We are one of Asia’s top manufacturers of CNC machine tools, therefore we are familiar with the typical challenges that can arise while milling. These include the full spectrum, from burn marks on machined parts’ finishes to power supply problems, jamming of various moving parts, and inaccurately manufactured parts.
In this article, we’ll attempt to address some of the most frequent issues and difficulties encountered during CNC machining and offer solutions. Modern technology can benefit us much from CNC controllers, but the more you rely on them, the more problems you’ll be in if you need CNC controller repair contact us.
The Big Four Mistakes with CNC Machine Tools
According to our observations, there are four basic obstacles that machinists have while using CNC lathes, milling machines, and multi-axis machining centers.
1.Use of improper cutting tools or settings
Poor-quality material finishes can frequently be the result of selecting the incorrect cutting tool for the task. This may appear as jagged edges, surface cutter markings, raised marks, or burn marks on the material’s corners or edges. This mistake could lead to significant tool wear.
Poor material finishes may be caused by a dull tool or an inefficient feed speed ratio. Incorrect tool dimensions in terms of size, quality, or compatibility with the material may also be to blame.
Selecting the appropriate tool and setting for the task and material will help resolve this.
2 programming mistakes
Since CNC machines are extremely sophisticated machinery, many of the problems that occur in CNC machining are frequently caused by programming. These may result from improper setup, incorrect data variables being entered into the CNC controller, or a lack of understanding of the various G and M codes utilized for the controller.
It’s crucial for new operators to have proper training in the various ways that CNC machines can be programmed in order to correct these problems. New operators should be given thorough instruction manuals and training about motion sequencing, the operation of the machine, and by experienced operators on the shop floor.
3 Poor CNC machine tool maintenance
CNC Machine Tools are complex, constantly moving devices that require routine cleaning and maintenance to function at their best.
Failure to remove dirt, materials, and other debris could cause a buildup that, over time, could lead to machine breakdowns or inaccurate machining.
It is essential for machine operators to adhere to a thorough maintenance schedule for the machine tools they are using in order to avoid this. To ensure that operations continue to run smoothly and without interruption, they should also routinely check the levels of coolants or airflow, for example, air filters.
Note that a blocked air filter in your cooling system could cause an overheated spindle.
4 Poor Worker Training and Skill
CNC machine tools operators today require a distinct set of knowledge and abilities due to the growing use of computing and programming. Even if they have machining expertise and experience with older versions of machines, workers lack the organizational, planning, and programming abilities necessary to maximize the production of these machines.
Hire the right machine operators who can visualize and design the machining process, choose the appropriate tools and sequences for the work, and create the program if you want to make sure that this issue is fixed.
5 Chucks and Fixtures Clamping and Unclamping Issues
This can become a significant problem if the workpiece cannot be grasped firmly by the chuck or if it moves or shakes while being machined. Consider taking the following actions to fix this:
- Make sure the item is positioned correctly to guarantee a tight clamp.
- Verify the setup of the hydraulic pump and hydraulic pressure.
- Verify that the jaws being utilized are properly adjusted and strong enough to hold the material. Instead of using a point grip, make sure you use a larger surface grasp.
- If the chuck won’t open or shut, make sure the foot switch is in operation. Check to make sure the contacts are still in place and that the wires are in good condition.
- Make that there is enough lubricant for the chuck’s various sections and that no dirt or debris is interfering with the motions.
- Based on the MDI M-code command, determine whether the chuck is operational.
- Verify whether the solenoid’s output is operational. If it does, an issue could be a broken wire at the connector.
- Verify the operation and tightness of the draw tube that links the hydraulic cylinder to the chuck.
6. Power Supply Issues
Occasionally, problems with the power supply may prevent the display or other components of the CNC machine tool from functioning. To fix this, check that the input side of the power and supply is receiving the appropriate voltage and power. Then, to confirm proper operation, the secondary side, or output, should be examined.
It is suggested that you let a professional do the examination.
If there is no power or a low voltage reading, think about disconnecting the output connections when the power is off, starting the device, and then testing the output side once more. You can also check the machines’ LEDs to see if they are on and look at the fuses to see if they are blown.Contact for more details about ASCO Solenoid Valves.
7 Issues with Automatic Tool Changers
Your CNC machine tool’s automatic tool changeover could occasionally present you with problems. Learning every stage of the tool-changing procedure and understanding what went wrong would help in troubleshooting this issue.
Verify the smooth operation of the base, gripper arm, tool holder, support arm, and tool magazines. Or check to see if the mechanical arm action and swiveling both function as intended. Keep coolant and chips off the automated tool changer and the tool holders.
8 Machine Chatter and Vibration
Your tool’s life may be severely shortened, your CNC machine’s durability may be compromised, and the quality of your machined product may suffer when your CNC machine vibrates while it is operating. Simply listening to the noise that is produced, which can occasionally be very loud, will reveal this.
You must determine whether the problem is tool chatter or workpiece chatter in order to fix it. You can also change the RPM of your machining operation so that the frequencies of the operation do not coincide with the frequency of the material.
9 Machine Tool Overheating
Overheating can occasionally happen during large volume, lengthy machining operations. Internal temperatures of 150 degrees or more may be reached by your CNC machine tool. This could have a detrimental impact on the outcome of your machining project, the tool used, and the CNC machine itself.
Make sure to routinely clear all channels and clean the machine to be free of dirt, soil, and debris to prevent this. Establish a schedule for cleaning up any metal shavings and any cutting fluids.
The main cause of a machine spindle overheating is prolonged use at maximum rpm. A spindle with grease lubrication cannot run at maximum speed for long periods of time. A spindle with air-oil lubrication is preferable, although an oil-jet lubricated spindle, such as the one used by Hwacheon, can operate for extended periods of time even at maximum rpm.
Machine overheating is also influenced by changes in the workshop’s ambient temperature. Your precision machine tool’s accuracy may be impacted by wind or air draughts coming in through open windows or doors.
10. Incorrect CNC Machine Tool Partners
In order to lessen the likelihood of machine issues and human errors, choosing the correct CNC machine tool partner is arguably most crucial.
Long-term costs for your business from blunders and faults with machine tools can be high. Work with reputable and knowledgeable CNC machine tool vendors who offer a complete after-sales maintenance, training, and servicing package to ensure that problems are minimized.To learn more about inverter repair services get in touch with us.