COMMON CNC

MACHINE FAILURES
INTRODUCTION:

 Have your CNC machines been behaving oddly lately? Do you notice
a strange tick in their output, or in the way the machines are acting?

 If so, you’re in the right place. We’re going to talk about a few of the
most common problems in CNC machines, and how to fix these
problems.

 Before we get started, however, let’s make sure everyone is on the

same page and understands the basics of what a CNC machine is and
what it’s for.

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WHAT IS A CNC MACHINE?

The earliest CNC machines — or perhaps the forerunners of the CNC machine — were developed
and used in the 1940s and ‘50s. These machines used a data storage technique known as punched
tape. Of course, this technique soon became obsolete, and the systems quickly turned to analog and
then digital computer processing methods.

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 HOW DOES CNC MACHINING WORK?

• The basic function of CNC machining is to take a blank piece of material, such as a block
of plastic or a similar item, and transform it into a finished product. The CNC machine
does this by telling the machine shop tool exactly how to move, and exactly what pieces of
the material to cut away, to eventually arrive at the desired result.
• It has many similarities with 3D printing, in that a computer supplies digital instructions
to tools that then work to create a finished product. Because the entire creation process is
distilled into a set of precisely coded directions, the process is much faster, more efficient
and less error-prone than if it were being done by hand.
• Several of the technologies commonly used to actually create the finished products
include drills, lathes, milling machines and other newer technologies like laser cutting
machines, plasma cutting machines, water-jet cutting material, electron beam machining
tools and many more. Materials that are commonly crafted with CNC machining include
aluminum, steel, copper, titanium, wood, fiberglass, foam and plastic.

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WHAT ARE SOME THINGS THAT CAN CAUSE
ISSUES IN CNC MACHINES?

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 Let’s look at a few of the most common problems in CNC machines.

• Poor or Improper Maintenance

CNC machines need to be carefully cleaned and lubricated on a regular basis — otherwise,
problems can begin to arise. A lack of cleaning could lead to a buildup of dirt and debris.
This might seem to be purely a hygiene issue, but it can have real implications in the
machine’s output.

For example, if you begin to notice the material sliding around during the cutting process,
a buildup of dirt could be preventing the machine from working correctly and providing the
most accurate instructions. If this issue continues to go unchecked, it will create challenges
as the machine struggles to locate and hold materials still. This leads to greater issues with
accuracy and precision, and ultimately leads to more errors.

Improper lubrication can lead to machine parts sticking or not moving as smoothly as they
should. This can lead to errors, as well as overheating and air blockage. Both overheating
and a lack of air can also cause problems like material movement during the process.
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• Improper Settings or Tools
Perhaps one of your tools is becoming blunt, a cutting coolant or lubricant is failing to
work correctly or a tool is moving at the wrong speed. All these issues will cause similar
sorts of problems. The most likely result of one or more of these issues is the appearance
of small burn marks around the edges and corners of the material.

The reason for this is simple. If the tool is moving too slowly, the material will be under
the cutting edge for longer than it should be. This results in the burning and scarring
you’re seeing. Similarly, if the coolant is not working correctly, things could be getting
too hot, and the edges of the material might be getting singed as a result.

If one of your tools itself is burned, you’ll need to adjust the settings as needed for that
particular tool so it isn’t scarring the material. Or, if the tool is blunt and not cutting
correctly anymore, it could just be time to replace it altogether.

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• Poor or Improper Programming
Another issue that could lead to serious problems in your CNC machining is incorrect
programming. This is a simple cause-and-effect problem, since the programming
directly controls the creation of the product. Therefore, if the programming is
incorrect, the product will have problems.

These problems can be difficult to detect, especially when there are new or
inexperienced employees involved. These employees may not have a completely
accurate understanding of the machine’s process and may enter the coding incorrectly.
They may not realize their error, although they recognize something is wrong.

To fix the problem, inexperienced employees may try to power the machine off, then on
again. This can jump-start the machine and cause it to correct the problem.
Meanwhile, the original problem — the incorrect coding — remains undetected.

To avoid this scenario, make sure every employee receives full and proper training on
how to correctly code a CNC machine. This way, these kinds of easy-to-avoid mistakes
will be less likely to happen, and you’ll be more likely to have a smooth and issue-free
CNC machining process.
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CNC TROUBLESHOOTING TIPS: THE MOST
COMMON PROBLEMS AND HOW TO FIX THEM.

We’ve put together a list of the most common CNC

machine failures, as well as their probable causes and the
solutions to fix them. FIRST UP 9
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 WHAT DO I DO WHEN SOMETHING GOES WRONG
DURING THE AUTOMATIC TOOL CHANGE PROCESS?
Solution: If you’re sure the problem is occurring at some point during the automatic tool
changing process, the best way to troubleshoot the problem is to learn every step of the
tool changing sequence. Once you are intimately familiar with the process, you’ll be
better able to spot where the problem is happening and diagnose what is going on.

For your reference, the sequence should go as follows:

• Axes move into position • Arm removes tool from spindle

• Spindle aligns for the tool change • Arm puts tool into spindle

• Doors open
• Spindle grasps tool

• Magazine pot gets into position • Arm returns to original position

• ATC arm moves to engage the tool on the spindle • Door closes

• Spindle releases tool

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 HOW DO I FIX A PROBLEM WITH THE DC MOTOR?

