Design and Planning Phase

• CAD Design (Computer-Aided Design)
  • Creating a 2D or 3D model of the part using CAD software.
  • Defining precise dimensions, tolerances, and features.
  • Exporting the design in a format suitable for CAM software (e.g., STEP, IGES).
• CAM Programming (Computer-Aided Manufacturing)
  • Importing the CAD model into CAM software.
  • Defining the machining strategy:
    • Selecting appropriate cutting tools (mills, drills, etc.).
    • Determining cutting parameters (speed, feed, depth of cut).
    • Generating toolpaths – the precise movements of the cutting tools.
  • Simulating the machining process to identify potential errors or collisions.
  • Generating G-code – a numerical control language that instructs the CNC machine. Post processing is often needed to tailor the G-Code to specific machines, such as HAAS ST 30 and Fadal machines.
• Material Selection and Preparation
  • Choosing the appropriate material based on the part’s function and requirements (e.g., aluminum, steel, plastic).
  • Preparing the workpiece:
    • Cutting the material to a rough size.
    • Securing the workpiece in a workholding device (e.g., vise, fixture, chuck) on the CNC machine table.

Machining Phase

• CNC Machine Setup
  • Loading the G-code program into the CNC machine’s controller.
  • Mounting and calibrating the cutting tools in the machine’s spindle or turret.
  • Setting the machine’s origin (zero point) – a reference point for all tool movements.
  • Performing a dry run (without the workpiece) to verify the toolpaths and identify any potential issues. The setup process may vary slightly depending on the specific machine being used, such as the HAAS ST 30 and Fadal machines, which have unique control layouts and setup procedures.
• Machining Operation
  • Starting the CNC program.
  • The CNC machine controller interprets the G-code instructions.
  • The machine axes (X, Y, Z, and potentially others) move the cutting tools along the programmed toolpaths.
  • Material is removed from the workpiece, gradually shaping it into the desired form.
  • Coolant may be used to lubricate the cutting process and remove chips.
• Monitoring and Adjustment
  • Observing the machining process to ensure it’s running smoothly.
  • Making adjustments to cutting parameters if necessary (e.g., to improve surface finish or prevent tool breakage).
  • Periodically checking dimensions with measuring tools (e.g., calipers, micrometers) to ensure accuracy.

Post-Machining Phase:

• Part Removal and Cleaning
  • Removing the finished part from the workholding device.
  • Cleaning the part to remove any chips or coolant residue.
• Inspection and Quality Control
  • Inspecting the part to verify that it meets the design specifications.
  • Using various measuring tools and techniques (e.g., CMM) to check dimensions, tolerances, and surface finish.
• Finishing Operations (if required)
  • Performing additional finishing operations such as deburring, sanding, painting, or coating to improve the part’s appearance or performance.