ECONOMICS AND MAINTENANCE

Factors influencing selection of CNC Machines Cost

of operation of CNC Machines Practical aspects of
introducing CNC machines in industries Maintenance
features of CNC Machines Preventive Maintenance,
Other maintenance requirements
SELECTING A CNC MACHINE
Working envelope
Types of workpiece material
Positional accuracy
Control system
Spindle speed & power
Tooling / cutters
Table type
Technical support

SELECTING A CNC MACHINE
What is the maximum job size that to be
manufactured ?

The larger the cutting area or bed size the
more expensive the machine.

Cutting soft materials such as wood, plastic is
normally fine for most machines, but cutting
steel usually requires a heavy duty machine.

SELECTING A CNC MACHINE
For a very fine engraving the resolution of the
motors that position the cutter is crucial to
the final product quality, and a precision on
(0.005mm) might be required.

Typically the more precise the more costly the
machine will be.

SELECTING A CNC MACHINE
Most of the new CNC machines have PC based
control systems that run from industry
standard file formats such as ISO G-code.
If the control system is proprietary (unique to
manufacture) then make sure that it will work
with third party software solutions.
Check whether the controller can be
networked to PC for easy & fast file transfer
directly from the design software

SELECTING A CNC MACHINE
Check there is need to a DNC (Direct
Numerical Control) link from the PC to the
controller?
Data processing speed is also a factor, notably
for high speed/ volume product or complex
3D work, where large toolpath files are
commonly used.
SELECTING A CNC MACHINE
G-code
Stepper
Servo
Speed
Accuracy
Quality
PC based
DNC Link
SELECTING A CNC MACHINE
When cutting finely detailed products, high
spindle speeds, typically over 20,000 rpm and
up to 60,000 rpm depending upon the
material being machined.
The power rating for the spindle is also crucial.
For high volume material removal rates the
spindle needs to be powerful, but not to very
fast (rpm)
SELECTING A CNC MACHINE
How many different tools will be needed to
produce your typical jobs ?
Automatic
ATC
Carousel
Rack
Manual
SELECTING A CNC MACHINE
How will jobs to be held on the table ?
Will you require a vacuum table, vice or
special fixturing?
What kind of Technical Assistant needed for
the machine ?
Checking for service availability
Maintenance of CNC Machines
Breakdown Maintenance
Starting a maintenance work until failure occurs.
This type of maintenance will be useful, when the
machine does not affect the operation or
production or generate any significant loss other
than repair cost.
This type of maintenance lead to loss of
production.

Maintenance of CNC Machines
Preventive maintenance
It is a daily maintenance (cleaning, inspection,
oiling and re-tightening), design to retain the
healthy condition of equipment and prevent
failure through the prevention of deterioration,
periodic inspection or equipment condition
diagnosis, to measure deterioration.
Periodic maintenance ( Time based maintenance
TBM)
Predictive maintenance
Maintenance of CNC Machines
Time based maintenance consists of
periodically inspecting, servicing and cleaning
equipment and replacing parts to prevent
sudden failure and process problems.
Periodic maintenance is a method in which
the service life of important part is predicted
based on inspection or diagnosis, in order to
use the parts to the limit of their service life
Maintenance of CNC Machines
Corrective Maintenance- It improves
equipment and its components so that
preventive maintenance can be carried out
reliably. Equipment with design weakness
must be redesigned to improve reliability or
improving maintainability
Maintenance of CNC Machines
Maintenance Prevention :
It indicates the design of a new equipment.
Design failures/weakness of current machines are
sufficiently studied (Onsite information leading to
failure prevention, easier maintenance and
prevents of defects, safety and ease of
manufacturing ) and are incorporated before
commissioning a new equipment.
Maintenance of CNC Machines
Backlog Maintenance
Maintenance that is necessary to prevent the
deterioration in the performance or functioning of
the machine but which has not been carried out.
Accordingly, backlog maintenance has a higher
priority than deferred maintenance. The
maintenance practices to be deferred and which
comes under backlog list will have to be reviewed
annually and documented.
Systems and Sub-Systems of CNC
Machines
Mechanical system
Electronic systems (CNC and drives)
Work holding systems
Tool clamping systems.
Lubrication systems.
Coolant systems
Hydraulic systems
Pneumatic systems
Chip Conveying Systems
Functions of Mechanical Systems
Primary functions of the mechanical systems
in CNC machines are similar to conventional
machines.
CNC Lathe Machine sub-systems
Headstock, Axis assembly, Tool post & Tailstock
Axis assembly, Tool magazine, Bed


DC Motor Troubleshooting

ATC Troubleshooting

Hydraulics and Pneumatic
Troubleshooting