March 24th, 2009 by admin

HOW TO PROGRAM A CNC MACHINE

CNC programming uses a code similar in structure to BASIC. So, if you know how to construct a simple counting program, chances are, you already know what a G-Code looks like. However, there a few other things you have to consider before you start encoding instructions.

The first thing that you have to do is to assign values for each of the variables. These variables include the programmable motion directions (axes), and the reference point for the axes. The values that you assign to these variables dictate the movement of the machine.

The next thing that you have to do is to take into account the accessories of the machine. Many machines have accessories that are designed to enhance the capabilities of the basic device. However, using these accessories requires you to include them in the coding system. This means that if you want a more efficient machine, you will have to know the machine inside out.

READING CODES

After those steps, you have to create a subprogram that will deal with the math. This step will then allow your machine to compute the necessary variables and effectively operate without stopping to ask the operator what the limitations are.

To show you what these codes look like, 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.

March 21st, 2009 by admin

If you think that you will just sit back and relax when you have a CNC machine in your shop, think again. CNC may help you speed up your operations and even make them more efficient. However, CNC is not a “wonder robot” which will make you disregard all your employees and expect your shop to run on auto-pilot.

Though you will need more people without the CNC technology, you will need only three very, very skilled people. Call these people your friends, your team, whatever. In the long run, they might be just all you need to keep the shop in good shape.

THE PROGRAMMER

The first person is the CNC programmer. S/he is like the “playmaker”. S/he will create the programs that the CNC machines are intended to execute. Since the programs are in the form of CNC codes fabricated like sentences, he should have mastered these codes because they work like a different language. The regular CNC machine can use up to 50 codes, so that’s like learning 50 new words for the newbie.

Also, the programmer should have at least and engineering or machining degree. Remember that the CNC machine will only execute WHAT IT IS PROGRAMMED TO DO. If the program is wrong, the whole operation goes down the drain with it. Moreover,s/he should also be flexible and have a fast turn-around because a CNC machine is often used to machine a huge selection of different work-pieces.

THE OPERATOR

The second person that you need is the CNC operator. S/he will simply recheck the programs loaded to the machine and push the right buttons to get the work done. However, thinking that a CNC operator can have little or NO SKILL AT ALL is wrong. A CNC machine operator must have at least basic machining skills and s/he should have undergone some form of training to run a CNC machine.

These machines can produce very intricate motions, making it possible to make shapes that cannot be created on conventional machine tools. So, the operator should foresee this complexity and know how to cruise with it. The skills that an operator must have though, are lesser compared to the operators of conventional machine tools.

THE TECHNICIAN

The third person that will need is the CNC technician. Although this may still be the programmer, it’s more convenient to always have a technical expert on-call because in the long run, you may have more than one CNC machine and you may need to prioritize over the other in case both gets crippled at the same time. Just like the programmer, the technician should also be flexible and articulate. CNC offers a lot of complexity when it’s running right, how much more if it’s behaving badly?

So, if you are having job openings for positions that need to be handling a CNC machine, ask the applicants first to do a demo for you and make sure that during the demo, they know what they’re doing. An exam may also do wonders too. If they have no experience with any kind of CNC machine, it is advisable that you encourage them to take short courses on CNC.

Eighty-hour courses are available online and hey, it’s better than nothing. Experts even encourage employers to hire CNC machinists who have finished AND PASSED the National Occupational Competency Testing Institute (NOCTI) assessment just so they could be sure that their CNC machines will go to good hands. After all, a CNC machine is still an asset.

March 20th, 2009 by admin

The advent of Computers lessened the need for human intervention in almost all aspects of our daily lives. This is especially true in the industrial sector now that production is virtually automated.

Precision and accuracy

Computer numerical control has been able to help companies in terms of precision. With the need for more complex designs and more complex operations, human workers could not cope with the required precision that comes with advancement. CNC machines were able to alter that idea by allowing increased precision and lesser error ratios with regards to production.

Another important improvement that CNC has brought with it is the increased accuracy. The dimensions of components have to be very accurate. And since an increase in production speed also increases the error ratio, CNC has helped lower that ratio by the increased level of automation and the error detection capabilities that computers have.

Speed

In the industrial sector, speed is of the essence. With CNC technology, the normal production capacity has been increased exponentially. This means that effective and accurate production methods have been developed. Mass production requires more scrutiny for errors and mistakes. However, anomalies can also be corrected. The programming structures of CNC machines can be altered in a fast way. This means that mistakes do not have as serious an impact as they had before CNC was improved to this level.

