Earlier this year TU Delft successfully launched a scale model of its Flying V jetliner. This new future-ready aeroplane is the epitome of next-gen aerospace engineering showing better fuel efficiency and an interesting design.
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Dec
2020
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Dec
2020
CNC machines, or Computer Numerically Controlled machining, refers to a manufacturing process involving pre-programmed computer software. This dictates the movement of CNC machines which results in several major benefits over other machining methods. Compared to manual processes, CNC machining can help tremendously with improved accuracy and efficiency, faster production, better safety and cost savings.
Today, many sectors in the economy rely on CNC machining including aerospace, automotive, medical manufacturing, construction and woodworking. It has revolutionised manufacturing as other industries have also caught on from window and door manufacturers to those specialising in household appliances and electronics. In this article, you’ll discover the main advantages (and some drawbacks) of CNC machines.
Automating The Manufacturing Process With CNC Machines
Looking back at the history of manufacturing, the early days mostly involved hard, intensive labour. That all changed with the introduction of certain technologies with CNC machining at the top of the list. It has automated most of the manufacturing process that has resulted in less manual labour and increased efficiency which means a reduction in cost.
Thanks to advanced computer software transferring the required data to a CNC machine, it does all the work automatically with very limited input from a person. CNC machining has become more versatile in recent years as some can now even have additional axis. This has increased the types of machines that can effectively manufacture much smaller and more intricate parts with precision.
Recommended: ‘5 Axis Machining In Modern Engineering’
How Does CNC Machining Work?
We touched on the process earlier but here is a more detailed overview. CNC machines work through a numerically controlled computer program using a CNC machining language (‘G-code’). This controls various aspects of the process such as the feed rate, coordination, location and speed. The computer software controls the exact positioning and velocity far better than a human can which is why CNC machining is ideal for manufacturing metal and plastic parts.
The first step is to create a drawing using 2D or 3D CAD software and enter a computer code that the machine will understand. From there, technicians load the program but before any form of machining takes place, a human operator tests everything. This is referred to as a trial run and if better known as “cutting air”. Such a trial run is crucial in the manufacturing process as any mistake regarding speed or tool positioning can lead to broken parts or damaged machines which is unnecessary and avoidable.
Why Manufacturers Prefer CNC Machines
CNC machining has become increasingly popular as it greatly streamlines the manufacturing process. Considering the numerous advantages of CNC machines mean operator-required equipment been replaced in many cases. Regardless of the few disadvantages, manufacturers across all sectors still highly rate CNC machining for fabrication and manufacturing applications. Here are some of the main benefits for your business, manufacturing processes and staff.
CNC Machines Increase Production Speed And Efficiency
CNC machines allow manufacturers to work at a much faster pace while delivering the same high standard of products. Whilst other manufacturing methods require additional resources, CNC machining can do the job without adding to the overheads.
CNC machines can work continuously overnight, weekends and holidays. They will only be stopped for maintenance, repairs or to input a new project. These machines can produce multiple orders much faster than traditional labour-intensive methods. CNC machines require less staff so that means saving time and money on training.
Computer Control Means Fewer Human Errors And Less Material Waste
It’s only natural that people make mistakes but the risk is massively reduced with CNC machining as fewer people are involved in the manufacturing process. Remember, the computer is programmed to do something specific with tight tolerances and specific requirements and will perform as the software dictates no matter what.
It certainly helps that when operators enter the design parameters and specifications that the machine will consistently execute repetitive processes. Everything works according to scale and specifications which leaves almost no room for material waste. This has the potential to help you save big on costs and potential rework time.
CNC Machines Are Safer To Operate
Aside from operators entering the code and maintaining the machines, the process is entirely automated. That means operators don’t have to be anywhere near the cutting tools. This has resulted in decreased occupational health and safety accidents and that is a massive bonus for business and staff. Indeed, operating a CNC machine may not be as simple as using a cordless drill but they are relatively simple to use with some training and practice.
Allows For Advanced Fabrication In A Future-Ready World
CNC plays a pivotal role when it comes to fabrication as several operations are involved which these machines can perform. This includes welding sheets of metal, shearing, punching holes and flame cutting. Due to the incredible precision that CNC machines offer, they can produce extremely complex shapes that manual machines would not be able to replicate. Due to the operator programming the machine, they are highly flexible and should be your first choice.
Considering CNC machines are all around us in almost every industry, implementing it into your business will help you prepare for the future. If you think how much technology has changed in just the last 10 years, the manufacturing sector is looking pretty sharp with CNC in its corner. With the advanced capabilities, you can keep up with all the latest trends, changes in design, building codes and any other standards.
Disadvantages Of CNC Machines
CNC machines are typically more expensive and do require a larger initial investment than manual machines. However, as this technology becomes more widely used and the accepted standard, supply will increase and that means costs could gradually go down.
There is also an element of skills loss as the demand for manual machine operators decreases. This results in fewer new students having to adopt specific skills that may eventually lead to the total loss of long-preserved skills.
At the same time, unemployment is always a big talking point when it comes to any form of automation. The good news is that even though CNC machines require fewer people, there is a growing demand for software engineers and mechanical engineers. If companies and universities adopt and provide the necessary education and training, the skills gap may be closed somewhat in the manufacturing industry.
CNC Machining At PRV Engineering
CNC machines are incredibly versatile and you’ll know how impressive they can be once you see them in action. They serve a multitude of industries with great success, especially in the aerospace sector where they favour five-axis machining which enables them to manage hard-to-cut materials like Inconel.
