6 months by cncdivi
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Let's assume you have a working CNC machine that you've just acquired, but that you know very little about CNC. Let's further assume it is a mill and that you will be focused on cutting metal. You're ready to start milling custom chopper parts, build a tool changer, or scratch build a Colt handgun. With CNC, you can build almost anything and you're chomping at the bit to get started on your pet projects.
Not so fast! Remember, you just got the machine and you're a beginner. You're not ready for those projects yet.
If you have some idea how to make your first CNC parts, charge ahead with these 10 suggestions. Otherwise, you need to see the whole process of making a part mapped out in detail.
Take a break and go read our
Beginner's Step-By-Step Guide to Making CNC Parts
. It will fill in those hazy details you've been wondering about, then, you're ready for this article.
If you're even more of a beginner, and likely don't have a CNC machine yet, don't worry! Start with our 'What is CNC?' article
After that, here are 10 things you should focus on to maximize your chances of becoming quickly successful:
1. Buy Some Decent Cutters
Don't get the package of assorted sizes of cheezy imported cutters. You also don't need the solid green unobtanium aerospace cutters from Men-In-Black-Cutter-Supply. Get some decent cutters from a reliable source that has reasonable prices. I like Lakeshore Carbide for example. Try for a name brand, one that's on sale.
If you don't know what the good brands are, check out our End Mill survey. It'll show you which brands are most popular and have the highest customer satisfaction.
Having a decent quality cutter eliminates a whole bunch of problems right up front. I would also go with HSS when you're
just
starting out. You'll
eventually
want carbide for a lot of uses, but HSS is cheaper and more forgiving.
The exception is high speed spindles such as CNC Routers
commonly
have. They need carbide to stand up to the higher speeds.
Get yourself a few sizes:
' 1/2'
' 1/4'
' 3/16'
Nothing smaller at this stage until you've learned on less delicate cutters. Buy 2 or 3 flutes for aluminum and some 4 flutes for everything else. I'd get 3 of each in each size to start. You are going to break some cutters, so get over it and accept the idea. It's a good thing at this stage to remind you to wear your safety glasses because you will break some cutters!
While you're at it, buy a full twist drill assortment. HSS from a decent brand on sale will work fine. I like the idea of replacing the ones I break with cobalt over time. That way my most-used sizes wind up higher quality. And one more twist drill tip'buy screw machine length, not the usual jobber length bits.
The screw machine length bits are more rigid and you will seldom drill super deep holes anyway.
2. Get a Decent Vise, a Clamping Kit, and a set of Parallels
Yeah, I know, vises are expensive, but workholding is very important.
Get a decent Kurt-style vise for your mill. It'll be money well spent on a valuable piece of tooling that will last for years. In my shop I have used Kurts purchased from eBay and a couple of brand spankin' new Glacern vises. There is sneaky stuff that goes on when you clamp a workpiece into the vise. If you don't have a good one, the workpiece will shift and you'll be wondering what happened.
You'll need a way to mount your vise to the T-slots of your table, so you may as well get a clamping kit too. Any old kit will do. Buy the one that is on sale at your favorite supplier. These are step clamp kits that give you a basic set of cnc clamps. There are many other types, and you can expand your collection as needed over time.
Lastly, you'll need a set of parallels, at least until you get proficient at making step jaws.
CNC Routers are a different story. You'll mostly be clamping things to your spoilboard. Do yourself a favor and go read up on how that's done so you can get a lot of good ideas before it's your turn to start clamping.
3. Get yourself a misting setup for coolant and use it while being paranoid about chip buildup
If your machine didn't come with flood coolant, and isn't set up for it (i.e. you don't have an enclosure to keep the wet inside), get yourself a misting setup. I got mine off eBay for about $100. It's a Noga. There are a lot of different brands. Get a jug of coolant to go with it. I use KoolMist, but again, there are a lot of brands.
Now train yourself to be paranoid about chip buildup.
Recutting chips is bad for cutters and in the worst case leads to breakage. Being paranoid means you're watching the cut like a hawk and you fiddle with your mister's nozzle until you figure out how to position it right the first time and every time thereafter to blow away the chips from the cut. Learn more about the different CNC Coolant options.
