George Ure asked:

CNC milling finds application making a wide range of custom parts. CNC milling is a cutting process in which material is removed from a block metal or plastic by a rotating tool. In CNC milling the cutting tool (called a “mill”) is moved in all three dimensions to cut a desired shape from stock.
In this process, the material is usually removed by both the end and the side of the cutting tool. Unlike a drill which removes material only from the end, in CNC milling the cutting tool rotates about an axis that is perpendicular to the table that holds the work. Cutting tools of various profile shapes are available including square, rounded, and angled. A wide variety of part shapes and geometries are possible. The most common are the “end mill” which finishes to a flat bottom surface while a “ball mill” has a rounded end.
A wide variety of 2D and 3D shapes are possible in the process. Some of the examples of CNC milling are engine components, custom jigs and mold tooling, complex mechanisms, enclosures, etc.
The thing CNC Milling does especially well is create complex shapes block material. While CNC milling can be used on 2D projects, there are lots of other choices for thin stock. Waterjet cutting and plasma cutting, for example, come to mind. But thick stock, needing metal removed? That’s where CNC milling shines. The CNC Milling process proves to be cost effective for short runs.
In the event you run into large production quantities, then you might wish to consider cast or forged parts.
When you set about designing a new custom part, keep a wide range of cutting machines in mind. Depending upon the production quantity you can model the cost of Laser Cutting, Turret Punch or Fixed punches, and the cast or forge decision.
The easy way to get started making custom CNC parts is to design them in free 3D CAD software available from www.emachineshop.com, the world’s first online machine shop. Once a part is draw, it can be assigned to different machines and prices and deliveries compared. If you like your design, eMachineShop is only too happy to build it for you.

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Antony G asked:

I own a CNC router and I have been cutting some MDF into strips. I’m currently using a slitting saw blade which is OK but ideally I would want to use a standard circular saw blade because it will cut through the MDF easier.

The trouble is all these circular saw blades are normally advertised for use with either a table saw or a hand-held circular saw. Are these saw blades OK to use with a CNC router?

Basically, what I have done is to bolt the spindle on my CNC router sideways and attached the saw blade using an arbor. Using a slitting saw works fine but I really want to use a circular saw blade instead.

I can’t see any reason why there should be a problem but for safety reasons I just thought i’d better check.

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Thomas Cutler asked:

Manufacturing is the sole focus of ResourceMFG allowing a better manufacturing workforce. ResourceMFG understands that it takes good people to get good results. Experienced manufacturing professionals know how to find the talent needed to deliver results for manufacturing businesses. ResourceMFG has been nationally recognized for having workforce management initiatives that impact the bottom line. In 2006 ResourceMFG won the Optimas award for “Financial Impact.” This value allows the company to provide award winning workforce management capabilities and processes that produce better results. The key to delivering better manufacturing employees lies in the fact that it is all that ResourceMFG does. With superior screening, OSHA outreach programs and ongoing safety training, ResourceMFG delivers the kind of workers needed for every manufacturing facility.

Polaris Electrical Connectors (www.polarisconnectors.com) is using Manufacturing Placement Leader ResourceMFG for providing CNC Operators, CNC Set-up/programmers, Maintenance Personnel, and Conventinal Machinists. Ninety percent of the ResourceMFG temp-to-hire employees have gone permanent with Polaris. Joy Waltson, Polaris’ human resources manager noted that prior to using ResourceMFG the company was, “Predominately using the local newspaper classified and employee referrals; we were unable to find enough qualified candidates for the positions we had available.”

Working with ResourceMFG, with industry sector expertise, versus generic placement organization was important to Polaris according to Waltson because, “They were able to provide a larger number of candidates with the skills necessary for our particular needs. Unless a company is located in an area with an unlimited supply of potential employees for their skill needs it has almost become a necessity to use an agency. They save time by doing the initial screening and are committed to providing good service in order to remain profitable. Although we are hopeful to maintain our current staff we would certainly give RMFG the opportunity to provide candidates for us to interview when and if positions become available.”

About ResourceMFG:

ResourceMFG is the nation’s leading manufacturing support organization. It focuses on the demands of the manufacturing sector to serve the needs of employees and customers. The company has immersed themselves in the manufacturing community and has close relationships with support organizations such as The National Association of Manufacturers (NAM) and The American Production and Inventory Control Society (APICS).

ResourceMFG is involved with the total spectrum of manufacturing positions including production, quality, maintenance, supervision, and all levels of management. The company serves a wide variety of industry segments that include automotive, electronic, machining, sheet metal, fabrication, and many other specialized producers.

The foundation of ResourceMFG is a commitment to understanding the specialized needs of clients, employees, and the community, which provide the foundation for success. Like the manufacturers they represent there is a philosophy of continuous improvement. ResourceMFG is dedicated to improving programs, processes, training and people to meet the diverse needs of the US manufacturing sector. A benchmark of the organization is on time delivery. The company understands manufacturing professionals and provides excellent programs and productive employees. ResourceMFG delivers the right person with the right skills at the right time.

