CNC machines are computer-driven motion control machines that help in making the manufacturing industry more efficient. These machines are so capable that they can create products out of almost any given hard material.
However, when it comes to design oversights, technical problems, and other software glitches, no technology can be said to be perfect, and CNC machines are no exception.
From erroneous tool cutting to wrong programming, jamming parts to power supply failure, an entire range of issues may arise during the machining process, which might disturb the manufacturers. However, there are always numerous ways to fix and avoid them.
Here's a look at some of the commonly encountered problems that you might face with your CNC machine with potential remedies to correct them.
If your CNC machine’s display or components are acting up, it could be a hiccup in the power supply. This glitch might cause inaccurate results or even a complete shutdown.
Firstly, make sure you’re using the right power and voltage settings. Next, check the secondary side for functionality. If the voltage reading is low, turn off the power, disconnect the output wires, power up again, and reevaluate. Keep an eye on the LEDs – they should be shining bright.
Efficiency in some machines is gauged by how well they vibrate, but for CNC machines, vibrations aren’t ideal. If your CNC machine shakes during a task, it could harm its lifespan and overall functionality. This might lead to longer task completion times, affecting cost-effectiveness and potentially prompting the need to sell CNC milling machines.
To tackle vibration problems, pinpoint if the chatter originates from the workpiece or the tool. Adjust the machine’s RPM using a balanced tool holder and aim for spindle speeds above 8,000 RPM for smoother operation.
When it comes to CNC machining, programming errors can throw a wrench in the works. This usually happens when there’s a misunderstanding of the G and M codes used for the controller, incorrect setup, or feeding the CNC controller with wrong data variables.
Ensure new operators receive thorough training covering various programming approaches for CNC machines. Machine suppliers should provide comprehensive user manuals, along with training on motion sequencing and machine operation. This training equips operators to navigate and troubleshoot programming errors effectively.
CNC machines rely on constant movement, making regular maintenance crucial for optimal performance. Neglecting to clean off dirt and debris can result in a harmful build-up, potentially causing machining inaccuracies or even machine failures.
To address this issue, machine operators should adhere to a comprehensive maintenance routine. Regularly check coolant and airflow levels, including air filters, to ensure the CNC machine operates smoothly. Consistent attention to these details will contribute to the machine’s longevity and reliability.
In the realm of CNC machines, the need for proficient operators is crucial as these machines heavily rely on precise programming and operation. Inadequate training and skills among workers can lead to suboptimal performance.
To address this issue, it is imperative to hire well-trained machine operators who possess the necessary skills in visualizing and designing machining processes, selecting appropriate tools, sequencing tasks, and writing programs. This ensures a more efficient and productive operation of CNC machines.
Fixtures and chucks get loose over time causing these fixtures not clutched firmly by the spindle. It can lead to a machine tool’s vibration during the machining process.
Clamping/unclamping of the fixtures and chucks can lead to the injury of the operator and poor design of the machined part in the worst-case scenario.
One needs to make sure that the part is correctly positioned which will ensure proper clamping. Check if the chuck is working properly on the MDI M-code command.
CNC machining is a non-stop process and due to high orders a CNC machine works continuously. It results in the machine tool’s overheating.
When a CNC machine works for a prolonged period of time, the temperature reaches over 150°C. It affects the quality of the parts produced, life of the CNC machine and the tool being used.
The right way to do it is to take care of the CNC machine. Don’t allow metal shavings and liquids to get accumulated and clean all the areas of the machine. Try to use a spindle with air-oil lubrication that will help in preventing issues when operating for long hours.
Picking the wrong cutting tool can seriously degrade the final build quality of the products, typically visible through burn spots and raised marks on the corner of the material.
Poor material finishes directly result from either an improper feed speed ratio or the tool being blunt. Another leading reason can be choosing inappropriate tool dimensions for the task at hand in terms of the material, sizes, and build quality.
Resolving this issue demands that you select the appropriate tool and setting for the material and the build quality. You must consider proper instruction manuals that will tell you the parameters for quality and various tools used.
Faults with automatic tool changers are usual in a CNC machine. However, if it occurs, it can lead to issues during the manufacturing process of machined parts.
So, it’s important that you take the automatic tool changer problem seriously.
You need to make sure that the support arm, the tool holder, and the base are working fine. Check the mechanical arm to make sure if it’s working well or not.
It’s important to remain diligent when it comes to planning and doing the maintenance of a CNC machine. Here are some tips and best practices:
Maintain detailed maintenance records. A Cloud-based CMMS software can help you automate data collection and ensure easy and quick access to maintenance history for your machine.
Ensure proper employee training. Make sure that technicians who use, maintain, and deal with CNC machines are sufficiently trained for their levels of responsibility.