If you're a CNC Router user, the story is different, unless you plan to cut a lot of aluminum. If you're cutting aluminum, you still need a misting system. Otherwise, a ShopVac or even just blowing the chips out of the way with compressed air will serve as you cut wood or plastics.
4. Learn how to use MDI
Your next step is to learn to run your CNC as though it was a manual mill with power feeds and DRO's on every axis. In the process you'll learn some basic g-codes so that you have some idea what your program is doing the first time you run a real g-code program (that's a little ways away yet!). It's very convenient to be able to do this trick, and you can learn all about it through our article on this topic:
Don't stop there. When you've got a grip on MDI, start on the CNCCookbook G-Code Tutorial.
Start out with the cutter way high and don't try make any moves in the Z-axis so you won't crash the cutter into anything. Practice making moves in X and Y. Until the cutter goes where you want it to and you're not making mistakes.
One more trick: don't use G00 in MDI'that makes the machine move in rapids mode which is as fast as it can go. Use G01 and set a slow feedrate. 'G01 F20' will make the machine move at 20 inches per minute (or metric units if you're in metric). You'll have a lot more time to react this way if it starts heading into trouble. Visualize pressing the red E-Stop many times so it'll be almost automatic when you need it.
5. Get yourself a feeds and speeds calculator and use it
You're getting close to making your first cuts.
Do yourself a favor and get a feeds and speeds calculator. Trying to figure out feeds and speeds as a beginner or asking people on forums is a recipe for frustration and faillure. And it is such a false economy to try to save a few bucks by skipping the calculator or using a cheezy free online calculator. Stuff will go wrong that you're just not equipped to understand. So, get a decent feeds and speeds calculator so your spindle speeds and feedrate are perfect for that first cut.
We recommend our own CNCCookbook G-Wizard feeds and speeds calculator (natch!). It doesn't cost much more than 1 single cutter to get started, and you can use it for 30-days completely free.
Best of all, there's a great deal just for beginners and hobbyists that we call 'G-Wizard Lite':
When you subscribe for 1 year of G-Wizard, you get Lifetime use of the product for up to 1 horsepower. You can do a lot with 1 HP, especially if you're a student or hobbyist. In fact, it may be all the power you ever need!
So check it out, your cutters will thank you and your projects will go by faster and easier.
6. Get yourself a Z-height measuring gizmo and learn to use it to touch off your tool lengths. While you're at it, get an Edge Finder and use it to touch off your Part Zeros.
Your machine needs to know where the tip of the tool is or terrible things can happen.
As a beginner, you tell it by using a Z-height measuring gizmo of some kind. Have a look at our article on the subject to see what's available. Don't get wrapped up in the fancier stuff in that article. The first few options will get your going.
Learn how to use these to tell the machine what your tool length is. This process tells your machine where the tip is in Z. To establish the position of X and Y you'll need and Edge Finder. The first thing you'll do after sticking a piece of material in your vise and inserting a tool in the spindle is to set these zeros.
You can learn more about touching off and setting part zero from our G-Code Tutorial.
Want more information on cnc milling for intricate details? Feel free to contact us.
Also take a look at our 2-part series on Tool Data Management for information on Z-Height Gizmos (more properly called touch setters) and tool lengths. Use your newfound MDI skills from #4 to start using your Edge Finder and Z-Height Touch Setter.
7. Learn to Tram your Mill and Vise
How to square and tram your vise on your CNC mill'
Tramming is what machinists call getting things square by sweeping an indicator around. It's a basic skill everyone needs to learn.
When you first start machining, get into the habit of checking your mill's tram every time you walk out into the shop. You'll know later on whether you need to do it every time, but for now, you could use the practice. While you're at it, be sure you know how to tram your vise so the jaws are aligned properly with one axis or the other. Let's don't try to square you mill just yet, but tramming the mill and vise are a good step at this stage.
For details on how to do this, refer to our Mill Tips and Techniques page.
8. Start out with wood, aluminum, brass, and plastic. Avoid stainless.
Okay, the very next step involves making some cuts. Sorry if it seems like you had to do a lot before getting there, but I did say I wanted to tell you some things that will help you succeed and there's quite a few things in that category!
