The Essential Guide To CNC Milling Machines

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So what are the different parts of a CNC Milling Machine or Machining Center? The diagram below provides a breakdown of its main components.

#1 Frame

The frame is the main structure that supports the milling machine and helps to give it stability and rigidity. It usually comes with a base and detachable column/s.

An important part of the frame is the machine headstock where the main spindle is mounted on. The headstock, while important, is often overlooked. If the headstock is not rigid and fails to provide stability and support to the spindle, you could get vibrations and chattering during the machining operation. This could result in machining errors and a shorter lifespan to your cutting tool.

#2 Spindle

The spindle can be considered as the &#;heart&#; of a CNC milling machine. It normally comprises a rotating assembly, and a tapered section where tool holders may be positioned. The shaft of the spindle is normally where the tool is attached to, usually via a tool holder.

A motor with different levels of transmission is used to rotate the spindle.

To keep your spindle in good condition over the long-term, various forms of lubrication are used. They may include Grease Lubrications (not suitable for long durations of high speed operations), Air-Oil Lubrications (sufficient for longer cycle runs at higher speeds) or the Hwacheon Oil-Jet-Lubrication (ideal for all conditions &#; even extreme, long and high speed applications).

Depending on the machine type, the spindle can be vertically or horizontally positioned.

#3 Axes

In general, CNC milling machines have X / Y / Z as well as additional rotational axis or C / A or B (subject to configuration). These can be programmed using g-code in the CNC controller.

#4 Column/

s

The columns of the CNC machining center can be single (eg travelling column HiRex or also C-Frame like HiT 400 / 360; VESTA line including &#;B&#;; SIRIUS-650 / 850 / ) or double (SIRIUS / / L1 / L2). This depends on the level of complexity needed in the machining task.

#5 CNC Control Panel

This is the main &#;nervous system&#; of the machine tool. It contains the electronics that helps to control the different cutting actions through programming functions. The control panel has a CNC monitor and programming buttons where data and codes can be punched in. It usually also offers a manual function. For ease of machine operation, the control panel should be easily accessible and within easy reach.

#6 Tool / Tool Changers (Automatic Tool Changer or ATC)

These are either mounted at the column or separately mounted to the machine. The latter is preferred if larger tool changers are needed with 40 up to 300 different tools. Doing so not only helps to save time and effort &#; it also helps your operators to avoid unnecessary vibrations during operation.

#7 Tool Holders

These come in many different sizes, systems and for various applications. The standard sizes for tool holders are BT 30 to BT 40 and BT 50 (BT refers to the taper angle of the cone on the holder).

(In Europe, the term used is SK 30, SK 40 or SK 50, which has the same angle as BT holder but with an additional orientation groove at the flange. Together with a key-stone mounted at spindle nose, SK holders can be orientated in a specific position. Eg.: boring bridges, boring bars, angular milling heads etc.)­­­

For higher rigidity and balanced fast rotations, BBT versions are recommended or the HSK System.

The BBT version is an up-graded version of the standard BT system providing double contact points between the tool holder and spindle. As such, it connects and bonds more strongly, provides significantly less vibrations as the tool holders are balanced to class Q 2.5. This improves not only the machining capabilities and results of your machine tool, but provides better surfaces to your part / mould, extends your tool life and lastly saves spindle replacements in the long run as bearings will last longer.

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What about the HSK System? It is lighter (good for HSC machining), shorter (good for faster tool change), and stronger than the BT system (a HSK-A63 holder is 2.5 times stronger than a BT 50 holder). The HSK System also offers excellent balancing (Class Q 2.5). Due to the strong and powerful clamping from inside to outside, the bonding between the tool holder and the spindle is ideal for heavy duty operations, heavy cuts or extremely high-speed operations at the same time.

Both the BBT and HSK versions offer far stiffer and more rigid bonding between the tool holder and spindle as these systems come with double contact clamping (i.e. between the caper / cone and front spindle nose surface).

#8 Table

The table provides a solid base to clamp the work piece directly on, and can be used to mount fixtures or vice to hold the piece in place. Most of the tables use T-slots for easy clamping of vice, fixture or part.

On Horizontal CNC milling machines, pallets are also available with Tap-holes. These allow greater flexibility in moving different work pieces to be machined. Increasingly, magnets are also being used for easy, fast and secured clamping. These should preferably be built into the machines table to avoid the loss of Z-axis height.

(See Hwacheon&#;s SIRIUS UM+ as an example.)

#9 Coolant Tank

Most CNC machining centers have a coolant tank to help supply coolant to the cutting surface or the spindle with tool during machining action. This helps to lengthen the life-span of the machine and its parts. Beyond this, the coolant will also remove heat generated by the machining action, and hence keep temperatures under control.

