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Tuesday, February 17, 2009

The Basics of CNC Machining Information

CNC Machining refers to any process that uses a CNC machine. This could be for routing, milling, drilling, or other types of work that is done with metal, wood or other materials. This is a manufacturing process that uses the automatic opportunity from the computer to create shapes or forms that must be precise.

Raw materials are used and they are put into a CNC machine that uses cutting tools to make these shapes. The CNC machining process involves computers that have at least one microprocessor and several units for storage. With CAD or CAM software systems added to CNC the computer can be programmed to produce the precise movements that are able to create the part.

In CNC machining the process is automated which saves the operator time and saves the business money. The operator is able to load the materials, program the machine and then the machine can work without attention when set up properly; the amount of time it is run without attention is also programmed in.

An important aspect of any Machining is for the operator to know the machine well. CNC is an addition to the general aspects of the machine. As an example, if you are doing routing, adding CNC to the process only automates it. However, for the operator, it means that they must understand the machine, how to put in codes or use CAD or CAM and how to operate the machine; they must also understand how basic routing works.

Another area that is important in order to understand Machining is the basic components of the machine. You are going to always want someone working with the machine who knows how to put it all together so if something breaks they know how to fix the machine. You really want the operator to get the most out of the machine and you really want that operator to know the limitations and capabilities of the machine in order to do this.

Eventually in a CNC Machining project you will have a few different areas that come up for the operator and really its about 5 areas that he will need to define. They will first think about the project they want to design and plan it out. It will be worth your time to sit down and really draw out some plans in this instance.

The next area is to understand CAD to translate the drawing into the computer and then an understanding of CAM to translate the CAD information into machine language. In the final area the individual must understand the Controlling function in order to make the machine do what is required. When all these areas are fulfilled properly they allow the individual to create the project in the way they saw it in their drawing.

CNC machining was traditionally only done in commercial settings with very large CNC machines. Today, there are mini-CNC machines that allow the process to be done on a smaller scale in a home workshop. Before the smaller business really had a rought time building parts and products on a smaller scale but now this technology has allowed smaller businesses to be able to do this.

CNC machining can produce both simple and complex designs and can be used on a variety of materials including aluminum, foam, wood and other metals.

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Wednesday, January 28, 2009

CNC Mini Lathes Info and CNC Mini Lathe Tips

CNC

A mini CNC lathe is generally converted from a regular lathe when a hobbyist wants to experience a machine that can do twice the work they can do manually. Usually these are small machines that have a lot of power but that can sit on a desktop or workbench in the home.

Sometimes a nice way into a new hobby is to take a smaller chunk of that hobby that this is what you can do with a CNC Mini Lathe. The CNC mini lathes are good for metalworking in general and for making small parts that need to be made with precision. Generally speaking the individual starts with a CNC Mini Machine that they buy and then convert it to do CNC.

Most mini-lathes are a smaller version of those used in commercial shops but they can be a different design than those that are made strictly for working with wood. The mini-lathe is able to shape plastics, woods and other materials. Since technology continues to evolve you will find that more and more manufacturers are making things readily convertable to CNC.

Mini lathes usually come in three sizes: 7x10, 7x12 and 7x14. Each one is measured by the length that length of the swing as it goes over the bed of the lathe. Today you can also find 9x models. The conversion of a general mini-lathe to include CNC has many benefits.

There are very different steps that some people take to do items which is why sometimes you will find that there will be manual and CNC instructions in various plans incase you want to do some things manually. At other times they may want to use CNC capabilities to produce repetitive pieces or ones that require a lot of time manually.

Converting to CNC also allows you to be able to produce both 2D and 3D contours which are unavailable when you are only working a CNC Mini Lathe by hand. All you have to do is program the computer to create the part you need. You can use wood plastic or metal to make a mold and using the CNC portion you can produce a mold that you can use as many times as you want because it creates a perfect mold. You can do multiple holes drilling by creating the diameter of the whole and then programming it into the computer; from that point the CNC lathe does the work.

When converting to CNC Mini Lathe it will generally take one or two weekends to finish the conversion; however plans will vary depending on what you want your CNC mini-lathe to do. Sometimes you can find somepicutres with perfect step by step directions that are usually under one-hundred dollars.

To convert to CNC you will need to understand either CAD or CAM software because currently these are the types of software that is used in the CNC mini-lathe machines. Usually you can control the lathe right from your PC because the software is created to run in that way. Generally it seems that you can make this conversion for under $2000.

Tuesday, January 27, 2009

CNC Mini Machines and CNC Mini Lathes

CNC

The CNC Mini Mill is actually a smaller CNC mill that has been adapted for the use of hobbyists. What is nice about this machine is that it is much smaller and can fit into a lot of home worshops easier and perfect for DIY CNCers. Some people have been able to take a basic small mill machine and turn it into a CNC machine by adding the computer control panel; this is called a CNC conversion.

This machine is also called a table top CNC mill. The mini-mill also allows an individual who doesn't have a lot of space to work within a chance to do so because they don't take up as much space as the larger CNC mill.