Machine versatility

CNC machines have become very versatile with regards to the tools that they use. They can easily be assigned to different tasks and thus can be very productive. Tools and networks can be switched without compromising the speed of the production. Aside from this, one machine can do more than one task at a time. This exceeds the normal human capacities as it allows more tasks to be accomplished at a faster rate than before.

Furthermore, when one machine tool breaks down, it can easily be pulled off the grid to prevent it from affecting the whole production cycle. It can then be replaced or repaired on the spot.

Lesser human intervention

Since component production is a very tedious and repetitive operation, human error skyrockets as time passes. This is due to fatigue and other factors. Furthermore, the ability of a person degrades due to psychological and emotional factors. This means that if a person works on the same job for a certain amount of time, the person may eventually get bored or tired or both. This increases the possibility for the human to commit an error and thus causes a drop in the efficiency rating of that person. A machine, however, does not get tired or bored. A machine does not have any concern at all.

Therefore, a machine increases efficiency ratings by speeding up production and eliminating or reducing factors that threaten efficiency. In this case, one must simply program the machine to start a cycle. Furthermore, humans have to be fed, paid, and rested. Machines only have to be rested when failures occur to often and they do not need to be paid or fed.

This brings us to the conclusion that companies will be able to save a lot in the long run. While investing in CNC machines is not cheap, maintenance will only cost a fraction of what will be paid to manual laborers.

March 19th, 2009 by admin

Pad printing is a process where a 2-D object is transferred into a 3-D object. It is done by using an indirect offset printing process that involves an image being transferred from the printing plate via silicone pad over a surface that is to be printed.

Pad printing is used on a lot of industries that includes medical, automotive, promotional, apparel, electronics, appliances, sport equipment and toys. Pads are three dimensional objects typically molded of silicone rubber. They function as a transfer vehicle that picks up ink from the printing plate, and then transferring to the thing to be printed upon.

Examples of pad printing are the printing of labels on the keys on a keyboard or the logo of a toy manufacturer on a Frisbee. The unique properties of a silicone pad allow it to pick the image up in a variety of surfaces such as a flat, cylindrical, spherical, compound angle, textures, concave surfaces or a convex surface.

In presses that uses pad printing with Computer Numeric Control (CNC), the substrate or a material that can be printed on, such as paper, film, plastic, fabric, cellophane, or steel, is stationary and the silicone pads are programmed to print one image at a time.

With a press that uses Computer Numeric Control, the substrate is stationary and the pads are all programmed to one image at a time to achieve a multicolor print.

Though the robotic actions of these presses that uses Computer Numeric Control seems rather complicated, it allows simple setting procedures that enable several programs to be inputted into the machine. All actions are controlled by servo-motor drives giving a very smooth and highly controllable printing action, also giving stroke lengths to be infinitely variable to the dimensions of the machine. Manufacturers even claim that using presses with pad printing capability that uses Computer Numeric Control gives considerable energy savings to the industry.

The Computer Numeric system of control can be built on standard machines or modular assemblies that can be produced to suit any application. The degree of complexity is regulated only by the imagination of the designer of the product/s and the number of modules he wishes to use to complete his desired quota.

All of the elements of component manipulation can be achieved by combining with multiple closed cups, pad cleaning, varying pad-stroke lengths, alternative pad shapes and a lot more. This type of system is often used where items must be printed in line with other assembly processes, or for complex multiple prints on different surfaces.

The flexibility of a Computer Numeric Controlled press comes close to producing the ideal machine for a particular application. Although a CNC press is substantially more expensive than that of a conventional pneumatic press. If the workload can justify the use of a CNC press for the increase in investment, then the CNC press is well worth considering.

Although it is wise to not be carried away by the current technology at hand, it still must be a capable printer.

March 9th, 2009 by admin

Steel products are everywhere, from cars to computers to grills. The process of creating holes in steel to accommodate almost any metallic design can involve several entirely different methods:

One method is called “milling,” and in some cases “machining,” where holes are slowly ground into steel by a powerful drilling machine not much different than a hand drill-only on a much larger scale.

