Today’s ETCN machines offer unparalleled design freedom, speed, precision, and consistency. Learn how to unlock their full potential.

Traditional CNC machining uses a subtractive process, which removes material from a workpiece to create the desired part. Hybrid CNC machines can combine additive and subtractive processes to construct parts in a single setup, reducing production time and saving costs.
AI and Machine Learning

Artificial intelligence (AI) is a major force in the manufacturing industry. It has the potential to dramatically increase productivity levels, save on labor costs, and bring us a step closer to a lights-out setup in CNC machine shops. However, introducing AI to machining processes is not without challenges. Some experts argue that incorporating AI into CNC machines will result in a loss of job control, while others are skeptical.

In the end, it all comes down to the goals and capabilities of the machine shop. Despite these concerns, there are many positives to implementing AI into CNC machines.

Whether it’s scheduling maintenance, organizing jobs or maximizing process concurrency, the influx of data provided by AI software makes it easier to get these tasks done on time and on budget. As a result, machine productivity and efficiency have never been higher in the CNC industry.

In addition to its ability to reduce downtime, machine AI can also boost productivity by reducing cycle times and overall production costs. It does this by minimizing repositioning and eliminating air cuts, which ultimately leads to higher accuracy and faster machine performance.

Additionally, a good machine intelligence system should be able to predict and prevent machine problems before they arise. This way, production can continue on-time and the company can avoid costly repairs or downtime.

A good ML model should also be robust to noise in the input and output data, as well as a variety of different metals and dimensions. This is a difficult problem to solve, but it is crucial for manufacturing applications.

Finally, it is important to take a holistic view of ML, which includes consideration of the ethical implications of this technology. The book Engineering Perfection: Solidarity, Disability, and Well-being by Elyse Purcell argues that the commercialization of human enhancement technologies threatens to create a widening gap between the “haves” and “have-nots.”

A responsible approach to enhancement technology is essential for the success of CNC machine shops using AI. By embracing this philosophy, manufacturers can incorporate AI into their machine tools while remaining confident that their work is of the highest quality and integrity.
Workpiece Holding

A well-executed workholding setup can unlock a host of CNC machining capabilities. It improves precision and accuracy, increases efficiency and safety, and enhances the versatility of a machine. It can also reduce costs and lead to improved quality. In contrast, a poorly executed workholding setup can result in quality issues, efficiency loss, tool damage and safety risks.

A good workholding solution can significantly increase productivity by minimizing changeover time and eliminating the need for scrapped, out-of-tolerance parts. It can also help manufacturers achieve tighter tolerances by maximizing spindle utilization time.

However, the workholding solution used will depend on the specific geometry and machining operations of a part. For example, a vise may be suitable for most jobs, but it is not ideal for holding small, delicate parts or parts with thin walls or non-parallel sides. Other workholding methods such as soft jaws and fixture plates may be better suited for these situations.

When it comes to choosing the best workholding method, a manufacturer should consider its production volume, part complexity, machining operation and the type of machine. It is also important to note the machinist’s experience and preferences. For example, a manual machinist will have different needs than an experienced CNC machinist.

Moreover, a factory’s production model should also be taken into account. For instance, a job shop may be more focused on consistency and safety while a flow shop is more concerned with quick-change capability.

Workholding is a crucial factor in CNC machining and can make or break a project. It can increase or decrease efficiency, quality, safety and cost, so a machinist should choose the best method for each situation.

Whether you’re working on a large and complex part or a small and delicate one, the right workholding method can unlock a world of machining capabilities. Fortunately, there are many options available, so finding the best fit for your needs is easy. Just make sure you’re using the best tools, feeds and speeds for your specific application to maximize your output. Good luck! Isaac Aloyan is a mechanical engineer with experience in machinery design and manufacturing. He is an expert in CNC programming and machining, vacuum mold design and production, and manual machining.
Tool Access

CNC machining is the process of using automated computer-controlled tools to remove material from a workpiece, transforming it into a finished product. It’s like 3D printing, but instead of sending a digital file to tools that work together to create the end result, a computer sends a series of precisely coded instructions to a machine shop tool and the tool works on its own to produce the desired part.

CNC machines are very fast, efficient and capable of performing a variety of complex operations. However, they are not infallible and there are certain things that can cause a CNC machine to crash or stop working altogether.

The first is that a machine may run into an issue that prevents it from completing the operation it was programmed to do. For example, the machine might get stuck on a piece of material, or it may not be able to reach a specific area of the workpiece. This is not uncommon, but it can lead to a significant delay in the production process, and may also affect the quality of the final product.

Another common problem is that a machine may crash while trying to complete a task. This is most often caused by human error, but it can also be a result of a misalignment between the machine and the workpiece or an overload of a spindle or axis drive. Many manufacturers have installed load sensing systems on axes and spindle drives, but these may not prevent all crashes.

In order to unlock the full capabilities of a CNC machine, it is important that the machine can access the areas it needs to do its job. In most cases, a machine cannot be used to produce a part that requires it to reach an area of the workpiece that is inaccessible from above. This includes holes, cavities, vertical walls and undercuts. To avoid this, product teams should always aim to align all of these features with one of the six principal directions.

Newer CAD and CAM software capabilities are better at understanding the configuration of a 5-axis CNC machine and creating cutting programs that take advantage of all its axes. However, it’s crucial that product teams train their operators and industrial designers on the best techniques for working with this advanced equipment.
Part Size

CNC (computer numerical control) machining is the automated use of a programmable machine to create parts from a piece of metal, plastic, or wood. By following coded instructions, a CNC machine uses tools to cut, shape, and finish the part to meet precise specifications. This process has largely replaced the traditional method of drafting 2D engineering drawings on paper and is used by a wide range of industries for both prototyping and production purposes.

Modern CNC machines are programmed with G-code, which is generated automatically by CAM software and controls the machine's movements. These programs can also include commands to change tool sizes and axes of rotation, as well as turn on/off coolant and other auxiliary equipment. The resulting part can be made out of virtually any hard material, such as aluminum, steel, brass, Delrin, or ABS. This makes CNC machining suitable for a broad spectrum of industrial applications, including consumer electronics, automotive manufacturing, and robotics.

While CAD and CAM have made CNC machining more efficient, there are some special considerations when working with large or small parts that need to be produced quickly and cost-effectively. Product teams must optimize their designs for manufacturability to ensure they can be created using CNC machining, and machinists must practice some workarounds when attempting to produce extremely large or small parts.

For example, a large-scale CNC machine may have to move the workpiece multiple times during the cutting process to access all dimensions of the part. Using an expertly calibrated CNC machine can help to mitigate this issue, but it's also important for designers to understand how a workpiece moves during the cutting process and plan accordingly.

Another issue when working with large parts is that they are often too heavy for a CNC machine to lift. Fortunately, there are several workarounds to this problem. For instance, using a lighter weight material for the part can reduce its overall weight, which in turn helps to offset this limitation.