Project on making a CNC machine in Ethiopia

Questions

What is a CNC machine?

What is it used for?

Why use a CNC machine?

How does it work?

What are the parts used to make a CNC machine?

Who uses a CNC machine in Ethiopia?

How much is the retail price of a CNC machine in Ethiopia?

How much would it cost to make a CNC machine in Ethiopia?

Building a CNC machine

Instructions and Assembly

Software tutorial

Conclusion

Reference
Numerical control (also computer numerical control, and commonly called CNC) is the automated
control of machining tools (such as drills, lathes, mills and 3D printers) by means of a computer. A CNC
machine processes a piece of material (metal, plastic, wood, ceramic, or composite) to meet
specifications by following a coded programmed instruction and without a manual operator directly
controlling the machining operation.

A CNC machine is a motorized maneuverable tool and often a motorized maneuverable platform, which
are both controlled by a computer, according to specific input instructions. Instructions are delivered to
a CNC machine in the form of a sequential program of machine control instructions such as G-code and
M-code, then executed. The program can be written by a person or, far more often, generated by
graphical computer-aided design (CAD) software and/or computer aided manufacturing (CAM) software.
In the case of 3D printers, the part to be printed is "sliced", before the instructions (or the program) is
generated. 3D printers also use G-Code.

Coding

G-codes

G-codes are used to command specific movements of the machine, such as machine moves or drilling
functions. The majority of G-Code programs start with a percent (%) symbol on the first line, then
followed by an "O" with a numerical name for the program (i.e. "O0001") on the second line, then
another percent (%) symbol on the last line of the program. The format for a G-code is the letter G
followed by two to three digits; for example G01. G-codes differ slightly between a mill and lathe
application, for example:

[G00 Rapid Motion Positioning]

[G01 Linear Interpolation Motion]

[G02 Circular Interpolation Motion-Clockwise]

[G03 Circular Interpolation Motion-Counter Clockwise]

[G04 Dwell (Group 00) Mill]

[G10 Set offsets (Group 00) Mill]

[G12 Circular Pocketing-Clockwise]

[G13 Circular Pocketing-Counter Clockwise]

M-codes

[Code Miscellaneous Functions (M-Code)][8]. M-codes are miscellaneous machine commands that do
not command axis motion. The format for an M-code is the letter M followed by two to three digits; for
example:
[M02 End of Program]

[M03 Start Spindle - Clockwise]

[M04 Start Spindle - Counter Clockwise]

[M05 Stop Spindle]

[M06 Tool Change]

[M07 Coolant on mist coolant]

[M08 Flood coolant on]

[M09 Coolant off]

[M10 Chuck open]

[M11 Chuck close]

[M13 BOTH M03&M08 Spindle clockwise rotation & flood coolant]

[M14 BOTH M04&M08 Spindle counter clockwise rotation & flood coolant]

[M16 Special tool call]

[M19 Spindle orientate]

[M29 DNC mode ]

[M30 Program reset & rewind]

[M38 Door open]

[M39 Door close]

[M40 Spindle gear at middle]

[M41 Low gear select]

[M42 High gear select]

[M53 Retract Spindle] (raises tool spindle above current position to allow operator to do whatever they
would need to do)

[M68 Hydraulic chuck close]

[M69 Hydraulic chuck open]

[M78 Tailstock advancing]

[M79 Tailstock reversing]

Application of CNC machine
These days the CNC machines are found in almost all industries, from a small scale industry to big companies.
There is hardly any facet of manufacturing that is not touched by the automated CNC machining center.
Everyone involved in the manufacturing should know what a CNC machine can do for their company. Due to
extensive applications of CNC machines in various industries, there is a great surge in the demand of the CNC
programmers. To meet these demands a number of schools have come up that teach the operation and
programming of the CNC machines.

CNC Milling Machines are incredibly useful pieces of machinery to both

commercial and industrial production. The aerospace industry, the medical
industry and the electronics industry are all able to benefit from the products
of CNC Milling – but how do these machines operate, and what makes them so
unique?
CNC stands for Computer Numerical Control milling. This essentially means
that the milling machine is moved and monitored by numerical computer
control, rather than by hand. CNC milling tools perform a machining process
similar to drilling and cutting parts with incredible precision, and therefore
leave no room for human error. The process is an increasingly popular
industrial solution since it can accommodate detailed sizes and shapes of all
kinds of material.

How do CNC Milling Machines work?

