Milling and machining are some of the longest-standing post-industrial revolution industries. Given these manufacturers have been around for a long time, there have been many changes and improvements over the years. To stay ahead of the game, as a manufacturer based in milling and machine you need to be up-to-date with technology.
This article is about how you can work faster and better in the milling and machining industry.
Hi-Tech Milling Machines
If you want to be working as fast as you can whilst still maintaining high accuracy and performance then you need to have a hi-tech machine. Many companies offer different qualities and focus on different aspects of performance. Some techniques such as cnc mill machining, aim to offer the ideal trifecta of performance. The three main points are speed, accuracy, and surface finish. Generally to improve one of these points you will degrade the quality of at least one of the other points.
Below are some of the main features of hi-tech milling machines that will contribute to you being able to work faster and better.
1. Acceleration And Deceleration
When machining a specific material, the speed of acceleration and deceleration is vitally important. If your machine does not have smooth control over its change in speed then you will likely lose out on the speed, accuracy, and surface finish of your product. By having a smooth, bell-shaped curve of acceleration and deceleration you can have full control over your machine and the output this produces. Extra control will save you time as you will be able to get to where you need to be much faster.
The quality of the product will be increased due to the more consistent accuracy of the machining. These qualities will also improve the surface finish too. Having a smooth control of the acceleration and de-acceleration by using a hi-tech milling machine will enable you to work faster and better.
2. AI Contour Control
As a manufacturer, you will want to have complete control over every aspect of your milling machines. With AI contour control, the software looks ahead to the next action that needs to happen and preempts any issues. It also can minimize the acceleration and deacceleration delays that may occur when using a servo. Utilizing AI for the more fiddly and minute issues is a really smart move for a milling and machining manufacturer.
Moving to a more computer-oriented system will enable you to work faster and better. Over time, your accuracy will also be improved as you remove human error.
3. Faster Positioning
Employing a more hi-tech milling machine will allow you to reposition your machine much faster. Often when transitioning between contouring modes or even just moving from one part to another, there is a significant downtime. These pauses and gaps between the operation of the machine add up and cause you to lose valuable productivity. With the new technology available the milling machine will be able to re-position itself much faster than any human could manually control it.
This will also improve the accuracy of the machining as you will be able to jump to presets with ease. Naturally, time saved between reposition is incredibly helpful for making you work faster and better as a manufacturer.
4. Jerk Control
No, new milling machines do not give you some kind of superpower to eliminate jerks in your workplace. Jerk control is the term used for a machine’s ability to absorb vibrations and shocks that occur when machining. Hi-tech machines these days can reduce all of these shocks and vibrations to a minute amount. Improved jerk control will help with the accuracy of your products but also the surface finish.
Improved accuracy over time leads to a faster workflow as you will not redo fewer parts to meet quality control. Minimizing errors due to vibrations and shocks is a great way for a milling and machining manufacturer to work faster and better.
5. High Response Vector Control
High-response vector control (HRV) is an advanced form of field-oriented control that uses high-speed DSPs and nano-interpolation to improve surface finish, cycle times, and accuracy. There are a lot of intense technical details that go into how HRV works and how it can help you. Essentially, it boils down to give you more control over the minutia of your machine. Rather than having options in steps with large gaps between each one, HRV offers a more fluid control where you can dial in exactly what you need. Having a machine that has HRV capability is ideal if you want to work faster and better as a manufacturer.
6. Programmable Machine Controller (PMC/PLC)
With all of the hi-tech improvements that can be made to your milling machine, you need to have an interface that can keep up with it all. Having a hi-tech programmable machine controller means that you will have a super-fast processor that can give you feedback on the machine’s performance. Why is it important for this processor to be ultra-fast? Well, you want there to be a little delay between what is happening in the machine compared to what you are seeing on the screen.
The almost instantaneous feedback is what provides high accuracy and fine-tuning of the machine’s performance. Using the most up-to-date programmable machine controller will enable you to work faster and better as a milling and machining manufacturer.
7. Servo And Machine Optimization
The final important aspect of upgrading your milling and machining machines to the highest tech versions is that you can optimize everything. With the use of computer modeling and AI, you can streamline every part of the process. Employing the use of 3D models your computer will fine-tune the machine so that it is operating at maximum efficiency. As you will know, efficiency will improve output, both in speed and accuracy. This is a great way to work faster and better as a manufacturer.