In contemporary manufacturing, computer numerical control (CNC) machines play a vital role in ensuring seamless manufacturing processes. The techniques used in CNC manufacturing greatly contributes to the advent of industrialization.
How Does it Works?
CNC machining involves inserting 3D files into a computer software which dictates the motion of the tools and machinery, mainly in the milling process. This process is fully automated and can be employed to control various complex machinery from grinders and lathes to mills and CNC routers.
A typical CNC file consist of line by line commands that instruct an action to the tools. These commands ranges from simple actions such as a single hole drill to complex actions such as a circular cut. When executed in order, the various instructions work to create the desired fabrication based on the design requirement. As the process is fully automated, fewer human supervisions are needed and the machines can run 24/7 to meet production demands.
Operating a CNC Machines
A CNC machine system consists of a combination of tools (i.e., drills, lathes, and milling tools), which are built into cells where the machine can select and utilize them. The complexity of the machines can be defined by the number of axes where the simplest machines move in one or two axes. On the other hand, more advanced systems featuring three axes where X- and Y-axis motion can also move longitudinally in the Z-axis. With more axes, the machines can perform more complicated movement such as rotational motion and even flipping parts automatically so material can be cut on all sides without manual intervention.
The machinist skills and experience are crucial in ensuring that the CNC machines can achieve the required specifications especially the dimensional tolerance and surface roughness. Temperature controls are important as different materials will have different coefficient of thermal expansion which will affect the final dimension of the machined parts. The higher the coefficient of thermal expansion of the materials, the quicker the expansion of the materials in reaction to being heated. Therefore, the temperature needs to be strictly controlled to ensure low dimensional tolerance. To achieve this, usually coolant is used to lower the heat generated during machining, with different kind of coolant having different performances.
CNC Software Simulation
With the development of CNC computer software, the machinist can simulate the machining process (i.e., the direction of the machining tools motion) and predict the time required. This greatly helps in minimizing the errors and ensuring the lead time is achieved. Typically, the capability of a CNC machinery house is determined by the ability to achieve low dimensional tolerance (< 10 um) and surface roughness (<1.6 Ra). Microwave/RF applications requires precise manufacturing tolerance and surface roughness to prevent leakage and ensure smooth wave propagation.
Quality Control
With software to help simulate the optimum production quality and lead time, and high precision CNC machines to achieve the desired results, it still cannot escape from the need for quality control. Quality control (QC) checks are performed after the machining process to ensure the machined parts can meet the dimensional tolerance and surface roughness requirements. QC checks ensure the quality of the machined part and is part of the requirements for quality management systems. CNC manufacturing involves multiple considerations and processes to ensure that the final product are robust.
The Necessity for CNC in 5G
The telecommunication industry has always demanded high precision components due to how sensitive equipment are in higher frequency. With 5G deployment in the new mmWave region, and IoT and Industry 4.0 equally requiring equipment that function in this frequency range, high precision components are in an even higher demand. This will inevitably necessitate the advancement in CNC technologies.
One thing is for sure, a mastery of CNC technologies and techniques is and will be a “must have” for any companies seeking to be relevant in the manufacturing sector now and moving forward.
Originally published at http://filpal.wordpress.com on July 24, 2022.