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Plootahead asked:

I lost my job recently due to economic downturn. I was working with CNC Machines. I would like to continue in that line of work. I got a call about a job from a recruitment agency but they didn’t continue with an application to their client due to my lack of a specific type of experience. They wanted someone who had a knowlege of FANUC based cnc machines. What is FANUC and how can I find out more information about it?

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happytriger2000 asked:

I am seeking for cnc training courses in London and the one that I know are based outside London, eg. forelink, ymtltd, ..etc , does anyone know a place that trains people on how to use cnc machining?

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George Ure asked:

Water can cut metals. Sounds impossible, but is true. Water jet cutting is a process of cutting the sheets of metals with a high-pressure stream of water containing some abrasive particles. Water jet cutting can yield any 2D shape from metal sheets. It can cut any metal sheet between the thickness ranges of 0.001” to 4”.

CNC water jet cutting is the computer mediated water jet cutting process. In this, the user has to draw the design to which the metal sheet needs to be cut and the software for the CNC water jet cutting process follows it to cut the metal sheet to that particular shape. CNC water jet cutting is advantageous, as it does not release any heat during the cutting process that may distort the cut edges of the metal sheet. It cuts smooth edges and hence does not any further finishing, although deburring may be specified.

The process also does not release any poisonous gas and is thus very safe. CNC machining falls short to water jet cutting at the points that it produces the distorting heat while cutting the edges and also it wastes a lot of metal during the tearing process. Laser cutting can be a great alternative if you want to cut a thin metal sheet. Plasma cutting can be used, but due to the high temperature, there is a greater chance of heat distortion of the metal.

Water jet cutting can cut almost any material like steel, carbon, aluminum, metal alloys, brass, copper, magnesium, titanium, plywood, rubber, glass, wood, gasket material, laminates, foam, marble, fiberglass, etc. Because a robot rather than a human handles CNC water jet cutting, it is cheaper being somewhat free of human labor except for set-up. Plus, it has high accuracy and repeatability.

If you want to know more about the various processes of designing machine parts, please visit eMachineShop. This website is the first of its kind, supplying you the machine parts through the web. We have CAD software for you to download free. You simply download and draw the part or shape that you require and order it. We supply virtually any range of machine parts. Do not worry if you are new. Using the eMachineShop Design software is easy and has additional features to guide the user. It does not matter whether you need a single part or a thousand parts. We will supply you whatever you need with great convenience and ease. Visit the site www.emachineshop.com and get more details about water jet cutting, laser cut and the services offered.

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loyed83 asked:

please help me to get the right feed rate , plunge rate the dwell time and rpm for cutting and drilling the aluminium 10 mm thickness sheet

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Ivan Irons asked:

CAD Design Process

When designing something complex in CAD you will find there is a bit of a process. First you design parts. Then you build the parts into Sub-Assemblies. Next you build sub-assemblies into Groups. Then you build the groups into the machine. It is a logical pyramid process. You can also think of it like a file structure inside of a computer.

Designing Parts

Parts are your building blocks. Without this level, nothing could be produced. The part level breaks the entire “thing” down to its simplest form. You also manufacture at the part level. You make parts, and then assemble them into other things. Parts are generally made out of raw materials.

Think of a differential on the rear axel of a car. The differential is made up of gears and a housing. Each of these are parts of the differential and the differential is the assembly of these parts.

Designing Sub Assemblies

Sub Assemblies are the next level up and I am guessing you are getting the idea. You first design parts, then put them together into sub assemblies. In the car example above the differential is a sub assembly in the axel “Group” of the car. Sub Assemblies are put together to form groups.

Designing Groups

Moving up the design chain, groups are usually things you can identify with. It could be a door, engine, transmission, or cooling package on a car. Above we used the example of an Axle as a Group. Groups are put together into machines. Our example is a car, which is at the machine level.

Designing the Machine

Finally, the top level of all your designing, the machine. The machine could be built for the end user or be sold to another manufacturer. That manufacturer could use your “machine” as a sub assembly or group. You can see all this is just a matter of viewpoint. You can consider just about anything a sub assembly, group or final machine. It is all just semantics and what you are using the item for.

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Paul Disley asked:

The development of computer numeric controlled (CNC) routing, using affordable personal computers has already begun to revolutionise all aspects of the woodworking industry. In so doing it has created new opportunities for large and small businesses as well as for individual craftsmen.

CNC is a technique whereby the movement of a router head is controlled by instructions from a computer. These instructions come from a computer program or list that the user keys into the CNC 860 console or into a computer as ISO standard commands called ‘G’ codes.As an example, the code G01 X100 Y100, instructs the head to move in a straight line to a point horizontally and vertically 100mm away from its starting position.

