Engineering Industry Today

9 Common CNC Machining Challenges and Solutions

It's normal to face several challenges while working with the CNC machines and how to fix them? Here are some solutions that can be used to overcome these Challenges.
Published 29 January 2021
We have to face several challenges while working with the CNC machines and the right strategy should be used to overcome these Challenges. Here we will discuss in detail the various challenges and some of the most common issues that normally face while working with custom CNC machining services and various strategies to overcome these issues.

What Are the CNC Machining Challenges and Their Solutions?

Some of the CNC machining issues and their solutions have been discussed in detail;

1.Processing of Data:

Operation of Prototype machining totally depends upon the hardware used in the system. Appropriate software installed in the system and working depends on it. Software used for the transfer of command from the computer to the machine and when it’s not working smoothly at that point the performance of the machine will also affect.
Solution: In order to overcome this problem, there is a need for upgrading the system.  Keep in mind that the computer you have attached to the machine should be up to date with very powerful hardware to send commands to the machine faster.

2.Complex structure:

The structure of the CNC machining is also very complex like making a cathode ray tube is really a complicated process and it provides a simple but important feature to the machine. While maintaining the roundness of the tube is the main concern.
  • It should be held properly to get the required shape. The insides, as well as the outsides of the parts, should be deburred properly. 

3.Programming errors:

One of the main challenges usually faced in CNC machining is an error in the programming. The error arises when the setup is not right, the codes (G and M) that used for the programming are not understood well or the data of the CNC is incorrect.

Error in G-Code
Solution: In order to overcome this problem, there is a need to hire a well-trained worker with a better understanding of the codes and other functions. You can also arrange manuals or arrange workshops or training related to the programming. The experienced worker works very efficiently with the best techniques and delivers a quality product. 

4.Repairing Cost:

Whenever the CNC prototype machining needs repairing, it will cost high because the repairing process consists of repairing hardware as well as software.
  • To control this issue there is a need for proper maintenance of the machine. Hardware and software should be monitored daily and fix the problem instantly to control big losses in the future. 

5.Chattering:

Chatter (machine vibration) is also a challenge for CNC machining. Vibration during the working of the machine makes the life span of the machine parts shorter and also affects the durability of the machine. So it is important to avoid this problem as much as possible.
  • Observe which part is chattering and resolve it. Sometimes the chattering sound is loud that you can even listen to it. To control the issue, you can adjust the RPM of the machine. 

6.Material Selection:

A very critical point in custom CNC machining is the selection of the material. Material is selected according to the nature of the work. Machining conditions, types of tools, and Stiffness of material can be taken into consideration before starting the process. Otherwise; it may lead to an accident when you carry out machine CNC parts or prototypes.

CNC machine using coolant
  • Always use the durable, machinable, and non-corrosive material in the manufacturing of the machine and also use coolant where required. The plastic material provides machinability and the metal material provides strength and is also resistant to high temperature.  

7.Overheating of machine

Overheating of the prototype machine is usually observed when the machine runs on high RPM for a long period of time. It can cause a high temperate even more than 150 oC. Overheating can cause a negative impact on the overall working of the machine.

CNC machine overheating
Solution: To solve this issue there is a need to clean the machine properly and regularly it will remove the dirt from the parts of the machine. Also, avoid running the machine for a long period of time on high RPM. 

 8. Inappropriate Settings:

If the tool set of the CNC prototyping machine is inappropriate then the working will be affected. For example, the tools are not cutting properly, the speed of the tools is wrong, or the coolant is not cooling the system properly. Some tools can also get damaged due to various reasons that can also affect the working of the system.
Solution: In such a case, there is a need for repairing or replacement of the tool. 

9.  Communication Failure:

Communication is the most important key to success and the failure in the communication will lead to the failure of the complete project. Take low volume manufacturing processes for an example before you start to work.
Solution: The entire team should have to communicate and decide about the schedule of the work, the complete budget of the project, and all the specifications related to the working of the rapid prototyping machining. The discussion should also be made about the various steps of the procedure and the use of proper material and methods. Such type of communication proved beneficial and minimized the chance of failure.
Explore more CNC machining capabilities here to handle those complex problems.

Conclusion

There are a lot of challenges being faced in CNC machining but our job is to build-up some strategies to overcome these issues without affecting the work efficiency of the industry. There are some precautions that need to be done to prevent any damage while machining. As we all know that “Prevention is better than Cure” So, to prevent any damage while machining the preventive maintenance should take place which will check software’s as well hardware’s of every machine and compare the results with the control charts to identify any irregular behavior of the machine. Challenges may be occurred due to the lack of communication between the workers or the customer. To overcome that issue we need to develop effective communication between everyone so, that everyone will have a clear image about what he is going to do and what will be its consequences. By taking the above-mentioned considerations you can overcome these challenges with ease.
 

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