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Problems Faced by CNC Machines End Users at Coimbatore District

Article · August 2017

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Jour of Adv Research in Dynamical & Control Systems, 12-Special Issue, August 2017

Problems Faced by CNC Machines End

Users at Coimbatore District
R. Ganesh Kumar, Ph.D. Research Scholar, Management, Karpagam Academy of Higher Education, Coimbatore.
R. Velmurugan, Associate Professor, Commerce, Karpagam Academy of Higher Education, Coimbatore.
Abstract--- End users of CNC machines will feel discomfort and may spread negative feedback and information
about the problems to their friends and relatives and also to the public, if any sort of problem is noticed at CNC
machines. This will seriously impair the turnover of the CNC machines. Further, the negative feedback may also
ruin the brand image of the CNC machine manufacturers. In order to improve the market share and also for retaining
the existing market or achieving the targeted sales of CNC machines, it is essential to study the customer's problem
on using CNC machines. Thus, in this study, an attempt has been made to ascertain the major problems faced by
CNC machine end users at Coimbatore district. By employing purposive sampling technique, primary data have
been collected from 150 CNC machine end users. The collected data have been analyzed by the employing factor
analysis. The result of the study discloses that coolant less flow, difficult of chip disposal without chip conveyor less
guide way wiper life are the frequent problems faced by the CNC machine end users.
Keywords--- CNC Machines, Coolant Problem, End User’s Problem.

I. Introduction
CNC machine means “Computer Numerical Control” machines. In CNC machines, functions and motions are
fully automatic which are controlled by the Programme (set of instructions). Hence, for operating the CNC
machines, frequent supervision and manual intervention is not required. In CNC machine, there is two major parts
(Hardware part and Software part) in operation. Hardware part consists Electrical motors, motor drives etc., and
software part consists Electrical Logic and CNC programme. Purpose of the CNC machine is either metal removing
or metal forming process. CNC machines are being used for metal cutting process and non metal cutting process.
CNC machines are also being used for Laser cutting process, Electric discharge machining and other special
process.
CNC machines in India offers employment opportunities directly and indirectly to two lakh employees. Total
Turnover of Indian CNC manufacturers are $690.80 per year. Turnover will change every year depending upon the
Indian Industry’s need and usage. CNC industry contributing major role towards the growth of Indian Industry by
providing high quality with best price CNC machines as per the Indian industry’s requirements and also reducing the
need of CNC machine imports from foreign countries (Preventing our Indian money which goes to abroad.
Ultimately it results our Country’s growth). Coolant less flow or low pressure at tool tip, Difficult of chip disposal
without chip conveyor, Less Guide way wiper life, Machine idle due to spindle alarm/CNC system problem,
Hydraulic oil temperature is high, Machine spares cost is high, Delay in supply of spares (due to shortage at “CNC”
machine manufacturing place) are the common problems faced by CNC users. Rectifying the problems at CNC
machine user place are essential for achieving the customer satisfaction, getting repeated orders from the same
customer and also for running the CNC manufacturing and selling business.

II. Review of Literature

Multimcam (2017) in their study stated that burning of material on the outside of the edge, chatter and
overheating are the common problems faced by CNC end users. AMMC (2016) in their study pointed out that the
improper tools settings and improper programming are the major problems committed by users of CNC machines. A
study by machinetoolhelp.com observes that the Tool changer ATC problems, Servo & Drive alarms, Pulse coder
alarms, Way Lube problem, Low voltage problems at device, Zero Return problems, Power supply problems, Axis
brake, Door interlock circuit problems, Chuck will not clamp/unclamp, Relay board problems and Hydraulic
problem are the common problems faced by the end users. Anand (2017) in his article mentioned that improper tool
settings, improper maintenance and improper programming of CNC machines lead to break downs in CNC
machines. Nazir B. Tamboli (2016) in his article pointed out improper setting, improper maintenance and improper
programming lead to failure of CNC machines. Joe Bennick and John Frauenhoffer (2006) in their study states that
cutting fluid problems, which reduces the quality of output in CNC machines, is major problem that prevail at CNC

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Jour of Adv Research in Dynamical & Control Systems, 12-Special Issue, August 2017

machines. Hinsu Jindal, Rakesh Kumar and Kartik D. Kothari (2014) in their study ascertained the axis slips
downwards due to inertia and gravitational force in Vertical axis CNC machines and motion errors of the rotary axes
in five-axis CNC machine tools are the common problems prevail at CNC machines. Sushrut S. Pavanaskar (2014)
in his study observes that 5-axis tool path planning problem is the common problem that prevail at 5 axis CNC
machines. Ghetiya and Saurin Panchal (2014) in their study ascertained that the problem of Ovality deteriorate the
quality of output of CNC machines. Major of the studies covers only few specific problems on CNC machines. Not
much study has been carried on addressing the various problems faced by CNC machine end users. Thus, the present
study covers numerous problems that prevail at CNC machines from end users’ point of view.