CNC has been used in commercial shops over the last ten years or so because of their convenience and ability to allow the operator to get more work done. For hobbyists, the prices have come down and there are more opportunities for the hobbyist to use these machines; many already understand CNC from their jobs so it is easy to convert a smaller machine.

Sometimes with machines the smaller they get the less production intent you get out of them but this is not the case with CNC Mini Machines. These Mini Machines can really do a great job for cutting aluminum or for short finishing work. They also can cut steel because of the low-end torque they use.

Manufacturers like Haas and Syil make reliable CNC Mini Mill that fit on a desktop but have high capacity for work. These are usually bought as regular mills and then converted through the use of a kit into the CNC mill. There are some ways to convert these mills and usually you will find that is a pretty painless process that goes by quickly. Some conversion kits can show how to set up robotics as well.

The conversion process is much more cost effective according to those who have done it, than purchasing one out right. Its important to look at all of the costs beause a CNC Mini Machine can cost two thousand dollars or a kit could be under one thousand dollars.

There are many advantages for hobbyists to use computerized programs for milling at home. Some of these include:

§ They can work more materials like soft waxes and hard steels and this allows them to experiment with materials they may not have used when they had to mill it by hand. They can also produce parts much faster than with regular milling machines.

§ This process allows them to work with more intricate patterns and produce higher precision components. This allows for more ideas to be produced.

§ The small CNC Mini Lathe can create smoother finishes on their projects and make for a better design.

There are a variety of projects that can be done with a CNC mini mill and may are being produced by a company called Sherline Products. On their website they show many projects from a mini-steam engine to a small hobby church that people can actually duplicate. These are some of the ways that a CNC mini-mill can be used. These projects can be seen by going to their website at http://sherline.com/CNCproj.htm.

Monday, January 26, 2009

What is CNC Foam Cutting

CNC

A CNC Foam cutter is a machine that cuts blocks of foam into a variety of different shapes and sizes through the use of a computer that fully automates the process. This process uses a hot wire to cut the block of foam so its known in the industry as a hot wire foam cutter.

Usually the wire is made from stainless steel, nichrome and the wire can be very thick. What is unique about this process is that the wire never touches the foam because it is heated up very hot so the foam vaporizes before the wire can touch it. What happens because of this process is a smoother cut and you can product a variety of shapes and sizes.

Depending on the length of the wire, the process will cut a shallow or deep cut. As you can imagine it is not good when the wire sags so there are machines that are keeping this wire very tight when it makes the cuts. On many CNC Foam Cutter machines this wire is held vertically so that it doesn’t create the problem with sagging.

These shapes are cut by the cutting wire that is attached to the machine. They will cut either polystyrene or polyurethane blocks. The types of foam that a CNC foam cutter can cut include anything that is thermofusible and expanded. What this basically means is that the foam has to be able to melt at one of the lower temperatures. Some of them include:

§ Polystyrene -- these are blocks of balls that are expanded.
§ Polystyrene -- this is extruded foam and comes in a variety of colors that include green, pink, purple or gray and these are usually plates that are smooth.
§ Polymethacrylimide -- a very expensive material and it is rigid foam with a low density.
§ Polypropylene -- which is flexible and expanded and can be a solution to protection from shock.
§ Polyethylene -- these are foams that are tear resistant and flexible.

With the CNC Foam Cutter you can form a more prism like or tapered shape in the block of foam. A hot-wire that is under a high tension to cut the foam. In order to get precison and accuracy you have the stepper motors and in order to keep the stiffness and tension of the wire you have a part called the races.

Some CNC foam cutters also offer different attachments like a lathe and this allows the machine to use either preformed or stretched wire. Also the machine is able to cut a variety of shapes including spirals or blocks of ornamental structure like balusters for stairways or planters.

There are a variety of uses for foam cutters that include making signage, model airplanes, protyping, lost foam cutting and more. The CNC Foam Cutter is a flexible machine and is only limited by the imagination.
Although many people prefer to purchase a CNC foam cutter there are also plans on the Internet that show how to make them inexpensively for hobbyists and others who are interested in working with foam.

Saturday, January 24, 2009

CNC Programming Basic Information

CNC

CNC Programming is one of the most effective ways that people are using today in order to cut metal and do other processes in manufacturing. Many hobbyists are using CNC programming to produce woodworking, metals and foam objects. CNC has created a way for many people to manufacture or fabricate parts quickly and effortlessly.

CNC stands for computer numerical control and is basically the use of a computer to do certain types of operations. This is a process that can be applied to lathe, router, foam cutters and laser machines; it can also be applied to mini versions of these types of machines.

There are basically two types of categories that CNC Programming will fall into point to point positioning or continuous path positioning. It may be worth it to check to see if your computer can execute both types of programming and this all depends on how advanced the software program is being used. This means that the operator must understand both processes in order to run the machine.

Here is a simple explanation of these two categories:

Point to point positioning -- this category is mostly used when drilling, boring, punching or tapping is needed. This is a process used to position from one point to another when the machine process is being done. The program will work going to as many positions as it needs to in order to get the process finished whether that is from the X to the Y position or not.