A CNC Milling Machine uses a rotating cylindrical cutter to move along
multiple axes, and create slots, holes and details in material to turn it into a
vehicle or mechanical part. Most machines operate on three to five axes,
creating much more precision and detail. Modern CNC milling machines are
assembled as both horizontal and vertical machining centers. Components
can be made with materials such as plastics, ceramics, and composite
materials, in addition to metals. Technical features include automatic tool
changers, tool carousels & magazines, coolant systems, and enclosures to
keep machines running smoothly on their own without manual interference.

What are the different types of CNC Milling

Machines?
The orientation of a CNC Milling Machine has a significant effect on the final
product. A Vertical mill is a very standard type of milling machine, simply
meaning that the spindle axis on the mill is vertically oriented. Vertical CNC
Milling Machines usually have long and thin cutting tools, while Horizontal
machines have shorter and thicker cutting tools. 
Horizontal mills are not as versatile and are typically much better suited for
long material work, often used to cut gears or for axle machining. 
Turret mills work vertically, and their spindle does not move, while their table
adjusts parallel and perpendicularly to do the cutting job. CNC Turret Milling
Machines are most effective when they remain relatively small, so they are
best suited to detailed work – such as creating parts for toys and plaques.
CNC Bed mills are similar to Turret Milling Machines. Still, their below table
only adjusts perpendicularly to perform the cutting, meaning they can be built
larger since their frame is more rigid than the Turret. A larger build allows for
larger jobs, so Bed mills are perfect for jobs such as milling parts for mid-sized
electronics that the Turret mills couldn’t handle.

How does a CNC Milling Machine benefit

business?
As previously mentioned, Computer Numerical Control milling is incredibly
precise. Small mills, such as the Turret, can be programmed to perform
complex processes like cutting intricate medical machine parts with very little
human interference. All parts will be uniform, meaning a consistent batch of
products and few mistakes for commercial or industrial businesses to pay for.
Standard milling machines are subject to the hand, and therefore to error and
imperfection. 
An initial purchase of a CNC Milling Machine may feel costly. Still, one
operator can maintain an entire workforce of machines electronically,
ultimately saving money on labour in the long run. The CNC Milling process is
also faster than 3D printing with a broader range of materials available to use,
meaning aerospace companies, electronics factories, and medical companies
alike can reap the benefits of CNC milling in their respective fields.
 

CNC Milling Machines are incredibly versatile, with different types to fit all size
and business need. Where precision is key to a product functioning, there isn’t
a more reliable choice for machinery than Computer Numerical Control,
despite the higher price point initially. For further information, or to discuss
your needs with a professional, don’t hesitate to call our friendly team on
03302 234567.

How Many Axis’ Do You Need?

11 Dec 20
The process of CNC Milling (Computer Numerical Control) involves a
minimum of 3 axis points. As a standard, the cutting tool of a milling machine
moves along an XYZ plane to work through the material. The X-axis is
vertical, the Y-axis is horizontal, and the Z-axis dictates depth. An additional
axis is added for a 4 axis milling machine, while a 5 axis milling machine is
even more detailed than a standard 3 axis model.
Jobs with different complexities require different amounts of axis points on a
milling machine. How many axes do you need, realistically, for your new
milling machine?
 

3 Axis Milling Machine

Your standard vertical machining centers operate with 3 axis points. This
machine will utilise the X, Y and Z axes to cut your material while the piece
remains stationary. The 3 axis milling process is best suited for milling slots,
drilling holes and cutting sharp edges.
Though it is a more straightforward process, choosing a 3 axis machine may
be ideal for your project if your business is smaller. You’ll have more time to
oversee the milling process and smaller batches of material to shape. Any
rotation of your workpieces will have to be carried out manually since the
machine isn’t capable itself, so you’re more reliant on your workforce.
 

4 Axis Milling Machine

4 axis milling utilises the same processes as 3 axis machining, where a
cutting tool is moved along an XYZ plane to shape your chosen material. The
difference is that a 4 axis machine introduces an A-axis, allowing rotation of
the workpiece around the X-axis. 
The 4 axis milling process is most useful when cut-outs and holes need to be
made around a cylinder or around the sides of a piece. Your 4th axis can be
used in an ‘indexing’ mode or a ‘continuous’ mode. Indexing means that no
cutting occurs until the 4th axis stops and locks with a brake, allowing for the
cutting of material in increments rather than continuously. The indexing mode
works perfectly for the manufacture of gears, where continuous mode cuts
smoother.
 

