Large-scale manufacturers worldwide rely on flexible manufacturing systems (FMS) to accomplish demanding outputs. These highly adaptable, automated machining setups can easily manufacture various products and handle rapid production changes. These factors are vital for businesses that need to change product design, type and volume frequently with as little downtime as possible.

Learn how FMS works and benefits businesses in this guide by �鶹Լ��. We specialize in integrated U-axis contour head machining centers and��have decades of experience��with challenging manufacturing projects. We also do in-house integration and can work with integrating partners.

Flexible Manufacturing System Definition

A flexible manufacturing system is a highly adaptable production setup that uses automation technology. These custom systems include a centralized computer that controls various machines, material handling systems and robots. They exist to offer manufacturers production flexibility, as you can adapt the system to accommodate varying batch sizes, product designs and process sequences. FMS are almost entirely automated to reduce labor costs and improve productivity.

Components of Flexible Manufacturing Systems

FMS comprises modular components that manufacturers can adapt and reconfigure to meet changing production requirements. The core components of an FMS include:

• Work machines:��Each FMS has a unique combination of workstations to suit the manufacturer’s production requirements. These can be various robots, computer numerical control (CNC) machines, tool changers or inspection and assembly stations. Each workstation performs the required processes to turn materials into a finished piece.
• Material handling systems:��FMS requires multiple material handling systems to achieve complete automation. These hold and transport parts to each workstation in a specified order. There are also systems to store the parts and materials before and after processing. Examples of material handling systems are robots, conveyor belts, automatic pallet changers, automated storage and retrieval systems and automated guided vehicles.
• Control computer system:��The control computer system is the main component of an FMS that automates the entire process. This system houses a computer, programmable logic controller (PLC) and the necessary software. It allows operators to input programming to��control the movements and sequence��of each machine in the setup. It also monitors the machining process and updates the operator when issues arise.
• �ʱ�����DzԲԱ��:��While FMS is mostly automated, machine operators are still necessary to control them. Trained personnel instruct the FMS to perform specific tasks, start and stop the process, and make adjustments when needed. Once started, the FMS can operate 24/7 until the material runs out or the instruction is complete.

Routing vs. Machine Flexibility

Flexible management systems can offer two types of flexibility — routing and machine flexibility. Some advanced systems can even do both.

Routing flexibility refers to the system’s ability to change production sequence or order. This type of flexibility is essential when a machine breaks down or material runs out. The system can adapt and change the processing sequence to continue producing parts while operators resolve the issue. This also helps shift production to a new product requiring a different manufacturing order.

Machine flexibility means multiple machines can perform the same task within tight machine tolerances. When one machine stops working, the others can take over and produce the same result. This type of flexibility is also vital when demand for a product rises. The manufacturer can increase output by diverting other machines to manufacture the same product.

The Advantages of Flexible Manufacturing Systems

Manufacturing automation refers to the use of technology in manufacturing processes to reduce human intervention. Automated machinery — often controlled by computers and programming — can complete repetitive tasks quickly and accurately. It can also take over dangerous tasks to improve worker safety. This assistance streamlines manufacturing operations and allows workers to use their skills for more essential tasks.

With material and labor issues rampant throughout the industry, manufacturing automation is now more critical than ever. Automated machines primarily benefit businesses by helping to increase output and grow profits. In this article, you’ll learn more about the different types of automation and how they improve manufacturing. We’ll also explain how �鶹Լ�� helps businesses in various industries integrate automation into their setups with innovative machining centers.

Why Is Manufacturing Automation Important?

The manufacturing industry currently faces various challenges. Most notable are the rising material costs and labor shortages. While inflation rates are slowly reducing, businesses and consumers are still experiencing the effects of a����in 2022. With higher inflation rates, raw materials and energy cost more. Greater expenses make it hard for businesses to profit without charging consumers more for the finished product. This is another issue, as higher inflation rates reduce consumer purchasing power.