Continuous path positioning -- this category is generally used when a lathe or milling machine is being used and is used for contouring (contouring is another name for this category). This means that the cutting tool moves in a continuous motion from one point to another until the piece is completed. This means that the operator has to be able to program the machine so that it continues on several axes at a time and simultaneously.

Continuous path positioning also uses a series of processes called interpolation which is the way in which the machine is programmed to go. Interpolation can be helical, parabolic, cubic, circular and more. The basic function of this interpolation is to keep the programmed information stored and to monitor and direct the axes in how it should go.

What needs to happen first before any programming can start is that we are going to need a finalized design of the basic drawing of what the computer is going to make. This must be studied to make sure that the operator understands the intricacies of the drawing so they can translate the information into the computer software they are using.

This means that the operator must be skilled enough to understand how the paper drawing will translate to the computer, and then be able to program this information into the computer so that the machine will perform the cuts or the processes accordingly.

When you think about this process, it is a good idea to think about what you would do if you were producing the work manually because anything you would do manually, you will depend on the machine to do automatically. By understanding CNC Programming the individual will be more successful.

Friday, January 23, 2009

Basics of CNC Plasma Cutter

CNC

The CNC Plasma Cutting process has been in existence for over 50 years and was created during World War II. At that time the government needed a welding process that would weld together aircraft parts in a better way than what they were using. This process used inert gas that acted as a barrier to protect an electric arc that stopped oxidation from forming on the weld.

As this process was improved over time, people experimented with the openings in the arc to see how they could create the best way for the process to be done. There was another discovery where you could get a hotter flame if you restricted the opening where the gas passed through. If you look at it a different way, you can make the opening smaller and this in turn would cause the flow to speed up.

The plasma-arc cutting process which is what came out of all of these experiements, became used in the commercial industry in the early 1960s. It was found after looking into this system that you have to have a lot of capitol to take on this business.

Today, the process has improved dramatically and there are even CNC Plasma Cutter that are portable; some models even have air compressors build in for a fuller portability. Many are smaller and are able to cut sheet metal as their primary work but others can output a lot more in voltage and in work. Also as the CNC plasma cutter was created the process could be totally automated; all an operator has to do is key in how they want the plasma cutter to cut and it does the cut perfectly every time.

CNC plasma cutters come in a variety of sizes but they all basically work the same way. The process sends a gas that is pressurized through a channel. The gas could be argon, oxygen or nitrogen that is sent through this channel. Inside the channel is an electrode that is negatively charged. When power is applied to the electrode and the tip of the plasma cutter is touch to the metal, it creates a full circuit.

At this point this circuit makes a high powered spark that goes through the channel; the gas is heated to a very high heat called the fourth state of matter. You will get metal that turns into molten slag when you apply a direct stream of plasma to the metal. What this means is that you have a very high heat and a very fast moving beam of light that hits the metal.

The plasma is what makes the electrical current and this power supply keeps working until the circuit between the electrode and the power supply is broken. Also the cutter nozzle has channels in it so that it can continue to create a consistent flow of shielding gas. This also allows the plasma beam to stay consistent on the metal to be melted.

Some CNC Plasma Cutter have robotic arms that do the work. The point to having this in the CNC mode is that the process is totally automated and it will continue to work to cut with precision as long as the information is programmed correctly into the computer.

Wednesday, January 21, 2009

DIY CNC Router Built Yourself

CNC

Many people like to build their own CNC Router because they like having something that functions that they have built by their own hands. There are many different ways that you can do this yourself if you would like to do it.

Some people like to bypass some of the making of the CNC Router and they do this by purchasing a kit. Kits are a good idea to get a start on what you want to do because they show you, step by step, how your machine will work. If you are a visual person who needs something to look at while you build, this will be a perfect way for you to start your do-it-yourself project.

Plans vary however so make sure that the plan you use has the information you need. As an example, some plans give you a brief idea of what you will be doing to create the plan. Others will give you full blueprints that will show you step by step what to do and what it should look like at every step of the way.

Some people prefer to just wing it and try their hand at the building of their own CNC Router. If you are this type of person, having a plan to look at as a guide can be the perfect way to make sure your design is workable. Either way you will have a finished product.

The greatest reason to build your own CNC Routing is that you can get the parts for a fraction of what you would pay in the store.

Things to Think About when Making a CNC Router
When you first think about making your own CNC Router the first thing you will need to do is decide on a design. There are basically two types of designs that you will have to choose from. Either you want one with a stationary gantry and a mobile bed, or you want one with a mobile gantry and a stationary bed. Like anything there are pluses and minuses for all things.

The mobile bed is usually used on smaller machines like engravers and isn't as common as the stationary bed. You will also need to decide on how large you want the cutting area to be which will be determined by the size of the material you will want to cut. Running through this project you will find there will be things that change as you look for parts and try a few different things.

Another item to take into consideration is how big a machine you want. If your space is limited, you will have to consider how far you want your router to travel. This may mean that it just goes the length of the space. In any case you won't want to have wasted space in the area where you are going to use your CNC Router .

One of the final steps is for you to decide what kind of tolerance you want on the machine and then you are good to go. This will speak to the accuracy and the precision of the machine. Once you understand what you want, it's time to look at the steps to building it which will be talked about in a different article.

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