III. Statement of the Problem

When the problem found in the CNC machine, customer will feel discomfort and may spread negative feedback
and information about the problems to their friends and relatives and also to the public. This will seriously affect the
turnover of the CNC machines. This may also spoil the brand image of the particular product and also spoil the
name of the CNC machine manufacturer. In order to improve the market share and also for retaining the existing
market/for achieving the targeted sales of CNC machine, it is essential to study the customer's problem on using
CNC machine. Studying the customer's problems and solving the same will result in improving (more) the life of
the CNC machines. Further, Customers will place repeated orders to the same brand (Model) of the CNC machines
when they did not face any complaint in the particular product. Thus, in order to increase the turnover and Sales of
the CNC machines, it is essential to study the customer's problem on using CNC machine. Hence, in this study an
earnest attempt has been made to ascertain the problems faced by the customers on using CNC machine and to
suggest suitable measures to enhance customer’s satisfaction.
Objective
To identify the problems faced by CNC end users.

IV. Methodology
Data
Data required for the study have been collected by employing Questionnaire method.
Area of Study
The present study is confined to end users situated at Coimbatore district.
Sample Design
By adopting purposive sampling method data collected from 150 end users of CNC Machines.
Framework of Analysis
The collected data have been analyzed by making use of Factor analysis.
Analysis and Interpretation

Table 1: KMO and Bartlett's Test

Kaiser-Meyer-Olkin Measure of Sampling Adequacy. .720

Bartlett's Test of Sphericity Approx. Chi-Square 1444.000

df 136
Sig. .000
To ascertain vital problems faced by end users on CNC machines factor analysis is employed. The following
table illustrates the imperative problems faced by end users. In order to ascertain whether the data is proper for
employing factor analysis, Kaiser-Meyer-Olkin (KMO) and Bartlett’s Test of Sphericity have been employed. The
result of KMO and Bartlett’s Test is found greater than 0.70. Hence, the collected data is fit for employing the factor
analysis. Further, the large values of Bartlett’s sphercity test (1444.00, df: 136 Sig=0.000) and KMO statistics
(0.720) indicated the appropriateness of factor analysis.

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Jour of Adv Research in Dynamical & Control Systems, 12-Special Issue, August 2017

Table 2: Problems Faced by CNC End Users

Particulars 1 2 3 4
Coolant Leakage 0.697 0.241 0.129 0.040
Cooalnt less flow or low pressure at tool tip 0.780 0.334 0.197 -0.064
Poor Chip Management 0.669 0.513 0.143 0.068
Less Guide way wiper life 0.757 0.261 -0.073 -0.131
Difficult of chip disposal without chip conveyor 0.771 0.018 0.304 -0.021
Spindle belt slippage due to coolant fumes entry at spindle belt area 0.503 0.538 -0.168 0.050
Machine idle due spindle alarm / CNC system problem 0.365 0.196 0.011 0.594
Operator discomfort due to coolant fumes generation during machining 0.381 0.389 0.110 0.341
Machine spares cost is high 0.286 0.260 0.762 0.117
Delay in supply of spares (due to shortage at "CNC" machine manufacturing place) 0.408 -0.111 0.707 -0.084
Hydraulic oil temperature is high -0.037 0.900 0.060 0.040
Hydraulic oil leakage (at few areas) 0.233 0.816 0.065 -0.227
Only trained operator can do “CNC” programme -0.337 -0.321 0.008 0.763
Only trained person can do the maintenance work in “CNC” machine -0.396 -0.435 -0.025 0.527
Few spare parts are not available in the open market (it is only available at "CNC" machine
-0.129 -0.048 0.782 -0.038
manufactures)
Some times customer dissatisfaction due to delay in technical support from the “CNC” machine
0.682 -0.134 0.190 0.095
manufacturers.
Break down maintenance cost is high 0.319 0.175 0.581 0.475
Eigen Values 6.093 2.351 1.442 1.349
% of Variance 35.838 13.830 8.485 7.935
Cumulative % of Variance 35.838 49.668 58.153 66.088
Four factors are identified by locating Eigen values greater than unity. Problems which have a component
loading of 0.7 and above are said to be vital problems faced by end users. From the rotated component matrix, it can
be seen that “Coolant less flow or low pressure at tool tip”, “Difficult of chip disposal without chip conveyor” and
“Less Guide way wiper life”. In the second factor, “Hydraulic oil temperature is high” and “Hydraulic oil leakage”
are found to be significant. In the third factor, “Few spare parts are not available in the open market (it is only
available at "CNC" machine manufactures)”, “Machine spares cost is high” and “Delay in supply of spares (due to
shortage at "CNC" machine manufacturing place)” are found to be significant. In the Fourth factor, “Only trained
operator can do the “CNC” programmes” which are found to be significant. Factor one contributes to a tune of
35.838 per cent towards the CNC machine end users problems. The other factor contributes namely, 13.830, 8.485
and 7.935 towards the CNC machine end users problem. The total cumulative percentage of problem contributed by
these four factors on the end users is 66.088 per cent.