Labor shortages also impact businesses. With fewer qualified workers, manufacturers find it hard to fill essential roles and complete core business operations. Unskilled labor can also lead to more errors and waste, which increases expenses. Automation offers businesses the chance to overcome these challenges by reducing costs and reliance on manual labor.

Types of Automation in Manufacturing

Various forms of automation are available today. Depending on your requirements, you may need a specific type or a combination. Learn more about each type below to understand which one is best for your needs.

1. Fixed

Fixed or hard automation refers to machinery that can only perform preprogrammed, set tasks or processes. It’s complicated and expensive to change their programming, as it’s often tied to physical configuration and components like wiring and gears. However, these machines can perform specific tasks at high speeds and produce consistent and accurate results each time.

Manufacturers that create high volumes of identical units and use repetitive tasks benefit the most from fixed automation. Once set up, these machines can complete the same task repeatedly with limited human input. Fixed automation machines work well in assembly lines and conveyor systems.

2. Programmable

Computer numerical control (CNC) machining centers are powerful, innovative equipment that can benefit multiple industries. Their complex capabilities allow companies to improve their machining quality while reducing manufacturing time. However, they are a substantial investment and require careful consideration before purchase.

In this guide, you’ll learn what factors you should consider when selecting a machining center for your business. We also cover some common applications for CNC machines within the industrial, energy, automotive and aerospace industries.

Most Popular CNC Machines

The two most popular and used commercial CNC machines are the lathe and mill. They’re also the best CNC machines to start with, as they can machine both simple and complex parts, depending on your needs.

• Mill:��A CNC mill rotates a cutting tool to remove material from a stationary workpiece. It’s suitable for parts that need flat surfaces, grooves or holes.
• Lathe:��A CNC lathe turns the workpiece on a central axis while the stationary cutting tool removes material to shape and profile it. It’s best for cutting cylindrical parts.

Some other CNC machines include routers and plasma, laser and water jet cutters.

How to Choose a CNC Machine

The best CNC machine for your business is one that falls within your budget and has all the required features. Below are five factors you can consider to narrow your options and find the optimal machine for your application.

1. Functionality

CNC machines have various tools that perform different functions. They can mill, grind, contour, turn, drill, tap, bore, rough, face and more. Decide what tools you need to achieve the desired shape and choose a machine accordingly. Sometimes, you’ll use tools that are similar in nature but require different machine functionality. For example, you can use the same tool to turn a workpiece as you can bore a workpiece, but the machine would need different functionality to perform either cut.

You can also consider a CNC machine with an automatic tool changer to swap out tools without manual intervention. For example, �鶹Լ��’s horizontal milling machines feature��an integrated facing head��that can perform various functions within one machine. We also offer a more specialized��Modulo Equipe turning center��that can hold up to six different tools per turret.

2. Speed

A CNC machine has two main speeds — the spindle speed and feed rate. Feed rate is how far the tool moves across the workpiece during one spindle revolution. It’s measured in inches per minute. Spindle speed is the rotational speed of the machine’s spindle, measured in revolutions per minute.

Speed is necessary to consider in your selection, as different applications need specific feed and spindle rates. The right speed will maximize the machine’s efficiency and precision. In addition, the right feeds and speeds are essential for the quality of the cut or material removal. Speed will also affect how much power the machine uses and how quickly the tool wears down.

3. Axes

CNC machines have varying axes for tool movement, and most CNC machines have around two to five axes. A machine with more axes can complete detailed, complex designs and cut the workpiece from multiple angles. A CNC machine with fewer axes may be sufficient if you have simpler requirements.

Some processes require a machine with a specific axis to perform the necessary functions. For example, some processes would be more efficient if you could adjust the diameter of a hole without manually moving the tool. Horizontal CNC mill machines from���鶹Լ����feature an additional U-axis��that meets this need.

4. Weight

Programming in machining is a crucial component as it controls every part of the process. Computer numerical control (CNC) machine operators train and practice for years to hone their craft, helping them improve efficiency and tackle challenges as they arise.��

�鶹Լ�� offers turn-key solutions with all our machines so they’re ready to go as soon as possible. Our support staff can help get you started with generating programs, tooling, fixturing and more.

