Transcript CAPS - CNC cycle time reduction, idle time reduction, CNC

CNC Machines – clearing
some misconceptions
Types of CNC machining
Sheet metal cutting, forming
Turret punch press
Laser
Water jet
Video
Video
Video
Turning
Video
Die - 3D milling
Video
Aerospace - 5 axes milling
Video
Production - 2D milling
Video
India machine tools – 2011 stats
India is
7th largest consumer of machine tools in the world.
12th largest producer
4th largest importer
Growth
31 % growth in consumtion
68 % growth in imports
Types of machines
80 % of machines are CNC, 20 % non-CNC
75 % is metal cutting, 25 % metal forming
Some common misconceptions
Misconception 1
Most industries do 3D, 5-axes machining.
A few low tech industries do 2D machining.
Which of these parts
do you see most
often
on shop floors ?
What type of
machining do you
mainly see in these
firms ?
Production machining accounts for 90 % of CNC milling.
Die milling / 5-axes milling for 10 %.
Misconception 2
3D, 5-axes machining is 'high tech'.
2D machining is 'low tech'.
Cycle time reduction - importance
2D
3D
High
Low
Nothing is 'high tech' or 'low tech'.
Each type of machining has its own complexity.
Misconception 3
CAM software designed for 3D / 5-axes
machining can also program for 2D
machining.
CAM software for production machining
Must support wide variety of machining operations
Must support wide variety of tools
Must have features to reduce cycle time
Must have features to check and optimize spindle power usage
Must generate shop documents automatically
CAM software for 3D/5-axes machining
Must have 3D CAD
Must be able to machine complex surfaces
CAM software requirement for each application is different.
Same software cannot do both.
Misconception 4
Programming is the main task in CNC
machining.
Programming is NOT the main task.
Programming is just one of the steps.
Misconception 5
Misconception : Most industries do
programming by CAM software. Only a few
small industries program manually.
Fact : Most industries program manually.
Skills required in industry
The gap – institute to industry
Main cause of poor productivity on shop floors is lack of
knowledge of tooling, cutting parameters selection.
Fact : 95 % of experienced CNC personnel on shop floors
do not know the full form of the commonly used word
'carbide'.
Institutes concentrate on teaching programming,
students think this is all that is required.
Fresh engineers are as a result useless in industry, take
6-12 months to learn required skills and be useful.
Skills required in industry
Machine construction
Machining operations
Tooling
Cutting parameters selection
Manual programming
Programming using CAM software (optional)