A much faster method for creating holes in steel is called “stamping,” which involves a machine called a punch press. A punch press is able to quickly apply ten, twenty, fifty, or five hundred tons (or more) of pressure to a slab of steel. The press uses a punch-and-die system, where the “punch” is a protruding element and the “die” is a flat surface with various recessed areas for the protruding element to stamp. The protruding element (usually on top) smashes into the steel (i.e. it “punches” or “stamps” the steel) with many tons of pressure, removing a portion of the steel slap called a slug, which usually falls through the recession in the die. The whole process can take less than a second and a complete metal part is usually the result. This stamping process is by far the fastest way to put holes into metal products. Often, there is a very high cost for creating a punch and die setup intended for a punch press, although the rewards of such a system is that the cost per piece is significantly less than any other method after the setup has been created.

While a stamping operation is ideal for high production runs, sometimes million piece runs are not required and it is therefore not feasible or logical. Without high production, it is usually difficult to justify the cost of a stamping setup.

When the cost of making a stamping operation is not justifiable, buyers can turn to a process called CNC Punching. Whereas Stamping is designed for high production runs of ten thousand parts or more, CNC Punching is designed to optimize short run costs, involving part quantities of ten thousand pieces or less. CNC Punching is by far the fastest way to put holes into steel without paying upfront for a punch and die stamping setup.

The term “CNC” means “Computer Numerical Control,” which is a system of using computer technology to effectively manipulate machines in very precise ways. In the case of CNC Punching, a computer code is used to instruct a stamping machine (similar to a punch press) to punch holes into steel. Whereas the stamping press can create a part in a single hit, the CNC punch press creates a part with multiple hits-very quickly. Usually a turret or tooling storage device feeds the correct punch and die into the punching center of the machine. Then, the machine receives precise commands from the computer in order to punch single holes in the locations specified by the computer program. Many CNC punching machines can punch a hole in half a second or less. While the creation of the parts takes longer, there is no need to wait for an expensive punch and die system to be made.

Milling is used in cases where there are either only twenty parts or less (prototypes) or unusually thick or steel designs that are not appropriate for punching. Stamping is used in cases where there are many parts to be made. CNC Punching is used to create an intermediate amount of parts. Which method you choose will largely depend on how many parts you require.

Joel Barrett has significant experience operating CNC Punching equipment. He recommends that companies looking for OEM metal parts consider cnc punching services
Berrien Metal Products, Inc.
Phone: 800-978-5300
Fax: 269-695-5300
Website: http://www.metalfabrications.com/services-cnc-punching-stamping.html

Article Source: http://EzineArticles.com/?expert=Joel_Barrett

March 7th, 2009 by admin

With a CNC servo kit, you are benefited from flexibility and versatility whenever you want. This device is known to be one of the most powerful and versatile control systems available in the industry, these days.

One of best things about utilizing this kit for one’s own benefit is that no CNC experience is required. The kit is very user friendly and available with a full range of canned cycles. You would be on top of the world to know that the CNC servo kit is user friendly. Here is information on the operating methods:

a) Teach Mode:

This operating mode allows you to start with the operation straight away without any prior training required. All you require to do here is to give an hour and you can learn enough to instruct the machine to come up with specific and angular moves and to run production parts. You need to use the serve pendant and move each axis to the position you want. This will teach the CNC system ways to cut the first part. Now you require pressing the SET key in order to store each move and feed the rate. Thereafter press the play key and then the RUN key. This will run the program again. Here, you do not need to use the PC-driven control. Once you create pendant program library, you can save them in the main computer memory of the system.

b) Conversational mode:

This mode tends to provide the simplest way to develop CNC parts with 2 to 4 axis. The dynamic graphic capabilities and canned cycles of this mode facilitate you to enjoy all the navigation tools you require to navigate through programming operations that are difficult and unknown to you. When using the CNC servo kit all you require to do is to follow the instructed messages while filling all the blanks to inquire about the part. This is not all. You would also be benefited from online help screens for elaborative explanation of any function. The help screens are context sensitive.

c) CNC mode:

This is a programming method of choice. It facilitates making various complicated shapes and even helps creating sculptured surfaces. All you require is some knowledge of G and M codes. The mode has been specifically designed to control all the CNC servo kit movements in order to facilitate the following features:

2-axis circular interpolation such as XY, XZ and YZ.
Cutter diameter compensation
4-axis continuous linear interpolation.
Canned cycles
Minor image
Scaling rotation
And much more.

The mode also allows you fast access to a user-friendly tool table. This table easily allows you to enter analyze or edit tool information. Additionally set tool length offsets semi-automatically. The mode also let you enjoy full CAD/CAM compatibility with most of the packages available commercially such as servo sown Quick ‘n’ in easy CAM. System.