That’s why it’s important to understand the essentials of CNC programming for beginners. In this guide, you’ll learn about the types of CNC programming, the basics every operator should know and the steps for programming a CNC machine.��

What Is CNC Programming?

Computer numerical control programming is the backbone of CNC machine operation. CNC machines and machine centers are a type of computer-programmable equipment that needs instructions to dictate their movement and functions. The machine operator gives these instructions to the machine . This code tells the cutting tool within the machine the path, angle and speed at which it should move.

While the machine’s tools perform all the work, it’s the code that makes it possible. It all starts with a 3D model of the desired part or product, which the operator turns into code for the machine to read. The CNC machine then removes material from the workpiece by milling, drilling, turning, roughing, tapping or facing. Using a CNC machine allows for the recreation of — this means there will be little to no variation between the specs and the final part.

Correct CNC programming is essential to achieve the levels of efficiency and accuracy possible with a CNC machine. It is always advisable to employ someone with CNC programming certification to operate a CNC machine. This is especially necessary with large-scale��industrial CNC machines. Professional CNC programmers go through training, receive certification and have years of experience. However, it is fairly easy to learn CNC programming if you have basic knowledge of coding, computers and mathematics.

Types of CNC Programming

The three different programming methods for CNC machines are manual, computer-aided manufacturing (CAM) and conversational programming. Which one you use depends on the machine type, your skills and the output requirements. Understanding all three types can help you select the best method for your application.

Manual

Manual programming involves manually inputting the code into the machine’s control console. This method requires intensive knowledge of the machine, its programming language and which instruction will create the desired outcome. It can be laborious and prone to errors, but it was the original method for CNC programming. Learning it provides a beneficial understanding of CNC programming.

Manual programming is best for simple tasks or creating highly customized machining processes. Understanding manual programming can also help you make adjustments when using CAM programming.

CAM

CAM refers to using software to control machinery, like with CNC machines. There is CAM software available that allows CNC operators to convert their digital models into G-code. This software handles most of the complicated mathematical equations, making the CNC process more efficient and straightforward.

CAM programming is suitable for most use cases as it’s easier to learn than manual programming and offers more customization and complexity compared to conversational programming. CAM software can also help you visualize the machining process and spot any errors before they happen.

Conversational

Conversational programming is a simple method for CNC programming as it uses the machine’s built-in interface and software. It doesn’t use code — the operator selects the commands on the console, which are represented by graphics and text. The machine may also ask a series of questions to understand which functions the user wants it to perform.

Conversational programming is useful for beginners and simple tasks as it’s quick and easy to learn. The software will also show a preview of the tool’s movements before starting the process to allow for pre-checks. However, more complex processes and paths are not possible with this method.

The Basics of CNC Programming

Besides choosing the type of CNC programming, CNC operators also need to know and consider a few other factors while operating CNC machines.

Codes

CNC machines use a special type of code to control the machining process. G-codes dictate the position and movement of the machine’s cutting tools. M-codes control the machine’s functions, such as stopping the program or rotating the spindle. Other codes handle tool selection, spindle speed, tool offset and feed rate.

Every���鶹Լ�� machining center��comes with an in-depth manual that includes all of the common G-codes, M-codes and other variables you need to control our machines.

Feed Rates

One of the codes used in CNC programming is the F-code. This code tells the tool how fast to move and it’s an essential thing to get right. Optimized feed rates ensure the process is as efficient and smooth as possible. While you can verify the path before implementing it, it’s necessary to monitor the process and adjust the feed rate based on how long it took and how accurate the finished piece is.

Compensation

Even when you triple-check the code and run it through various simulations, you may still encounter issues on the first few runs. For example, factors such as tool pressure, generated heat and positioning errors can impact the accuracy of the machining process. Accounting for these factors is called compensation, and each compensation adjustment will make the process more precise.

How to Program a CNC Machine