5 Axis Milling Machine

5 axis milling machines are some of the most complex machines available
today, capable of creating very intricate and precise parts for aerospace
products, medical supplies and car moulds. As well as the A-axis that the 4
axis milling machine boasts, the 5 axis milling machine also introduces a B
axis. The B axis rotates around the Y-axis in the XYZ plane.
The multidimensional rotation and tool movement of a 5 axis milling machine
can provide unparalleled precision, speed and finish in a workpiece. With the
different directions of movement that the 5th axis allows for cutting, there is
the option for single-step machining with this choice. Single-step machining
means that no manual rotation and human interference is required for a piece
to be completed.
 

Which is best?
The more axes that your milling machine has, the more capabilities it
boasts. 5 axis machining centers are fairly unbeatable due to the option of
single-step machining, but it’s therefore, the most costly machine of the
bunch. If the products you require from milling don’t need to be ridiculously
precise or intricate, purchasing a 5 axis milling machine won’t make sense for
your budget or your requirements.
If single-step machining isn’t a necessity for your business, but you’d still like
more precision and less reliance on your workforce, a 4 axis milling machine
could be perfect for you. It is capable of rotating your workpiece without
employee management, but it’ll still require more oversight than the use of a 5
axis machine. You may need to readjust the material outside of the A-axis
manually.
A standard 3 axis milling machine may be the perfect beginning for your small
business. It’s an ideal choice if your parts aren’t intricate, you have employees
to oversee the milling process, and all you need is to drill holes or cut sharp
edges through your material for basic construction. This machine is also the
least costly of the bunch so that you won’t suffer financially should this be your
choice.
 

For more advice on what milling machine will best suit you and your business
needs, please contact us.

A Guide to CNC Turning

11 Dec 20
CNC, standing for Computer Numerical Control, is the automated functioning
of machining tools and 3D printers by computer command. CNC machines
can process material to exact specifications by following coded instructions,
and without the need for a manual operator. CNC turning is an invaluable tool
for bulk manufacturers, allowing for efficient and perfectly uniform production
with a variety of materials. 
CNC processes are available in milling machines, horizontal turning centers,
lathes, laser cutters and plasma cutters. CNC milling machines, lathes and
cutters are incredibly accurate and often a worthwhile long-term investment
for businesses. To decide whether purchasing a CNC machine would be a
sensible move for your company, here is our guide to CNC turning.
 

The Advantages of CNC Turning

The reality is that skilled manual labourers can undertake work on basic lathes
and milling machines, so sometimes a CNC turning center can seem
unreasonably expensive. A CNC machine, however, can provide continuous
use (unlike manual labour) since the processes are automatic and don’t
require a break. 
This means that productivity is higher with a CNC machine, and you can put
workers to other uses. Health and safety risks are reduced significantly, and
workplace accidents are minimised.
CNC turning processes are also much more consistent than human execution,
so batches of any parts that you make with a CNC machine will be uniform
and exact. Human error in production can be costly, so you’re also avoiding
wasted material and time with a reliable CNC machine. Even further than
consistency, a CNC machine allows a new level of intricacy for your parts.
CNC processes can perform milling and cuts that are much more intricate
than a human could ever manage.
 

The Disadvantages of CNC Turning

The cost of a CNC turning machine is the most common deterrent. They’re an
expensive investment initially, and could seem a little out of reach for smaller
businesses. Traditional milling processes, like with Knuth manual machines,
are much more reasonable for companies that are just starting and satisfying
small demand for products! If precision isn’t a key concern for your
manufacturing process, then a CNC machine might not suit you best, either.
Automation of the manufacturing process with CNC machines also means
less employment for skilled manual labourers. This could be beneficial for
your bottom line as a business, but your team will be smaller. CNC machines
still require operators and supervisors for safety, but a tiny group of personnel
can operate and maintain a large number of CNC machines. 
Your CNC machines are also more expensive in terms of repair, but as your
workforce may not be large, those servicing prices might not feel extortionate. 
 

Choosing the Right CNC Machine

Horizontal CNC milling machines are best suited for large metal workpieces,
as the positioning of material being milled allows gravity to clear away chips
and debris. Vertical machining centers are well suited for general drilling
applications like cutting keyways and gears, and they boast a great deal of
versatility. CNC turning machines operate with a process called ‘subtraction
machining’, as the material is removed during its work. CNC turning suits rings
and complex curved components, while milling would usually work better for
flat surfaces.
If any parts during your production process are cylindrical or round, CNC
turning will suit your needs best. CNC turning machines will use two-axis
control to drive a turret or more complex tool over your turning workpiece to
machine it. Your parts will be shaped with tremendous precision, and the
material will rarely be wasted. 
 

For further advice on CNC machines that will best suit your business needs,
please feel free to contact us at DTS UK. We’d be more than happy to help.