V. Suggestions
The following suggestions are offered to contain problems faced by Industrial users.
• To contain Coolant problem, (a) Correct Volume of the coolant to be filled inside the machine coolant tank,
(b) As per the customer usage and application requirement, correct capacity and model no. coolant pump
must be selected and fitted in the machine, (c) Coolant leakage at hoses, end fittings must be checked and
arrested at machine assembly and testing area.
• Chip conveyor and chip bin are to be supplied to customer place along with the CNC machines for better
chip disposal.
• End user (customer) should maintain the machine with clean and also periodic cleaning the machine’s
cutting area and chips collecting area is essential for maintaining the (achieving) Guide way wiper life.
• Hydraulic oil coolers are to be used in the CNC machine for reducing the high temperature of hydraulic oil
and also for maintaining the correct recommended oil temperature. This results, elimination of machine
break down.
• Hydraulic oil leakage must be arrested immediately when it is noticed in the CNC machine. Periodic
maintenance of CNC machine will prevent hydraulic Oil leakage. Oil seals must be checked and replaced
periodically for eliminating oil leakage problem. Hydraulic connector, hoses and end fittings to be checked
periodically and defective parts to be immediately replaced.
• For the benefit of the customer, CNC machine manufacture should keep the spare parts ready for long term
for eliminating the machine break down time at customer place for the need for the spare parts. For the
benefit of the customer and also for eliminating the duplicate (Poor quality spare parts) in the open market,
manufacturer will sell the spares directly to the customer (not to outside shop keeper)

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 Jour of Adv Research in Dynamical & Control Systems, 12-Special Issue, August 2017

• Increasing the production volume of Spare parts will reduce the spares cost. For the benefit of the customer,
CNC machine manufacture should keep the spare parts ready for long term for eliminating the machine
break down time at customer place for the need for the spare parts. CNC machine manufacturer has to
manufacture and procure more quantity of the spare parts for reducing the spare parts cost.
• CNC machine manufacturer has to properly plan and maintain the required spares store stock for eliminating
delay in supply of spares. In addition to the above required quantity of the spare parts to be produced and
procured for eliminating delay in supply of spares.
• Training is essential for generating the CNC programme and also for operating CNC machines. However,
CNC System (Electronic parts) manufacture has to develop CNC machine user friendly interactive software
for eliminating the dependency of the trained operator.
• CNC machine must be maintained properly. Preventive maintenance to be done for eliminating this
problem. CNC System (Electronic parts) manufacturer has to solve this problem during manufacturing and
testing of Electronic parts. CNC Machine manufacturer also has to thoroughly inspect and test the machine
before dispatching to the customer place.

VI. Conclusion
In the CNC machine, the generation of problems are mainly due to the poor maintenance of the CNC machines.
For eliminating the problems, CNC machine end user has to thoroughly study and follow the instructions available
in the machine manual which is being supplied to the customers along with each and every CNC machines. For
eliminating major break down of CNC machines, it is essential to completely solve the problems when it is small.
For example, hydraulic oil leakage must be arrested when the leakage quantity is a single drop. When the hydraulic
oil leakage is ignored by the end user, major accident could be happened which results injury to the machine
operator and also damage to the parts of the CNC machine. Coolant less flow or low pressure at tool tip problem
may be eliminated by arresting the coolant leakage and replacing the defective parts like Coolant hoses and coolant
connectors. When this coolant problem is ignored by the end user, results in damaging of costlier cutting tool,
cutting inserts and producing the poor quality of the components, which results rejections and major lose to the CNC
users. Less Guide way wiper life problem could be eliminated by maintaining the machine with clean with proper
periodic maintenance. Failure of guide way wiper will result the leakage of coolant and rust formation to the
accurate parts of the CNC machine which results loss to the end user.

VII. Scope for Further Research

Customer's problem study shall be extended to many other industries and there is a wide Scope for Further
Research which shall be conducted in the other types of industry like textile machine manufacturing, food products
manufacturing industry, Consumer products manufacturing industry, Automobile industry, Cutting tools
manufacturing industry, Electrical components manufacturing industry, Cutting Oil manufacturing industry,
Electronic components manufacturing industry, Mobile phone manufacturing industry etc.,

References
[1] Multimcam (2017), https://www.multicam.com/4-common-cnc-machining-problems/
[2] AMMC (2016), http://ammc.com/common-cnc-machine-problems/
[3] Anand (2017), https://www.quora.com/What-are-the-problems-in-CNC-machines
[4] Nazir B. Tamboli (2016), http://www.tamboliengg.com/cnc-turned-components/most-commonly-faced-
cnc-machine-problems/
[5] Joe Bennick and John Frauenhoffer (2006), http://www.neucodistributors.com/files/Most_Common_Cutting
Fluid_Problems.pdf
[6] Hinsu Jindal, Rakesh Kumar and Kartik D. Kothari. Modern Techniques in CNC Machines–A Review.
International Journal of Advance Engineering and Research Development 1 (6) (2014) 1-4.
[7] Sushrut S. Pavanaskar. Improving Energy Efficiency in CNC Machining. Ph.D. Thesis, University of
California (2014).
[8] Ghetiya, N.D. Some Studies on Reduction of Ovality in Turned Component-Case study. Nirma University
Journal of Engineering and Technology 3 (1) (2014) 39-46.
[9] http://www.machinetoolhelp.com/Troubleshooting/Machine_tool_troubleshooting.html

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