One more is to avoid difficult materials for your first cuts. Stick with aluminum, brass, or non-metals like plastics and wood.
BTW, nothing wrong with sticking a piece of 2×4 in the machine to learn on, even if the eventual part is going to be made of metal. I often use wood to prototype what I'm doing until I get everything right. It's a lot cheaper than metal!
When you're doing okay with softer materials, graduate to mild steel. Only after you feel like you've pretty well mastered cuts in these materials can you try tougher materials. Master means you're not breaking or wearing cutters out too quickly, and your surface finishes no longer look like the material was attacked by a pack of rabies-infected beavers.
One more thing. It'll be tempting to try some 'mystery metal.' This is metal you think you know what is, that you got essentially for free, and that is therefore expendable. Trouble is, a lot of mystery metal is hard to cut. It's nasty cheap stuff that will break cutters and generally confound you. Not worth it!
9. For your first project, learn how to square a block of material and make yourself a few sets of step jaws in aluminum
Let's quit procrastinating and make some chips!
For this step, you're going to start by learning how to square a block of material. Get your saw and cut out some pieces of material that are slightly oversized to serve as vise jaws. Google 'Kurt Vise Jaw Dimensions' to find drawings of jaws if you need some. As mentioned, cut the stock slightly oversized from aluminum. Now you need to square those blocks. Squaring means you will make a series of milling cuts until all sides are properly parallel or perpendicular to one another, at which point the workpiece is 'square'.
The proper steps for squaring a block of material are described on my Turner's Cube page. The recipe described there is one I got from the great book, 'Machine Shop Trade Secrets.' Pick up a copy to continue your learning process.
One thing about the Turner's Cube material squaring: I use a Face Mill, but you should start out doing it with multiple passes and a 1/2' endmill. Why? Because Face Mills generate a lot of force. You can stall the spindle, yank the work out of the vise and throw it across the room, and other shenanigans a beginner could do without.
Leave the face mill in a drawer if you have one already and do it with a 1/2' endmill the first time until you know a little more what you're doing. Same goes for fly cutters, and for the CNC Router crowd, those big cutters you use to surface spoilboards. You're not ready for them yet.
Having squared the material, your next task is to cut it to size by continuing to mill it until it is a perfect fit for your vise jaws (you'll need 2 square pieces, one for each jaw). The last step is to drill and countersink the mounting holes.
Actually, I wasn't completely truthful. Once you have mounting holes, the last step is to mill a step along each jaw, maybe 1/8' square. Now you can use that step instead of parallels when you drop material into the vise. Over time, you'll learn a lot more tricks with aluminum jaws, but remember: it all started here with your first set.
10. Graduate to CAD/CAM
Friend, you're now able to do the basics. Sure, there's a lot more learning to do, but you're in a position to have a leg up on the manual machinist down the street who has a Bridgeport and no CNC. Your next step is to start pumping out the g-code. To do that, you'll need to be proficient with CAD/CAM. This is going to be your biggest step yet. Neither CAD nor CAM is very easy to learn.
I give myself 2 weeks to feel comfortable with a new program, and I've had the luxury of learning quite a few so far. If this is your first time, get ready to drink from the firehose.
I have put together a bunch of pointers to make it as easy as possible for you to choose the best CAD CAM software for your needs. Check out our Best CADCAM Software for Beginners article. It is chock full of buying guides, evaluation tips, how to learn ideas, and best of all, it has a guide to the secret deals on the most popular packages that can save you money. These are deals most people have no idea exist, including one from CNCCookbook.
Bonus: Delay the need for CAD/CAM a little while with Conversational CNC
Many talented manual machinists run afoul of CADCAM and it stalls their ability to be productive on CNC machines quickly. Even after they've learned CADCAM, they're still left with the feeling that manual machining can make simple parts faster than CNC, because they don't have to stop to make a CAD drawing and run it through the CAM package to get g-code.
Instead, they can just make a simple bracket with 4 holes shooting from the hip.
