Six Methods to Improve CNC Lathe Production Efficiency

September 22, 2023

In actual production, we find that different operators of the same CNC lathe have varying production efficiency within the same working time. The machining capability of many CNC lathes is not fully utilized and their optimal function is hard to achieve. In use, only by fully considering the various factors affecting CNC lathe production efficiency and trying to improve it, can the production capacity of CNC lathes be fully exploited.

1. Formulate a reasonable machining route to reduce auxiliary time of CNC turning

To improve CNC lathe efficiency, first analyze in detail the parts machined by the lathe - material, structure, tolerance, surface finish requirements, etc. Then choose an optimal machining process and simple route.

Process planning: A part often has several processes. Different processes affect efficiency, cost and accuracy. Under specific conditions, develop a reasonable process to maximize efficiency and minimize cost.

Machining route: A correct, simple route ensures quality and efficiency. When selecting the route, follow principles like - ensure precision and finish requirements, maximize efficiency; minimize route to reduce program blocks and tool idle time; simplify programming with less code; consider workpiece allowance, rigidity, tools; determine one-pass or multi-pass machining. Reduce workpiece setups to improve efficiency and positional accuracy.

2. Select suitable tools

Consider the capability, process and workpiece material when selecting CNC lathe tools. Tools need high hardness, wear resistance, strength, heat resistance, dimensional stability, ease of installation and adjustment. Use new high-quality materials and optimize tool parameters for proper size and geometry. How to select the right cutting tool?

(1) Choose suitable tools

Cutting tools play a crucial role in CNC machining. Tool materials need high hardness, wear resistance, strength, toughness, thermal conductivity, processability and economics. Under process requirements, use larger diameter tools for better strength and toughness. Minimize tool varieties to reduce change time. Select standard tools over specialized ones when possible.

(2) Determine tool point reasonably

The tool point is the starting position relative to the workpiece. Also called program start point. Tool point selection should - simplify programming and calculation; be easy to identify and inspect on the machine; minimize processing error. It can be on or off the workpiece but with dimensional relationship with workpiece datum. Select tool point on part design or process datum when possible, like center of a locating hole. Align tool with hole for better efficiency and quality.

3. Install and clamp workpiece reasonably to increase clamping speed

Design workpiece positioning and clamping to unify design, process datum and program calculation. Minimize setups; machine all features after one locating. Avoid manual adjustments to fully utilize CNC capability.

Consider workpiece positioning, clamping design and fixture selection. Ensure fixture coordinate system matches machine system. Coordinate workpiece and machine datum. Also consider:

(1) For small batches, use modular, adjustable, universal fixtures to reduce preparation and cost.

(2) Consider dedicated fixtures for batch production with simple structure.

(3) Quick, reliable workpiece loading/unloading to minimize machine downtime.

(4) No interference between workpiece and machine.

(5) Facilitate tool changing and avoid clashes.

(6) Use multiple fixtures for higher production rate.

4. Select cutting parameters rationally to improve material removal rate

Cutting parameters include speed, depth and feed rate. For roughing, use higher rates for productivity while considering economy and cost. For finishing, ensure quality while maximizing efficiency and cost. Use rapid feeds for non-cutting motions. Reference machine specs, parameters handbook and experience.

5. Preset tools and auto measure to reduce changeover time

CNC machining uses many tools. Presetting tools eliminates manual measurement and input for each change, reducing machine downtime and improving efficiency.

6. Utilize advanced CNC features and macros flexibly

Use tool compensation for precision; use same program for different operations. Macros represent repetitive features and sizes concisely, execute faster than CAM software. Modular macros just need information input for different parts. Reduce programming and input time.

Other functions like canned cycles, subroutines, mirror imaging, coordinate rotation eliminate manual programming. Used properly, they can multiply productivity gains.

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Author:

Ms. lydia

Eメール:

lydia@yienmachinery.com

Phone/WhatsApp:

+86 18629152164