How CNC Technology Will Change Manufacturing
Machining has come a long way since the early days when the skill of the user and the quality of the tool were two of the most critical factors in producing complex parts with tight dimensional tolerances. Today, the introduction of computer-aided solutions simplifies the manufacturing process and is capable of consistently producing quality products in large volumes. One of these game-changing technologies is computer numerical control (CNC) machinery.
Unlike conventional machining solutions, CNC machines rely on automation to control the production process. CNC machining relies on CAD (computer-aided design) models and computer-aided manufacturing software to fabricate raw materials into finished parts. The reliance on computer-aided manufacturing processes and the automation they support means the quality of produced items do not rely on the skills of the machine operators. Using CNC machinery, factory workers manage the manufacturing process through software and do not perform as many manual processes. This automation minimizes human error and results in improved part quality.
How CNC machines function
The design to be created is developed using computer-aided design software to develop digital 3D models. Once completed, the 3D models are fed into CAM (computer-aided manufacturing) software, and the CAM (computer-aided manufacturing) application is used to set up the manufacturing process. The CAM application is used to convert the machining program into G-code. The G-Code program can be written, manually, but automatic conversion is more commonly a feature of the software program. The G-Code instructions are loaded into the CNC machine. Executing the program then produces the designed part with little additional human intervention.
Computer numerical control is made possible by using software programs to control the operation of machine tools. The control software is generally developed using G-code, a programming language that enables the programmer to manipulate the tool path, tool selection, speed, and feed rate of the tools. Although skilled operators aren’t required to run CNC machinery, a skilled programmer is required to manage the control process that automates the manufacturing process.
Increased throughput and industrial-grade products
Accurate positioning systems are used to control the tooling attached to CNC machines, providing high-precision dimensional tolerances. CNC-machined components usually require only minimal finishing. CNC machinery can cut at precision levels of approximately 0.001 inches. The ability of CNC machines to repeatedly produce tightly held tolerances and parts that can often be used in the as-machined condition helps lower costs and part returns. Improved efficiency may create both the machine capacity and the desire on a customer's part to increase production, increasing the manufacturer's revenue. Unlike conventional manufacturing processes that require molds, CNC machining production capabilities are not hampered by the durability of a mold.
Increased productivity and flexibility
The manufacturing speed of CNC systems is a critical component of their ability to optimize productivity. The maximum feed and rapid rates of the average CNC machine can exceed 2,300 inches per minute (ipm) depending on the tool used, material, and geometrics of the fabrication process. The ability to perform cutting, milling, or drilling tasks at more than 500 ipm eclipses the manufacturing capabilities of conventional machinery.
The high precision levels, repeatability, and machining rate of CNC systems speed up manufacturing processes. Like all equipment, the tooling used in CNC systems is susceptible to wear caused by constant use. Sensor-equipped CNC machines can provide automated machine condition reports that allow needed maintenance to be predicted and scheduled before any irreparable damage to the machine occurs. Implementation of predictive maintenance strategies reduces downtime, which, in turn, increases productivity.
CNC machines can be equipped with diverse tools to execute multiple fabrication processes without human intervention. The integration of multiple spindles that are attached to cutting, milling, and drilling tools makes it possible to carry out multiple operations in planned sequences, with no intervention by the operator. The manufacturing flexibility offered by CNC machines allows the operator to produce components quicker to speed up go-to-market timelines.
Improved reliability and taking the next steps
CNC machines are reliable and capable of functioning for decades without encountering major operational challenges as long as they are properly maintained. This reliability and the option of automated diagnostics make CNC machines an excellent asset within every manufacturing facility. The average industrial-grade CNC system costs approximately $50,000 to $150,000. Its operational costs include hiring a professional and setting up a maintenance framework.
The total overhead cost associated with managing CNC systems is considerable. Depending on your needs you can offset this cost by going the outsourcing route. Speak to ACHB’s expert industrial designers to take advantage of CNC technology.
Implementing Industry 4.0 within the smart factory
A “smart factory” is a connected environment where machine-to-machine and machine-to-man intercommunications occur. Industry 4.0 refers to taking the next logical step to allow elements of artificial intelligence to provide adaptive functionality, including data-driven plant optimization, predictive maintenance, and remote monitoring. These changes can lead to increased productivity and competitiveness for the manufacturers who apply these strategies to their CNC machining business.
CNC technology provides the manufacturing industry with drive motors and position sensors to support the interconnected smart factory. Using the existing sensors and the CNC machine's controller, data can be sent to the primary AI control unit. The machine’s operational and maintenance status can be tracked remotely, including such factors as tool wear and product throughput. CNC machinery can also be connected to facility-wide communication networks to optimize capacity planning and scheduling strategies.
To learn more about how you can take advantage of the benefits CNC technology can offer for your medical device projects, contact an ACHB expert today.