Operating a CNC servo kit is not too difficult. You would be able to do it instantly without requiring any knowledge on CNC or its functions.

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 servo kits and related information.

http://www.computer-numericalcontrol.com/

By M. Applebaum

Article Source: http://EzineArticles.com/?expert=Martin_Applebaum

March 4th, 2009 by admin

Steel products are everywhere, from cars to computers to grills. The process of creating holes in steel to accommodate almost any metallic design can involve several entirely different methods:

One method is called “milling,” and in some cases “machining,” where holes are slowly ground into steel by a powerful drilling machine not much different than a hand drill-only on a much larger scale.

A much faster method for creating holes in steel is called “stamping,” which involves a machine called a punch press. A punch press is able to quickly apply ten, twenty, fifty, or five hundred tons (or more) of pressure to a slab of steel. The press uses a punch-and-die system, where the “punch” is a protruding element and the “die” is a flat surface with various recessed areas for the protruding element to stamp. The protruding element (usually on top) smashes into the steel (i.e. it “punches” or “stamps” the steel) with many tons of pressure, removing a portion of the steel slap called a slug, which usually falls through the recession in the die. The whole process can take less than a second and a complete metal part is usually the result. This stamping process is by far the fastest way to put holes into metal products. Often, there is a very high cost for creating a punch and die setup intended for a punch press, although the rewards of such a system is that the cost per piece is significantly less than any other method after the setup has been created.

While a stamping operation is ideal for high production runs, sometimes million piece runs are not required and it is therefore not feasible or logical. Without high production, it is usually difficult to justify the cost of a stamping setup.

When the cost of making a stamping operation is not justifiable, buyers can turn to a process called CNC Punching. Whereas Stamping is designed for high production runs of ten thousand parts or more, CNC Punching is designed to optimize short run costs, involving part quantities of ten thousand pieces or less. CNC Punching is by far the fastest way to put holes into steel without paying upfront for a punch and die stamping setup.

The term “CNC” means “Computer Numerical Control,” which is a system of using computer technology to effectively manipulate machines in very precise ways. In the case of CNC Punching, a computer code is used to instruct a stamping machine (similar to a punch press) to punch holes into steel. Whereas the stamping press can create a part in a single hit, the CNC punch press creates a part with multiple hits-very quickly. Usually a turret or tooling storage device feeds the correct punch and die into the punching center of the machine. Then, the machine receives precise commands from the computer in order to punch single holes in the locations specified by the computer program. Many CNC punching machines can punch a hole in half a second or less. While the creation of the parts takes longer, there is no need to wait for an expensive punch and die system to be made.

Milling is used in cases where there are either only twenty parts or less (prototypes) or unusually thick or steel designs that are not appropriate for punching. Stamping is used in cases where there are many parts to be made. CNC Punching is used to create an intermediate amount of parts. Which method you choose will largely depend on how many parts you require.

Joel Barrett has significant experience operating CNC Punching equipment. He recommends that companies looking for OEM metal parts consider cnc punching services
Berrien Metal Products, Inc.
Phone: 800-978-5300
Fax: 269-695-5300
Website: http://www.metalfabrications.com/services-cnc-punching-stamping.html

Article Source: http://EzineArticles.com/?expert=Joel_Barrett

March 3rd, 2009 by admin

CNC router machines are used for a number of different purposes, from cutting plastic to cutting metal. There are different machines for different purposes. These machines are designed to make signs or just general jobs. These machines can also be used to engrave various materials.

These machines are no longer just popular for industrial use, they are also popular for home use. CNC routers are extremely accurate and versatile. If people can’t afford new equipment people are often considering used equipment.

Used machines are still fairly expensive, however it is possible to make your own table using plans available on the internet. These plans allow you to save quite a lot of money.

Uses of a CNC Router

CNC routers are well suited to labor intensive tasks, or projects which would otherwise be impossible or require skilled labor. Common uses include creating metal inlays in wood. Even complicated designs are made easy by using CNC machines as compared to doing it all by hand.

CNC routers are also fantastic for making furniture. Every time you get high quality professional results. You can program the machines using computers so that you can get very accurate results. Anything can be engraved using these machines, from a very big sign to very small writing. It’s actually quite easy to use these routers once you have had the proper training.

Small CNC routers run from standard 120V power supply, this means that it can be run in a normal house. If you’re setting up a home workshop then this would be your best option. These small models typically cost around $7000 new, whereas a larger machine could cost $20,000 upwards. Buying a larger machine is defiantly a good idea as they can be half the price. If you will sell your furniture then you can hopefully treat it as an investment.

