decimal point programming
    Certain letter addresses (CNC words) allow the specification of real numbers (numbers that require portions of a whole number). Examples include X axis designator (X), Y axis designator (Y), and radius designator (R). Almost all current model CNC controls allow a decimal point to be used within the specification of each letter address requiring real numbers. For example, X3.0625 can be used to specify a position along the X axis.
    On the other hand, some letter addresses are used to specify integer numbers. Examples include the spindle speed designator (S), the tool station designator (T), sequence numbers (N), preparatory functions (G), and miscellaneous functions (M). For these word types, most controls do NOT allow a decimal point to be used. The beginning programmer must reference the CNC control manufacturer’s programming manual to find out which words allow the use of a decimal point.
    Other programmable functions
    All but the very simplest CNC machines have programmable functions other than just axis motion. With today’s full blown CNC equipment, almost everything about the machine is programmable. CNC machining centers, for example, allow the spindle speed and direction, coolant, tool changing, and many other functions of the machine to be programmed. In similar fashion, CNC turning centers allow spindle speed and direction, coolant, turret index, and tailstock to be programmed. And all forms of CNC equipment will have their own set of programmable functions. Additionally, certain accessories like probing systems, tool length measuring systems, pallet changers, and adaptive control systems may also be available that require programming considerations.
    The list of programmable functions will vary dramatically from one machine to the next, and the user must learn these programmable functions for each CNC machine to be used. In key concept number two, we will take a closer look at what is typically programmable on different forms of CNC machine tools.

     

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