The CNC 860 The Trend CNC package is based around the Elu/DeWalt CNC 860 Machining Centre, which has a machining area of 860mm x 860mm x 90mm. These dimensions relate to the three axes, X,Y and Z (width, length and height). Each axis is served by a separate stepper motor, controlling the movement of the routing head. Two head options are offered: a modified portable router or a continuously rated, high cycle motor, that provides improved performance for intensive machining applications.

Programming directly in G-codes through the console can be time consuming. To assist the operator, a PC software application called CNCTalk is included with the machine. This is a basic computer aided design (CAD) application which runs under DOS, the original PC operating system before Windows. It is useful for intermediate applications like cutting out irregular shapes. However, to gain the maximum versatility from the CNC 860,Trend’s Open Sign System Software for Windows is the most effective solution.

OSS consists of two separate software applications: OSS Draw which provides the drawing tools to create any shape or sign, and OSS Work which handles all the routing and tooling-related parameters like depth and offset. Graphical simulations are shown for all tool parameters enabling the user to perfect a design before routing any material.

Sign-writing As an example of how these products work together, the method of producing a simple sign is shown, incorporating two different lettering styles and a graphical logo. Having launched OSS Draw, the first step is to draw a box or boarder on the screen to indicate the overall area of the work. This can be either a simple rectangular boarder or a more decorative one. This border then needs to have a depth assigned to it. This is done by using colours to define the depth of each area.

The logo is then created using the drawing tools within OSS Draw. The words are keyed in using the text function. Again, colours are assigned to each area to produce a graphical representation of how the finished sign will look. The next task is to define the routing parameters. In the example, the red and blue areas of the logo and the lettering have been assigned a depth of 5mm and the green area assigned a depth of zero. The same dialogue box lets you specify whether a letter or object is engraved or routed through the material. The cutter profile that will be used can now be defined. With lettering, particularly serifed fonts, the cutter used needs to have a small diameter, perhaps 3mm. However, to achieve a 5mm cutting depth this will have to be routed in several passes.

A simulation of the cutting path is now drawn on screen. Having then created a G-code file of the sign ready for the CNC 860 to cut, the file is downloaded to the CNC 860. The design can now be routed, the material being held on the bed by an adaptable clamping mechanism. From the simulation, the path that the tool will take is known allowing a datum point to be set using the zero key on the console, and the program 8 INProfile is run using the start key. This type of routing operation takes around 20 minutes to complete and requires no further involvement by the machine operator. Other accessories Sign-writing is just one of the many complex and wide ranging routing operations that can be carried out using the OSS and CNC 860 package. OSS also has a range of tools for drawing component shapes and profiles directly or with an electronic sketchpad (graphics tablet). Vacuum Clamping To reduce the through-put time for this kind of operation, the CNC 860 can also be used with a vacuum bed. Trend offer a complete range of affordable vacuum pumps and jigmaking accessories to enable all CNC users to produce a highly automated production system to suit their own specific requirements.

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Ivan Irons asked:

Quick Explanation of the Process

This is how I view CNC. I break it down into simple steps that I can remember. Now, they all interact, but it is good to keep them in boxes for simplicity sake. I also like to keep them in a logical, progression type order. Here they are: Design, CAD, CAM, Control and Machine.

Today you are going on a journey. You are going to learn about the basics of CNC. I hope you are as excited as I am about this topic.

I have been using CNC equipment in my home shop for six years now. The technology gets better and better every year.

The software gets better every year. At one time large companies could only afford this technology. Now there are hundreds of thousands of these machines working in garages like yours and mine.

There are basically five elements to a CNC Project that you need to know:

Design - thinking and planning what you want to build
CAD - translating it into the computer
CAM - converting it into machine language
Controlling - directing your machine’s motion
Machining - building the part to specifications

These five elements are really the building blocks to a CNC project. As you see them above, that is generally the order people associate them in. For example, you can’t control until you have a design. You can’t use your CAM software before your CAD software. One of the main things you need to address is how these elements interact with each other.

Right now this may seem confusing. Over time, it will seem very basic. The more you use these elements with one another, the more their order will become second nature.

Note: The A-axis is the rotational axis. Why is it called that? I don’t know. It is also sometimes called the B-axis. I have even heard it called the W-axis. A-axis is the rotational axis around the X-axis. B-axis is the rotational axis around the Y-axis.

Buying a completed CNC Machine

If you purchase a CNC machine outright, it will have a machine controller as part of the package. Everyone does it a bit different though. Some try to make it a black box that only they can fix. Other use commonly used components so you could repair it if need be. You will just have to ask the manufacturer and see what they say. My experience says they usually tell you that it uses common components that you can get anywhere if needed. If something goes wrong, it seems you can only get the part from them. You will have to decide.

Internal Machine Controller Parts

There are many different electrical components that go into a machine controller. I won’t pretend that I am an expert on this. Actually, this is one of the components I buy pre-made so I don’t have to do it. If you are an electronics junkie you could build your own. I know where my skills are at and it isn’t in assembling and understanding electronics.

Here is what I know about the guts of a controller. There will be drivers. One for each axis.

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