Ensure that the machine is operating in a clean environment. Accumulating debris and dust causes machine degradation. A CNC machine, as well as the space in which it operates, must be regularly cleaned.
Keep an eye out for irregularities in machine operations. These could be anomalous sounds, machine vibrations, etc. Train employees to note down and instantly report such anomalies.
Schedule regular breaks in the operation of the CNC machine. When machines run incessantly, they are more prone to overheating and suffering serious damage. Establish standard break times for CNC operation.
Create maintenance checklists and standard operating procedures to ensure the machine is properly maintained and operated (Let’s focus more on this point in the next section)
Maintenance checklists help operators and technicians do their tasks efficiently and safely.
The following sections cover the maintenance tasks that must be done at different times (daily to monthly). These checklists assume that a CNC machine undergoes eight hours of operations every day, with proper breaks.
You need to adjust the time period of your maintenance as per the usage hours, after consulting with OEM guidelines of the machine. Use the following checklists as an idea to create a preventive maintenance plan that takes into account the requirements and needs of your manufacturing operation.
The following tasks have to be performed every single day, assuming regular usage hours:
1. Inspect the level and pressure of lubricant and top up if needed.
2. Check the level of coolant. Use a coolant refractometer to make sure that oil and coolant ratio is maintained.
3. The coolant disposal tray must be cleaned out.
4. Check for any moisture in pneumatic air and if detected drain that moisture.
5. With the help of a pneumatic pressure gauge, check the pneumatic air’s pressure.
6. Use a clean rag to clean the complete machine.
7. Check the voltage stabilizer’s output. Make sure that it adheres to the needed specifications.
8. Check the temperature of the panel cooler.
9. Observe bangs, noises, or any other irregularities in machine operation.
10. Watch out for any overheating indications during machine operation.
The following tasks have to be performed on a weekly basis:
1. Clean the machine shop, especially the area near the machine.
2. Check for any evidence of oil, coolant or lubricant leakage.
3. Check and make sure that all cooling fans are working correctly. These include hydraulic motor fans, cooling system fans and spindle motor fans.
4. Perform a visual inspection of the components of the machine. Apply an appropriate lubricant or grease to parts that seem dry.
5. Check whether tool heads are held tightly in the tool changer.
6. Lubricate the slider cap, v-groove, keys, plungers, extractor forks, and springs of the tool changer.
7. Check if all electrical components such as lights and switches are working properly.
Maintenance checks that you must have to do every month include the following:
1. Clean out the chip collector that is located close to the coolant tank.
2. Inspect, adjust, and remove chucks, jaws, and fixtures.
3. Clean or replace air filters if needed.
4. Check the tool heads’ condition and replace them if necessary.
5. Inspect, tighten, lubricate, and adjust conveyors and chains in the machine.
6. Clean machine fans to prevent the accumulation of dust.
7. Inspect the logs of oil, coolant and lubricant. Check for any irregular consumption.
8. Clean radiator grills of debris and dust.
You can use this article as your guide in troubleshooting the CNC machine’s problems. All the solutions and Checklists explained will work as your guide in keeping your machine in good condition. However, it’s also important that you use a good CNC machine with excellent quality, good precision, reliability and rigidity. And you can only find such machines at YANGSEN. With over 20 years of expertise, YANGSEN’s CNC machines are designed in a way that they can be kept in good condition with minimal care. At Yangsen, the following CNC machines are available:
· Horizontal machining center
· CNC drilling machine
· Gantry machining center
· Horizontal boring machines
· CNC vertical machining center
· Engraving and milling machine
Buy your CNC machine from YANGSEN now and start a hassle-free machining process!
Ans: You can find machining faults by doing a visual inspection of machined parts. It can be done by analyzing the finish of the surface, measuring the dimensional accuracy and watching the machine's performance during the process of machining.
Ans: Several issues can cause the spindle to stop spinning including faulty motor, electrical connection problems, loose or damaged belts or mechanical obstructions.
Ans: Common defects caused by machining include dimensional inaccuracies, surface roughness variations, chip accumulation, burrs or sharp edges, tool marks, as well as material deformation.
Ans: Common calculation errors in the programming of CNC include miscalculations of feed rates and spindle speeds, incorrect tool offsets, and incorrect tool path calculations.
Ans: If buttons are not lighting up on the control panel, look behind the panel or the screen for the power supply. Make sure the power is coming and going correctly. It might be due to the reason that a fuse back there is blown.
Try moving the axes (as you would if you were following the on-screen prompts), if the CRT doesn’t seem to be coming up. If they're moving perfectly then the issue is with the screen display, not the machine itself. Check that the power is going to the screen.
Tel : +86-592-6682467
WhatsApp : +86-18359729483
Email : info@cncyangsen.com
Address : No. 586-590 Shanbian Rd. Dongfu Industrial Zone Haicang Dist, Xiamen, Fujian Province, China 361027
