Como reduzir os custos de usinagem CNC sem comprometer a qualidade?

If you can avoid using Stainless steel do so. Slows machining time and using the correct tooling on stainless makes a significant difference

While we all would like to choose the material we machine on our mills and lathes, we have blueprints that need to be adhered to for the application. Having produced millions of parts on CNC equipment out of the very unfriendly 1018 material, it is very important that you find a mill or distributor that produces consistent quality.

El material se puede elegir, pero en general viene designado por el cliente, por lo tanto lo que debemos seleccionar bien son los insertos de mecanizado, luego regular bien los valores como velocidad de corte, revolución, avance y refrigeración, así podemos ir mejorando el proceso.

The most important thing to understand on how to cut costs is you must know what you can do in processing a part from start to finish on all materials. Simply put know how to do it.

Se pueden mejorar las piezas a veces en su diseño, pero lo normal es que venga designado por un plano proporcionado por un cliente, por lo tanto queda en nosotros elegir el proceso que más acomode para aumentar la eficiencia del mecanizado, para ello debemos elegir bien los portaherramientas que utilizaremos de la mejor manera y luego ir ajustando el programa de mecanizado o el proceso de mecanizado si es una máquina convencional.

Esto de reducir el tamaño sucede cuando somos los que diseñamos la pieza, pero en general las dimensiones vienen definidas, en cuanto al tamaño solo podemos elegir la máquina que más nos acomode para el trabajo.

One of the area often overlook is adapting latest solution provided by CAM software. Most of the time, it is human issue. Whether management unwilling to implement change or programmer/operator sticking of their knowledge and experience. While it is not wrong to stick to the proven method, optimising and adapting new machining strategy should be the forefront agenda of every CNC machine shop in order to be efficient. Because the only constant in universe is change.

It's not just optimizing your tool paths but the efficiency in tending the machine as well! When we think of the general cost of the CNC it's not just the materials and run time but the operator who is setting up the machine and swapping out parts! We should be leveraging robotics as much as possible for machine tending! There are a ton of advantages like improved efficiency, enhanced safety, scalability for when projects get larger and general cost-effectiveness.

It is important to know and correctly apply the insert that will be used in machining. The correct implementation of the cutting speed (Vc) allows us to predict the useful life of an insert. From experience I can say that by configuring the machining cycles, together with choosing the correct insert for the type of material, it will considerably reduce times, which consequently reduces costs.

Está parte es crítica, ya que de esto va a depender la eficiencia y el tiempo ⏲️ de mecanizado, para ello vamos a reducir las distancias en G0 , aumentar las velocidades y profundidades de corte, Los avances G1 utilizando insertos de mecanizado que nos permitan aumentar los valores de proceso, así mismo es importante definir el orden en el cual se irán efectuando los trabajos que convergen en un producto terminado, así podemos ir avanzando sin trabas en el proceso de manufactura.

Minimize tool travel time and movements to reduce cycle time. You would not believe how many people have the tool transfer movement at cutting speed verses as fast as you can move. Perform a study to determine how long you can maximize tool life while at the optimal speed. Perform tool changes a a predictive level that maximizes the ability to re-sharpen that extends the tool life.

While these are all great suggestions and ideas, you've overlooked a substantial savings opportunity and that is unit utilization. A key metric should be the percentage of time your CNC machine is actually producing parts and then focus on continually increasing that percentage. I find few shop owners use this metric and most are horrified when the find how low it actually is. Of course Lean tools will be essential in driving this, starting with the Value-Added Activity technique.

Having quality process engineers who can see issues and constantly improve flow, on and off the machine. CNC effectiveness should always include what is happening to the part during and after the cycle.