• Remove the brushes and springs after removing the cover using a slotted screwdriver.
• Make sure the brushes are moving freely as you remove them.
• Make sure all the brushes have equal spring tension.
• Look carefully at the faces of the brushes — are they clean and shiny? If not, replace them.
• Look at how long the brushes are. When these brushes are new, they should be about 7.5 inches
long. If they’re much shorter than this, there will be less spring tension.
• Shine a flashlight inside once the brushes are out of the way to see if there are any buildups.
Clean the area out with an air cleaner and make sure to clean between all the grooves as well.
• Replace any grooves that are exceptionally worn. FIRST UP 12
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 WHAT SHOULD I DO IF I CAN’T GET THE
EMERGENCY STOP TO CLEAR?
Solution: Make your way through this checklist to see if any of these items might be the problem.

 Make sure the conveyor is plugged into the power source. Check the power cord for any signs
of damage.
 Pull out or push in any emergency stops. Check for any problems with the conveyor, high-pressure
unit, gantry and barfeeder. Make sure there are no blown fuses in the electrical cabinet.
 Check to see if there are any axes near the overtravels.

 Inspect the door interlock mechanism or any other interlocking modules inside
the electrical cabinet. Check that the LED light is on and says POWER or
something similar.

 Make sure the power supplies are active. Check to see that there isn’t an electrical shortage. Do
this by looking at the LED lights and seeing if any are dimmed or burned out. If so, try removing
the wires from it. If it changes after you do this, you have a short that will need to be fixed.

 Locate the E-string and follow it. Check to see if there is a problem with the voltage.
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HOW DO I FIX IT WHEN THE MACHINE WON’T
POWER UP, OR ACTS STRANGE AS IT POWERS UP?
Solution: If no buttons are lighting up on the control panel, look behind the
screen or panel for the power supply. Check to make sure the power supply is
coming and going correctly. It’s possible a fuse back there is blown.

• If the CRT doesn’t seem to be coming up, try

moving the axes as you would if you were
following the on-screen prompts. If they still
move perfectly, the problem is with the screen
display, not the machine. Check that the
power is still being supplied to the screen.

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 HOW DO I FIX A PROBLEM WITH THE POWER SUPPLY?
Solution: In most cases, machines have multiple power sources. If you aren’t sure
which one is causing the problem, try checking these locations:

 Behind the CRT screen

 Door interlock circuit

 I/O card
 Individual power supplies for the drives and
spindle
 The external power supply

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THE MACHINE CHUCK SEEMS TO BE STUCK AND
WON’T CLAMP OR UNCLAMP. WHAT DO I DO?
Solution: Run through this checklist and see if any of these things might be causing the problem.

• Check to see if the hydraulic pump is working. If it isn’t, try powering the machine off
and then on again. With the power back on, test the pump and see if it works this time.
• Look at the adjustment valve and check the hydraulic power. If it is nonexistent or not high
enough, try setting the power higher.
• Inspect the foot pedal to see if it’s working. Look for the input signal for the switch on the
screen. If there seems to be a problem with the input on the diagnostic screen, look more
closely at the cable connections and contacts of the foot pedal. Check to see if any wires are
broken, or terminals are corroded. Make sure you can press the pedal all the way down, and
it isn’t being blocked by a chip or any debris.

• If the input doesn’t seem to be the problem, look more closely at the PLC output. If the
output is not being created after the foot pedal is pressed, try to determine what is
needed to turn on the output coil by following the ladder.
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• Can you get the chuck to operate by using MDI M-code commands, but not with
the foot pedal? This means the problem is almost definitely with the foot switch.

• Does the solenoid output seem to be working correctly? If so, your problem could
be at the connector to the solenoid, where a wire might be broken or the connector
could be loose. Try switching the connector with the coil and see if the coil works
correctly.

• Lastly, look at the draw tube between the chuck and the hydraulic cylinder. Is it
working? Check the tube by unscrewing it from either the chuck or the cylinder and
removing it. While you’re doing this, it’s also a good idea to examine the body of the
chuck. The internal wedge, in particular, ought to be greased regularly. If it’s dirty or
hasn’t been greased, the chuck won’t be able to operate correctly.

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  WHAT THINGS SHOULD I CHECK FOR IN THE
SAFETY CIRCUIT?
Solution: Follow this simple procedure to ensure all the necessary parts receive the check they need.

1. Ensure all the keys to the door interlocks are in rest position.

2. Look in the control cabinet to check the interlock modules. The LED lights in
here will help you locate any potential problems.

3. Make sure the interlock release keys are in the proper position, and make sure you
can remove them if necessary, as sometimes the vibrations can cause the keys to turn
unnecessarily.

4. Tighten any connections that need tightening on the switches and interlock
modules.

5. Look for the biggest connections in the modules and check these. Because of their
size, they tend to experience a lot of vibration and are prone to becoming loose.
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 FIRST UP
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THANK YOU ♥
By:

• Ahmed Yasser Mohamed

• 9

• Ahmed Elsaid Saber

• 2

• Ayman Mohamed Husien

• 14

• Malek Mansour Elgarhy

• 53
19