CNC Machining Helps Reduce Waste

CNC (Computer Numerical Control) machining has transformed modern manufacturing. It has dramatically improved precision, consistency, and increased throughput. One of the significant benefits of CNC machining is the positive impact on waste reduction. Properly implemented, it minimizes the amount of raw-material scrap and reduces the need for part rework, thus CNC machining helps reduce waste. Because of the flexibility of the CNC program for toolpath selection and consistent control of the cutting process, you can size your raw material to a near net shape, decreasing your need for more raw stock, and maximizing utilization of cutting tools.

Below is further explanation of the best practices that we at Intrex implement that enables our CNC machines to be effective in our continuous activities that reduce waste.

Precise Material Removal
Because of the advancements in CNC technology, it has allowed for the use of less raw materials. The                    latest generations of CNC machines have more powerful controllers which can generate added finite                        points defining greater precision. The latest servos which control machine axis movement are also                            capable of higher levels of axis movement definition and hence greater accuracies. These higher levels of                machining control minimize the need for excess raw stock that lessens scrap.

Advanced Cutting Tool Technology

With the progress in CNC machine tool design and manufacture, there has also been improvements in                    cutting tools. Many of our newest CNC machines have “adaptive controls”. This feature gives the machines              the ability to vary speeds and feeds of the cutting tools while in the workpiece, which allows for greater chip              control, size control and part finish. It not only helps optimize part tolerance, but also minimizes scrap.

Collision Avoidance System (CAS)

Another of the developments in CNC machining is CAS – Collision Avoidance Systems. It is a pre-                           machining simulation CAM (Computer Aided Machining) software. It gives the programmer/operator the                   ability to run the machine program through a simulated graphic process, enabling the operator to identify                 tool and work holding interference points, prior to actually machining the part. This helps avoid potential                   crashes, eliminating costly machine repairs, broken tools and loss of damaged parts.

Multi-Axis and Complete-Part Machining
Previous generations of CNC machine tools usually operated in a two or three axis machining mode. This                would require additional machine setups to achieve complete machining where 4 & 5 axis were required.                  Each additional setup would increase tolerance “stack-up” and the possibility for cumulative error, which                  inevitability adds to higher scrap rates. With the introduction our 4 & 5 axis machines, the number of                        setups is greatly reduced, there is less operator involvement and additional work holding is eliminated.

Automated Tool Management
The newest generations of CNC machines have controllers with integrated tool-wear monitoring and                        automatic tool-change systems. These machine tools can track tool cutting times, monitor tool wear and                  spindle loads all internal to the machine cutting cycle. They can also automatically change out tools at                     predetermined times, maximizing tool life and minimizing scrap.

CNC Data Analysis

Our latest CNC machines can record actual run cycle times, feeds, speeds, spindle loads and scrap                         incidents. These types of information can be very valuable in identifying areas of manufacturing strengths                 and weakness.  Continuous process improvement (often guided by Lean or Six Sigma methodologies) can               target these areas for refinement. The results can be measured for process improvement and reduced                     scrap rates.

CNC machining’s blend of digital precision, automated optimization, and real-time monitoring makes it a powerful ally in the drive to minimize waste. Coupled with data-driven continuous improvement, CNC processes help us achieve higher productivity, while lower operating costs.

We Would Like to Hear From You

At Intrex we have adopted and utilize the practices mentioned above. If you would like to have a conversation with us, we would welcome the opportunity. Please click here for contact information.