Last updated on
2024年6月23日
What are some of the common CNC machining errors and how can you avoid or fix them?
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One of the most basic but crucial errors in CNC machining is choosing the wrong tool for the job. Different materials, shapes, and features require different types of tools, such as drills, mills, lathes, and routers. Using the wrong tool can result in poor quality, damaged parts, or even broken tools. To avoid this error, you should always check the specifications of the tool and the material, and use the appropriate tool for the task. You should also regularly inspect and maintain your tools to ensure they are in good condition.
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To high of feed rate when milling a hole when the endmill is just under the diameter of the hole. (Hole Dia. – Tool Dia.) ÷ Hole Dia. is a good formula to use to slow the feed rate for better hole formation.
Another common error in CNC machining is setting the wrong feed rate and spindle speed for the tool and the material. Feed rate is the speed at which the tool moves along the workpiece, while spindle speed is the rotation speed of the tool. If the feed rate or spindle speed is too high or too low, it can cause problems such as overheating, chatter, tool wear, surface defects, or dimensional inaccuracies. To avoid this error, you should always follow the recommended feed rate and spindle speed for the tool and the material, and adjust them according to the cutting conditions. You should also use proper coolant and lubrication to prevent overheating and friction.
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Totally agree. Tool speed/feed must be provided by supplier in their tool book brochure. Special materials like composites are bit challenging as the material isnt often listen in their detailed brochure. Always keep material type, thickness, density & tool type, coating , angles, Fz, climb, conventions all in consideration before setting up S/F ..
Another common error in CNC machining is clamping the workpiece improperly on the machine. Clamping is the process of securing the workpiece on the machine table or fixture, to prevent it from moving or vibrating during the machining operation. If the workpiece is not clamped properly, it can cause issues such as misalignment, distortion, chatter, or even damage to the workpiece or the machine. To avoid this error, you should always clamp the workpiece firmly and evenly, and use the appropriate clamping method and device for the workpiece shape and size. You should also check the workpiece alignment and orientation before starting the machining operation.
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In the case of a CNC lathe, it is also a good idea to true up your jaws before each run and check for material run out. It may be necessary to measure your material and true it up prior to running your program.
Another common error in CNC machining is making mistakes in the programming of the machine. Programming is the process of creating and editing the code that instructs the machine how to perform the machining operation. Programming errors can include syntax errors, logical errors, calculation errors, or human errors. These errors can lead to unexpected or incorrect movements of the machine, resulting in wasted time, material, or even damage to the machine or the operator. To avoid this error, you should always use a reliable and compatible software for programming, and verify and simulate your code before running it on the machine. You should also follow the standard programming conventions and best practices, and document your code clearly and accurately.
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Wrong part set up on fixtures poorly made without proper poke-yoke system...it increases the chances that parts will be mislocated and the final trimming results will be unsatisfactory.
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Successful companies are using locked down proven post processors. Then using locked down and proven simulation. No substitutes for that.
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Most common error's include post processor compatibility issue. Setup of PP comes from the supplier and how well established process or knowledge they have on the controller and CNC synergy level. Several other type of issues are "Angle Over Limit" due to angle head angle exceeding the limitations. Manual over writing of M codes of SPINDLE/ON|OFF - P2P - Q-AXIS - VAC - ROTHEAD C AXIS etc. Junior programmers might also face errors on interpolation, level to level macros & the the level of understanding of cutter/head/spindle angles/approach/retract directions.
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Entering and exiting cutter compensation can cause many machining accuracy errors. A simple solution is to make two moves larger than the tool radius towards the point of accuracy after cutter compensation is called up. This works on turning, milling and 4 axis wire EDM from my experience.
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On the Fanuc CNCs, I have seen the occaisonal case where circular interpolation will not take the expected path. This usually showed up when using endpoint-radius notation, and would turn in the right direction, but use teh wrong of two possible centerpoints. The solution was to use the endpoint-vector, i.e. G03XxxxZxxxIiiiKkkk notation. In this example I am thinking of a lathe.
Another common error in CNC machining is ignoring or overlooking the environmental factors that can affect the machining operation. Environmental factors can include temperature, humidity, dust, noise, vibration, or power fluctuations. These factors can cause variations in the material properties, tool performance, machine accuracy, or operator safety. To avoid this error, you should always monitor and control the environmental factors in your workshop, and use appropriate measures to protect your machine, tools, workpiece, and operator from any adverse effects. You should also calibrate your machine regularly to ensure its accuracy and reliability.
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Dentre os itens citados acima, é de suma importancia checar periódicamente a geometria de máquina. Entender a geometria de uma máquina CNC é crucial para operadores e programadores, pois isso influencia diretamente na precis?o, na eficiência e na qualidade das pe?as produzidas.
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