How does CNC Machining Work?

Computer numerically controlled (CNC) machining is a new age manufacturing technique. With the rise of computers, these machines have become a popular choice when turning stock material into functional parts. Read more about CNC machining and how it works below:

What is it?

CNC machining is the act of using a CNC machine to remove layers of material from a standard piece of material such as aluminium. The CNC machine is one of two new age devices that use computer files to create a product. The file is used to determine where material is removed and how much is removed. There are a few high precision tools used to complete designs that are rotated around 1 of 5 axis.

How does it work?

CNC machining is a manufacturing process that is reliant on digital instructions known as G-code. The G-code leads the machine through the removal process. The three most common CNC machining operations are drilling, turning and milling. The CNC machine used most often between these three is a milling machine. This type of CNC machining involves the use of cutting tools that rotate in order to remove the material. These machines are very similar to drills as drills can also shift and rotate as necessary to remove material from a stationary piece of material. Although CNC machining is usually carried out on metal materials, it can be completed on various materials such as plastic, wood and more.

If your machinery is not functioning efficiently and you are struggling to diagnose the problem manually, then vibration analysis needs to be conducted. Not sure what vibration analysis is? Read all about it below:

What is it?

Vibration analysis is a technique used to diagnose various problems with the components within machinery. The reason vibration analysis can be used to determine the health of machinery is because of the differences in vibrations between a fully functional machine and a damaged machine. Any damaged parts will give off a specific vibration which can be identified through vibration analysis. The parts that are damaged can then be repaired or replaced.

How it is conducted?

The process of vibration analysis is complex. In order to conduct vibration analysis an accelerometer is needed. This device is will be able to read the vibrations from the machinery and measure the amount of vibrations per second or minute. The data will be collected, and software will be used to determine certain variables regarding amplitude, time and frequency. These variables can then be used to determine the health of the machinery through algorithms and analysis by professionals.

What can it diagnose?

Vibration analysis is one of the most effective techniques for diagnosing various problems in machinery. Vibration analysis can be used to diagnose the following; problems with the bearings, misaligned components, bent shafts, broken welds, loose components, gearbox failures, empty spaces or air bubbles and much more. Once the problem has been diagnosed, engineers can decide on the best way to solve the problems.  

Computer numerical control (CNC) machining is an automated method of completing tasks such as cutting various materials. These machines are used in many industries and are often chosen over their manual counterparts due to their advantages. Here are a few benefits of CNC machining:

Precision

Using a CNC machine is a very precise method of cutting materials. The automation of these machines removes the chance of human error and allows for precise designs and shapes to be cut into materials such as metal and plastic.

Quantity

Automated machining is a much faster way to produce goods than using a manual lathe or drill. Due to its speed, using a CNC machine will allow manufacturers to produce more in a shorter time frame. Thanks to the precision of CNC machining, they provide quality and quantity.

Reliability

CNC machining is a reliable output method as the machines can run for hours on end. The only time they need to be stopped is when they need maintenance, repairs or there is no operator to watch the machines.

Safety

It is much safer to use CNC machines than manual machines. CNC machining does not require an operator to get up close and personal with the sharp bits. They can setup the machine without being exposed to dangerous equipment and can watch their performance from a safe distance.

Maintenance

CNC machining is a machining technique that requires little maintenance. The regular maintenance of these machines includes regular dusting of the machine, its elements and the work area as well as timely changes of cutting tools. The machines software will update itself

Surface grinders are machines that can be found in many workshops. They are used by manufacturers to produce a final product with a smooth finish. There are many advantages of using a surface grinder. Read more about the advantages below:

Accuracy

Surface grinders are very accurate in their work. The chucks hold the materials in place as the grinding wheel smooths the surface. Machines of a high-quality will be capable of providing accurate finishes with less than a centimetre of depth.

Finish

The main reason for using surface grinders is to achieve a smooth finish on a material. Due to the accuracy of these machines and the abrasive materials used grinding, a smooth and even finish can be accomplished with every product.

Ease of use

Using a surface grinder is not a complicated task. They are easily set up and the operation of these machines is relatively simple. The use of the machine is made easier if the machine in question is a computer numerically controlled (CNC) grinder.

Materials

A misconception of surface grinders is that they can only complete tasks on metal materials. This is incorrect as they can provide accurate, smooth finishes on a variety of materials including non-metal materials such as plastic.

Machines

There are two surface grinder designs for you to choose from; horizontal spindle and vertical spindle. The horizontal spindle design is the best choice for precision due to the smaller grinding surface. The vertical spindle design is the better choice for faster grinding on larger materials.

There are a few types of thermal spraying methods; flame spraying, cold spraying, HVOF spraying and so on. Each spraying method uses different gases in order to create quality coatings. Here are the types of gas used for each thermal spraying method:

Flame spraying

Flame spraying uses different gases for each spray material. The spray materials used for flame spraying are wire or rod, powder or plastic. In all cases, the spray materials are melted with an oxy-acetylene flame (directly or indirectly). Wire or rod spray materials are sprayed onto the product with the help of compressed air or nitrogen. Combustion gases such as nitrogen, oxygen or argon are used to spray powder. Nitrogen and oxygen are also the carrier gases for plastic.

Cold spraying

This method of thermal spraying reduces the oxide in the coatings as the spray material is not heated to a temperature above its melting point. Nitrogen and helium are the two gases used to complete this spraying method.

High velocity oxy-fuel (HVOF) spraying

HVOF spraying uses a spraying technique that allows for dense coatings with high levels of adhesion. This dense coating is achieved by high pressure combustions of oxy-fuel gases (ethene-oxygen, propane-oxygen, propylene-oxygen, hydrogen-oxygen and acetylene-oxygen) in a combustion chamber.

Plasma spraying

The powder used for this type of thermal spraying is melted by a plasma jet. Plasma used for this spraying method is produced by an arc that burns in gases such as argon, helium, nitrogen or hydrogen. Once melted, the spray material is the transferred to the product with the help of nitrogen or argon.