For reliable and effective CNC machining services, contact PRV Engineering, one of the leading engineering service providers in the UK and Europe. We have state-of-the-art CNC machines to serve our clients from various industries. Some include food and chemical processing, pharmaceutical, railway, military, defence, automotive and aerospace.
Stay up to date on all the latest in engineering, manufacturing and technology by following our blog. You can also join the conversation on Twitter, Facebook, YouTube or LinkedIn using the hashtag #PRVtech.
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Dec
2020
Whatever your view might be on global warming or climate change, there’s no denying that there have been some fascinating sustainability innovations in recent years. If we were to show any of these to our younger selves a decade ago, you’d think we were mad.
Whichever way you look at it, change is coming as many innovators and businesses are moving toward building a greener future. With that, here are our top eight sustainability innovations that could make a significant impact on our environment.
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Nov
2020
There’s no denying that Covid-19 is responsible for creating loads of pressure on the manufacturing sector over the last eight months. This is mainly due to production slowdowns, restrictions on employee movement (social distancing) and changing demands. As a result, manufacturing companies have had to rethink business models and operations with many looking at digital technologies such as IoT.
With manufacturers striving toward increasing equipment efficiency, production quality, resilient and intelligent supply chains, IoT has become a key player. Microsoft, for example, is leveraging its knowledge and technical expertise to make this technology more readily available. Combining in-depth industry knowledge and expertise has already proven tangible as proven by the UK Ventilator Challenge.
Recommended: ‘How Manufacturers Can Plan For Covid-19 Disruptions’
Preparing For IoT In Manufacturing
Due to the continued impact of the pandemic, the UK manufacturing sector is looking to drive innovation through digital technology. It will help address key challenges in operational efficiency, supply chain management as well as workforce and sustainability issues. They can prepare by:
- adapting their operations around digital technologies
- actively integrating their value chain to the entire supply chain
- increasing efficiency and capacity of production
Pundits within the manufacturing sector believe that Industrial IoT (IIoT) will play a pivotal role. It not only helps with improving efficiency and monitoring quality but also better factory safety and cost reduction. This gives companies access to enhanced capabilities for asset tracking and preventing expensive shutdowns of machinery.
Industrial IoT Drives Long-term Momentum
By taking small steps to improve efficiency, the future of manufacturing looks promising as it connects siloed processes to more connected ecosystems. This will drive long-term momentum even in the face of current (and future) challenges. Truth is, manufacturing organisations are embracing emerging IoT technologies much faster than other sectors.
In a survey of nearly 600 manufacturers from around the world, some have reported fewer barriers to add edge computing to their IoT systems. Also, 73% said they have a strategy in place for the use of digital twins within their IoT solutions. Digital twins are replicas of potential and actual physical assets, processes, people, places, systems and devices (source: Wikipedia).
Recommended: ‘What Is Edge Computing?’
Investing In The Future Of Manufacturing For Scalability
There are still many challenges manufacturers need to address, especially around complexity and resourcing within an organisation. As previously mentioned, Microsoft is working on simplifying and securing capabilities to further democratise IoT which will certainly help.
The software giant has committed to “invest $5B in IoT (Internet of Things) and intelligent edge – technology that is accelerating ubiquitous computing and bringing an unparalleled opportunity for transformation across industries.” (Source: Microsoft.com)
This means developers are welcomed by a rapidly growing number of services and features. These will provide open, flexible choices for development, securing of data and achieving rapid global growth when companies need to scale.
Recommended: ‘Read the full IoT Signals Edition 2 Manufacturing Report’
What Trends Are Driving Industrial IoT?
According to the manufacturers, the top reported uses for IoT in 2020 are to monitor production flow, automate industrial processes, production planning and scheduling. As we’ve discovered, with plans to adopt IoT in manufacturing, several challenges and trends are influencing the process.
For many manufacturers, the primary driver for adopting IoT is the improved efficiency in operations. Not to mention expanded production capacities and better employee productivity. In some instances, more manufacturers are using AI as part of their IoT solutions. Here, 77% reported further improvement in efficiency when using AI in primary or secondary uses.
One of the main benefits of implementing IoT and AI is improved predictive maintenance. Many have also confirmed that they are using AI to enhance the online user experience by using customer service bots.
Addressing The Skills Gap Within The Industrial Internet of Things (IIoT)
Many of the surveyed manufacturers agree that bridging the skills gap is a top priority and are actively looking for employees with a wide range of technical abilities. This especially includes system architects and cloud developers who can successfully implement IoT.
For manufacturers to successfully navigate IIoT, they need employees who can maintain legacy IT while building new systems or maintaining IoT technology. The biggest challenge to adopting IoT on a larger scale is the lack of skilled workers and budgeting, especially for discrete manufacturers.
The continued growth of smart devices, networks and connections translates into skills gaps, especially when left unchecked. In a different study from Inmarsat in 2017, more than three-quarters of surveyed companies believed they needed more high-level IoT specialists.
Final Thoughts
As the industry matures, so do organisations’ requirements and expectations. Whilst there’s been significant improvements in recent years, there is still a long way to go before we see IoT adoption on a mass scale.
Looking ahead, government institutions must get involved with funding and training, where possible. Companies must let potential employees know they are willing to provide additional training and to invest in them by building on their current skillsets.
Senior leadership and management must also step up tothe plate and make sure everyone has the right attitude. If everyone shares the same vision, and the team already has good core skills, IoT adoption and training should be easier to implement.
For more interesting updates on all things engineering, manufacturing and technology, follow our blog or visit our website. You can also join the conversation on social media using the hashtag #PRVtech.
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Oct
2020
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