To hold a sufficient amount of coolant for cutting operations, the rule here is &#;the more, the better.&#; More coolant helps machine operators to avoid the warming up of coolant.

Generally, the CTS system or Coolant Through Spindle is recommended for deeper drilling operations (deeper than 4 x diameter) or when one is machining deeper cavities in mould & die applications. The standard should be 30bar with options of up to 70bar in coolant pressure. Only very specific applications would require even higher coolant pressures.

Attention needs to be given if tools with larger coolant hole diameters are used. Such machining needs may require a High Pressure &#; High Flow Rate Pump to be used.

Why automate with a CNC Milling robot?

Why automate your CNC Milling machine with a robot? There are several benefits to adding an automated robot to your CNC Milling process:

• Increased productivity: CNC Milling robots can operate 24/7 without breaks, increasing your shop's throughput. They're also faster and more precise than human operators.
• Improved safety: Automating dangerous manual tasks like machine loading and unloading keeps your human operators away from heavy machinery and hazardous chip debris.
• Lower costs: Although robotic CNC Milling has high upfront costs, it can lower operating costs in the long run through reduced scrappage, higher throughput, and lower labor costs.
• Flexibility: Many CNC Milling robots are easy to reprogram for different parts and jobs. They can handle a variety of materials, part sizes, and milling operations - Perfect for high-mix shops.
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When choosing a CNC Milling robot, consider the types of parts you produce, your shop's needs, and available floor space. Articulated arm robots are very flexible but require more space, while gantry-style robots save space but are less dexterous and adaptable. Either type should integrate easily with your existing CNC machines and CAD/CAM software.

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Types of CNC Milling robots: Articulated vs. Cartesian

When choosing a CNC Milling robot, you'll need to decide between an articulated arm or a cartesian coordinate robot. Both have their pros and cons, so consider your needs carefully.

Articulated arm robots have jointed arms that can move freely, similar to a human arm. The most common type is a Six-Axis robotic arm. They&#;re very flexible and dexterous, able to handle complex parts and move them around any cell environment. However, they can require more programming to avoid collisions or navigate tricky machines. They also typically take up more space.

Cartesian coordinate robots move along three axes - X, Y and Z. They have a simple, rigid arm structure mounted to a table which slides along each axis. Cartesian robots are often more compact, faster, and more accurate than articulated types. However, they are less flexible and struggle to maneuver curved or complex parts.

You&#;ll also want to consider using a Collaborative Robot or &#;Cobot&#;. Unlike their uncollaborative counterparts, these robots come with built-in safety features, such as automated collision detection or the ability to immediately halt in an emergency. These robots are safer for your machine operators to work around, but importantly they require less external safety equipment, like safety fences, and thus require less operating space.

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Key considerations when choosing a CNC Milling robot

Choosing an automated CNC Milling robot is a big decision that requires careful consideration of several factors. The robot you select will have a major impact on your shop&#;s productivity and bottom line.

Cost

CNC Milling robots vary widely in price based on the level of automation and features. Robots that handle the loading and unloading of parts tend to cost less than ones that can change tools and handle more complex milling operations autonomously. Consider your budget and how much you can invest to potentially reduce labor costs and improve efficiency. RO1 by Standard Bots start from $5/hour but some robots can easily be double or triple this price.

Software and programming

The robot&#;s software and programming options are important to evaluate. Some key things to consider are:

• How intuitive and user-friendly is the interface for programming parts and tool paths? The more complex the programming, the steeper the learning curve for your team.
• How much customization and flexibility does the software allow for unique and complex parts? Software that can generate paths for a wide range of part geometries will have the most utility.
• Does the software integrate with your existing CNC mill? Seamless integration will minimize additional programming time and reduce the chance of errors. Most robots will have the relays necessary to control your machines, but you may want to look for a deeper, &#;plug and play&#; integration such as that of Standard Bots and Haas.
• How much support does the robotics company offer for learning and troubleshooting the software? Ongoing support and training resources are valuable for quickly getting up to speed.
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Payload

One important factor to consider is the weight of the parts you need your robot to handle. A robot&#;s &#;payload&#; is the total weight the robot can handle at any one time. You&#;ll need to attach an appropriate end-effector or &#;gripper&#; to your robot to ensure it can handle the part. The total payload your robot is lifting at any one time includes not only the weight of your parts or blanks but also the net weight of the end-effector.

By carefully evaluating the costs, software, payload and other factors that match your needs, you can find an automated CNC Milling robot that will improve productivity without breaking the bank. The time invested upfront in choosing the right robot will pay off through increased efficiency and part quality for years to come.

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