CNC Machining Equipment and Their Cycle Time Reduction Principles

Cycle time reduction principles for CNC machining equipment The definition of cycle time: Cycle time is usually defined as the time that occurs from the moment a specific task or series of tasks is started off till the moment a task is fully accomplished. For instance, the cycle time is the time where a shipping order is printed till the time it is fully loaded on the truck and the whole system is updated. Another definition would be the time that requires to load, run as well as unload on a CNC machining equipment. The cycle time of a CNC machining equipment can be easily measured by timing that actually takes from pressing the button in order to start the series for the first task to the pressing of the button for the next task. The amount of production in an industry says that the more CNC machining equipment you run, the more significant it becomes to obtain the goal of reducing the cycle time. All that happens in a CNC machining equipment can be categorized into the following: a) Online productive tasks: These can be referred to as the real machining operations that exist during a cycle created by a CNC machining equipment. These are some type of milling, reaming, drilling, tapping and other machining operation that work towards accomplishing the task. In order to reduce the time of cycle in these areas, there are two different ways in which these can be obtained. One of these may be via vigilant planning process. The process engineer need to opt for a right CNC machining equipment, cutting tools, machining and tools in a manner that it matches the large number of workpieces so as to be machined. The cycle time would be an image of various process required to machine the workpieces. In case, the processes of your company have been created and implemented prior to starting the cycle time reduction program, then there is another alternative. This is to emphasize on the best of cutting operations. This would include selecting the right cutting tool materials, speeds and feeds to operate workpieces in an efficient manner. b) Online, non-productive tasks: These are tasks that need to be carried out during the machining series that do not work towards accomplishing the workpiece. Wasted program execution time is the foremost thing CNC machining equipment operators usually target. These include tool changes, rapid movements, M-Code execution and acceleration or deceleration. It is quite easy to reduce program execution time in this area. It usually does not take anything more than watchful monitoring to run production efficiently for a few workpieces. The CNC machining equipment worker need not over look the process that focus on decreasing program execution time. This actually results in a lot of wastes of cycle time. c) Off-line, non-productive tasks: These are various operations carried out in the CNC machining equipment cycle that do nothing more than completing the workpiece. These types of operations are usually carried out when the machine is producing workpieces. Hence, these do not increase the cycle time.

The machine operator can easily perform off-line productive tasks in case, they have a little or nothing at all to do during long machine cycles. d) Off-line, productive tasks: These tasks are carried out by the CNC machining equipment when the machine produces workpieces that would help in completing the workpieces. This facilitates during long CNC cycles.

DIMENSION

Abstract
The optimization of cutting conditions has been and still is an active area of research since Gilbert's (1950) first work in machining economics. Many concepts and optimization procedures have been developed since then to obtain optimum conditions, taking into account as many influencing variables as possible. However, the use of these techniques in machinability data base systems, NC partprogramming systems and process planning systems so far has been very limited, even though there is an urgent need for such a technique. Existing optimization schemes do not necessarily give optimum machining solutions. Several works reported in the literature restricted multi-pass problems to two-pass problem so as to simplify the solution method or to treat them as single-pass problems. This paper describes the development of a methodology for an effective optimization of machining conditions of multi-pass lathe operations. The objective is to use the optimal even depth of cut strategy to simplify the solution method that determines near-optimum and practical solutions. The solutions obtained can be conveniently implemented in the part programmes of a CNC lathe. Such work can provide a wider acceptance and more practical application of machining economics in industry.

CYCLE TIME REDUCTION TIPS:

Use adaptive feedrate function if available. The adaptive feedrate feature will save on insert wear and cost, possibly reduce cycle time and will prevent damage to cutter bodies and tool holders. Utilize the thru the tool coolant machine option. Very high drilling feedrates can be successfully achieved with machines supporting 600-1200 PSI thru the tool. (Higher PSI usually equates to higher feedrates!) Use hi-performance tooling (especially high quality coolant thru carbide drills) for high volume parts. Tooling is cheaper than part cycle times. For high volume parts, use carbide step drills and/or multiple diameter carbide or inserted form tools if possible.

Use wiper inserts on machining center finish face mill cutters and lathe finish turning tools. Noticeably higher feedrates can be achieved. For high volume parts, use CBN (or other technologically advanced) inserts for finish face mill cutters. Extremely high feedrates can be achieved with CBN inserts. Use round inserts whenever possible. They are more difficult to program but can utilize noticeably higher feed rates and have much higher insert strength. Round (and 15 degree lead) inserts are also great for milling and turning forged steels and flame cut steel.