Conversational CNC makes it possible to do that with a CNC machine. Imagine changing the long essay test that is CADCAM to a quick multiple-choice quiz. That's what Conversational CNC is all about. Here's the pictorial menu of Conversational CNC operations that can be performed on a mill:
You pick the operation, a popup asks a few simple questions, you press the Insert button, and you've got your g-code. We've built Conversational CNC right into our G-Wizard Editor product so you won't have to purchase an expensive stand alone Conversational package.
You'll still need to learn CADCAM, but with Conversational CNC you can be making simple parts before finishing the CADCAM learning curve.
Congratulations, you've got some Basic CNC Skills!Congratulations, you've learned enough to start doing some useful things with a little confidence. If you can design and generate g-code for basic parts with CAD/CAM software, you're particularly proficient. But stay tuned because there's a follow up on this article. It's another installment of things you can do to reach the next level of proficiency. There's always something more to learn'it's one of the things that makes CNC so interesting!
When it comes to CNC routing, there are a lot of things to learn about.
What does a router do? How do you operate one? And there different types of routers? How does it differ from laser printing and what can you make with one?
So, read on for a comprehensive list of the 10 most frequently asked questions we get about CNC routers and routing'
CNC stands for Computer Numerical Control, which is the term used to describe a computer-operated cutting machine like a CNC router.
A CNC router's main function is to cut, engrave and carve objects. The machine's built-in software tells the spindle where to make precise cuts.
The most common routers operate on these three axes:
X-axis: Runs the width of the machine
Y-axis: Runs perpendicular to the x-axis
Z-axis: Runs vertically
CNC machines rely on software to implement things like CAD files, but you don't need to be a programming expert to run it. The design system will automatically generate the code needed to control the machine, allowing you to customise your design and make edits if needed along the way.
Yes, CNC machines can come in different sizes and have different capabilities.
A desktop or entry level sized router is great for personal use or in a small business, whereas mid-size and high production, industrial sized machines and are specially designed for frequent use on large scale items.
From an axis point of view, there are also up to 6 different types:
A 2-axis router is great for creating automotive and medical machine parts, as well as engraving.
A 3-axis has an additional router bit with linear movement, so it can create slightly more complex 3D shapes and parts.
A 4-axis CNC router machine can move in four directions, giving it a 360-degree range of motion. For this reason, it has more power and higher accuracies than the 2 and 3-axis machines.
A 5-axis machine means that the spindle can rotate in 2 additional planes. This enables the cutting or milling tool to remove material in areas that are hard to reach.
6-axis and 7-axis routers have many advantages, most notably the ability to make highly detailed parts in record time. This makes them ideal for mass produced pieces.
CNC routers can be used to make almost anything 2D or 3D. The top 10 things you can make are signs, shop fit-outs, flat pack furniture items, outdoor seating, sneeze guards, musical instruments, backdrops and props, picture frames, kitchenware and kids toys.
Many different types of industries can benefit from CNC capabilities. The 6 most common areas we service are:
Retail
Advertising
Building
Boating
Furniture
Medical
A CNC cutting machine can work with a wide variety of materials, including solid pieces, full sheets and fragments. These materials include:
Handheld routers are good for small, woodworking projects, like trimming, cutting out decorative patterns and shaping edges. A CNC router is automated and computer controlled, so it's much more precise and can undertake tasks simultaneously and quickly.
The main difference is that laser cutters have to cut a piece all the way through or just do a shallow etching - there is no in-between. It will often burn the edges of thin materials too, like soft timbers, plywood and MDF.
CNC machines, however, can cut as deep or as shallow as you want. A CNC mill can cut both thick and thin materials, and all without leaving scorch marks.
Maintenance is important, but not difficult, and there are a few things you need to do on a semi-regular basis to keep your machine looking and working well.
You can start with some general cleaning, such as wiping down surfaces with metal polish and dusting off wood chips and any other cuttings that have accumulated in the machine. Then you can keep the rails and bearings lubricated with degreasing products to prevent parts from seizing up, and finally, changing the vacuum filters to keep the motor running smoothly.
If kept in good condition, a CNC router should last for at least 10-15 years.
Are you interested in learning more about rapid tooling for consumer product prototypes? Contact us today to secure an expert consultation!