Creating a CNC program for a dimensionally variable component

Automate repetitive tasks

A numerically controlled machine can be used to produce components that are exactly the same and conform to the program. Once the program exists, all that is needed is to load the program, clamp/insert the blank and machining can begin. In the beginning, creating the program can take time, especially if the component is complex to machine. 

For components where dimensions change, the machining is often the same, although the positions vary according to the customer’s needs. For example, the machining of a lock may be at a different height, of a particular shape or the location may change according to the customer’s choices. So a one-off CNC program must be created for a custom component.  

Often the program consists of subroutines that perform some frequently repeated machining operation. These macros can be used to simplify the program, since the main program only specifies the desired location and the desired machining for that location. Macros allow parameter-based programming, where the same CNC program block can be used for different components and at different points in the component.

Locations of machinings in the 3D model of the i3D configurator

So how is the trick done?

It all starts with an intelligent 3D model, which contains the information about which machining operations and where the customer wants them. Or, in fact, the customer doesn’t know anything about the machining or locations, but the production configurator can convert the commercial features chosen by the customer into the information needed by production. 

Once the 3D model is complete, it is exported to CAM software, where all the parameters required for machining are defined, including component dimensions, datum point, tooling and machining. These are used to create the machining paths and check for any machining errors. In addition, the process can be simulated to ensure safety and efficiency. Now that the 3D model has a machining path, this is not enough, as each machine has its own way of working. 

So when the machining paths are ready, they will be converted into G-code in a format suitable for the CNC machine. This is done by the CAM software’s post-processor, which modifies the code to suit your CNC machine. Now the program can be transferred to the CNC machine and the machining of the dimensionally variable component can begin.

Creating a CNC program directly from a 3D model is an efficient way to speed up the manufacturing process and reduce manual work. CAD and CAM software can be used to design an optimised machining path, which is converted to G-code and executed on a CNC machine.