Buying a Used CNC Router

Buying a used router can be fantastic value for money, you can save half of the price you would otherwise have had to pay. You do need to make sure you take your time choosing a used machine so that you can find a good buy. You have to make sure you don’t end up buying a lemon! A used machine probably won’t be as powerful as a new one even if it’s rarely used, however this may not matter.

You can opt to purchase a reconditioned machine, these have been inspected and had any parts replaced. This means that you can hopefully buy an as new machine. You must make sure you check out the options and find out exactly what has been done to the machine.

You should check out what form of support the company will offer you. Most will offer you installation and some basic training. It’s very important to buy a machine with training or be aware that you will have to pay extra for it if you have never used one before.

Ken Morris’s detailed reports can be found on different web pages related to cnc router and cnc router tables. You can come across his publications on cnc machines and tools at http://www.insidewoodworking.com

Article Source: http://EzineArticles.com/?expert=Ken_C._Morris

March 2nd, 2009 by admin

So you want to know what a CNC Router does, huh? Well, that is exactly what this article is about. I can tell you that when I first started my investigation into CNC Routers I had a difficult time finding specific information about what the exact uses of the machine are.

However, after furthering my research I was able to find that these machines have multiple uses. The Router can be used for anything from creating a decorative sign for your home to building furniture for your home goods retail store.

The CNC Router is predominantly used for various types of metals and woods.

The CNC machine has become something of a necessity within the wood crafting and signage industries; especially that of high volume manufacturers. These machines have the ability to produce at a rate of 20 times faster than the average man. It is for this simple reason that these machines have quickly become more cost effective than the hiring of hourly paid labor workers.

So how does it work?

Well, for starters you will have a software program that allows you to navigate and direct the entire process from your computer. You will be able to precisely direct your machines every move and with a cutting speed of up to 1500 inches per minute! This is a huge reduction in time per cut which ultimately means a large operations expense reduction.

In conclusion, I know that this article has not been the most detailed, however, it does give you the basic information about what exactly a CNC Router is. I hope that this has been somewhat informative and helpful and I wish you the absolute best in your search.

For more information on CNC Router or visit http://www.ez-router.com.

Article Source: http://EzineArticles.com/?expert=Bill_Mcyntire

March 1st, 2009 by admin

CNC machines are used in industrial settings such as factories and schools. CNC, the abbreviation for Computer Numerated Control, first came into use in the 1970s and are used in many places today. They have to be programmed for what specifically you want done, but once they are programmed, they are very easy to operate. Learning how to program CNC equipment and machines usually takes a special schooling.

CNC machines are very expensive and are usually only purchased for industrial use. They are sometimes purchased used for a lesser cost and used for woodworking jobs where you want repetitive cutting. In factories, they are used to drill holes, cut designs as well as give the product a finished appearance. They are time saving and very accurate.

CNC routers are used for drilling holes automatically when you have a large quantity and want consistency. They are great for large jobs where manual drilling would become repetitive and tiresome, thus making errors more common.

A CNC lather is excellent for cutting wood and is often used in the making of furniture pieces. Different models of these cnc woodworking machines are available in different powers from fifteen to forty horsepower. This will depend on the type of wood as well as your needs. Some high quality modes operate in several modes from manual to all power, allowing you to custom it to your individual needs for the job.

Milling machines are used in the milling business with Bridgeport being the most common. They are efficient and long lasting but very expensive and are used in small and large factories.

The CNC mill is a large tool that uses robotics and computer programming to assure accuracy. Because of their extreme accuracy, you will often see Bridgeport mills used in the airline business. A programmer will set the specifications for what tools it needs and at what degree and measurement and the CNC will do it all and eject the finished part.

Another form of equipment in the CNC industry is engraving equipment. These are used to engrave glass, stone, wood, metal and almost any material you desire. They are fast and more accurate than it could ever be done manually. They are used for small and large jobs.

CNC machines are very expensive and out of reach for most individuals. Most individuals, however, don’t have use for a CNC on a consistent basis. If you are considering purchasing one, you may want to check into refurbished or used equipment. Refurbished equipment is a better option than used because they are usually totally repaired as well as coming with some sort of warranty.

The magazine writer Guy Morris is very interested in themes related to cnc router and cnc router tables. You might see his abstracts on cnc woodworking machines at http://www.insidewoodworking.com

Article Source: http://EzineArticles.com/?expert=Guy_J_Morris