Top 5 CNC Machining Failures in Automotive Prototyping And How to Avoid

CNC technology is the core process that enables the production of high-precision parts for automotive prototyping. However, even experienced engineers will inevitably make mistakes during programming or operation, which can lead to serious consequences, such as part scrap, equipment damage and even personal safety accidents. In this article, we will discuss the automotive prototyping of five common CNC machining errors, and provide practical solutions to help you avoid these potential risks.

I. Coordinate system setup errors: may lead to tool, machine tool or workpiece damage

In CNC machining, a coordinate system needs to be set up to ensure the correct tool path. If the coordinate system is not set properly, the tool may deviate from the intended path, resulting in workpiece scrap or even equipment damage.

How to avoid:

To avoid accidental collisions, it is necessary to ensure that the origin of the workpiece coordinate system is set outside the workpiece blank, or at least outside the workpiece surface.

When programming, double-check the coordinate system setting and run a simulation to verify the correctness of the path.

II. Confusion between absolute and incremental values: leading to abnormal machine behaviour

Absolute and incremental values are the two basic programming modes in CNC machining. If these two modes are confused when programming, the machine tool may execute the wrong movement instructions, resulting in a collision between the tool and the workpiece or the machine tool.

How to avoid:

Clearly label the absolute and incremental modes during programming and add comments to the program to alert the operator.

Before running the programme, double-check the mode settings to ensure consistency with the programming intent.

III. Wrong plane selection: affecting the accuracy of circular or helical interpolation

When performing circular or helical interpolation, plane selection is critical. If the wrong plane is selected, the machine may perform the wrong interpolation action, resulting in degradation of the surface quality of the workpiece or tool damage.

How to avoid:

Specify the interpolation plane explicitly during programming and verify the correctness of the tool path through simulation runs.

During operation, periodically check whether the plane selection is correct, especially when switching machining tasks.

IV. Wrong compensation function: compensation may be cancelled, causing accidents

Compensation functions (such as tool length compensation and radius compensation) are commonly used tools in CNC machining, but if the compensation function is set incorrectly, it may lead to the cancellation of compensation, which in turn triggers an accidental action.

How to avoid:

Before enabling the compensation function, carefully check the settings of the compensation parameters to ensure that they correspond to the actual dimensions of the tool and workpiece.

Regularly calibrate the compensation parameters and add redundancy checks in the programme to ensure the effectiveness of the compensation function.

V. Torque limit problems: leading to tool or workpiece damage

In CNC machining, torque limits are an important parameter to ensure tool and workpiece safety. If the torque limit is not set properly, the tool may be damaged due to overload, or even lead to workpiece scrap.

How to avoid:

When programming, set the torque limit reasonably according to the characteristics of the tool and workpiece, and add a torque detection function in the programme.

During operation, monitor the torque changes in real time and adjust the machining parameters in time to avoid overload.

Choosing a professional CNC machining service provider

In order to avoid the above mistakes, it is crucial to choose a professional CNC machining service provider. JLCCNC has become a leader in the field of automotive prototyping by virtue of its advanced equipments and strict quality control:

Technical strength:

Equipped with high-precision 5-axis machining centre and intelligent compensation system to ensure machining accuracy and surface quality.

A team of specialists optimises machining parameters to reduce tool wear and cutting temperatures and increase machining efficiency.

Service Advantage:

Provide full process service to meet the needs of small batch customisation and large volume production.

Quicker response than other service providers, with over 90% of orders confirmed within 4 hours and delivered within 72 hours.

Successful cases:

Customised complex curved parts for an automotive manufacturer, reducing scrap rate from 5% to 0.3% and significantly improving production efficiency.

JLCCNC: A Reliable Partner for Automotive Prototyping

JLCCNC provides high-quality CNC machining services for the automotive manufacturing industry, and with its advanced technology and extensive experience, it is a partner you can trust. Contact JLCCNC for professional and efficient CNC machining solutions when you need!