Shifting from Manual to Digital: CNC Factory Information System

 1. Manual Era: Limitations and Challenges

In the past, CNC machine management often relied primarily on manual operations, which created several limitations and challenges:

  • Inconsistent Data: Manually recording machine status and production results in inconsistent (real-time) data and can be highly inaccurate.

  • Unable to see the root cause: When a machine goes down, it's often simply a "machine down," but without a clear and timely explanation for the cause. This delays corrective action.

  • Inaccurate Performance Measurement: Calculating key metrics, such as Overall Equipment Effectiveness (OEE), is often difficult, inconsistent, or unreliable, leading to production decisions based on feelings rather than data.

  • Deferred Maintenance: Maintenance is performed only when a machine breaks down, causing unexpected production line disruptions.

2. Digital Revolution: The Role of CNC Information Systems

CNC information systems are the bridge that brings factories into the digital age by connecting to CNC machines to automatically extract operational status data for analysis.

A. Automated Data Collection and Connection: The system communicates with the CNC machine controller and extracts all data in real-time, eliminating the need for manual recordkeeping, such as:

  • Machine status (running, idle, and setup)
  • Cycle time per piece

  • Error codes

B. Visibility and Transparency

  • The collected data is displayed on an easy-to-understand dashboard, enabling managers and production operators to:

  • Immediate Status: Know which machines are operating at full capacity, which are experiencing problems, and which are idling.

  • Downtime Cause Analysis: When a machine is down, the system automatically records and identifies the cause. This allows us to identify whether problems are caused by "waiting for raw materials," "waiting for operators," or "broken tools," leading to targeted solutions.


C. Data-Driven Decisions

The heart of this transformation is the ability to analyze data for superior decision-making:

  • Increased OEE: Use real-world data to identify "bottlenecks" and points of lowest efficiency to prioritize improvements.

  • Predictive Maintenance: The system can detect subtle patterns or anomalies in operational data (e.g., vibration, temperature) and alert before a machine actually breaks down, enabling advance maintenance planning to avoid disrupting production.

3. Revolutionary Outcomes: The Factory of the Future

The shift from manual to digital with CNC information systems has transformed factories into Smart Factories, ready to compete in the Industry 4.0 era. This results in the following key outcomes:

  • Higher Efficiency: Reduce unnecessary downtime and maximize machine utilization.

  • Lower Cost: Reduce scrap rates and reduce emergency maintenance costs. and optimize human resources.

  • Flexibility: Production plans can be quickly and accurately adjusted based on real-time machine status data.

Investing in this system is therefore an investment in a sustainable future of accurate, predictable, and adaptable production.


Digital Transformation:

  • Digital Transformation, Digital Transformation, Manual to Digital, Industry 4.0, Smart Factory


Systems and Technology:

  • CNC Information System, CNC Machine Information System, CNC Machine Monitoring, IIoT, Industrial IoT, Data Collection, Automatic Data Collection, Real-Time Data


Production Management:

  • OEE, Overall Equipment Effectiveness, Reduce Downtime, Increase Production Efficiency, Predictive Maintenance, Data-Driven Decisions


General Terms:

  • Factory Revolution, CNC Machine Management, Manufacturing, Manufacturing Technology, Manual Limitations, Future of the Factory

Title Illustration: "Changing from Manual to Digital: Revolutionizing Factories with CNC Information Systems"


Illustration for "The Manual Era: Limitations and Challenges"



What is a CNC Information System? 🤔 Why does your factory need one?

1. What is a CNC Information System?

CNC stands for Computer Numerical Control, which refers to automated machinery that uses computer control to process various workpieces, such as turning, milling, or drilling.

Therefore, a CNC Information System refers to a software system or platform used to collect, monitor, analyze, and manage all data related to the operation of CNC machines within a factory. This system is the heart of transforming traditional factories into smart factories in the Industry 4.0 era.

  • Definition: A system that connects to CNC machines to retrieve data on their operating status (e.g., running, stopped, waiting for setup), production efficiency (e.g., number of pieces produced, lead time per piece), and error information.

  • Key Components:

  • Data Connectivity: Connects to the CNC machine controller to retrieve real-time data.

  • Visualization: Displays data in an easy-to-understand dashboard format.

  • Analytics: Processes data to calculate key metrics such as OEE (Overall Equipment Effectiveness).


2. Why does your factory need a CNC Information System?

This system is not just a "state of the art" tool; it's a crucial tool for factories to stay competitive in today's world. It significantly increases productivity and cost management.

Key Content to Discuss (Focuses on Key Benefits):

A. Productivity Boost

  • Real-Time Monitoring: This allows managers to instantly know which machines are running, which are down, and why. This allows for rapid troubleshooting and prevents unnecessary downtime.

  • Minimize Downtime: The system can provide predictive maintenance when machinery is likely to fail or immediately identify problems (e.g., a machine downtime due to a raw material shortage).

  • Accurate OEE measurement: Automatically calculates OEE (Overall Machine Effectiveness), a universal metric, providing a clear overview of production efficiency.


B. Quality & Consistency

  • Reduce Scrap: Continuously monitoring production parameters ensures machines are operating according to standards. If abnormal values ​​are detected, the system will alert you to prevent defective parts from being produced.

  • Repeatability: Ensures that every piece produced is of consistent quality and dimensions as specified.


C. Cost & Resource Management

  • Efficient Resource Utilization: Provides an overview of energy consumption and machine uptime, leading to optimal scheduling.

  • Manpower Reduction: Automation and alerting eliminate the need for numerous employees to manually inspect each machine.


3. Conclusion: Transforming to a Smart Factory

Installing a CNC Information System is more than just upgrading tools. It's an investment in data, the most valuable asset in the Industry 4.0 era. It enables your factory to make intelligent, data-driven decisions based on real data, not guesswork, enabling faster, more accurate, and cost-competitive production. This is a key reason why factories seeking sustainable growth in the modern world need this system. 🚀


Key Technologies:

  • CNC Information System, CNC Machine Monitoring, CNC Machine Information System, CNC Machine Tracking, Computer Numerical Control System


Industry Concepts:

  • Industry 4.0, Smart Factory, Intelligent Factory, Industrial IoT (IIoT), Digital Transformation


Benefits/Metrics:

  • OEE, Overall Equipment Effectiveness, Increased Production Efficiency, Reduced Downtime, Reduced Waste, Quality Control, Real-Time Data, Predictive Maintenance


Management:

  • Factory Management, Production Management, Data-Driven Decisions, Reduce Production Costs, Optimize Resource Utilization


CNC Machines, CNC Systems, Factories, Manufacturing Technology, Why a CNC System is Needed


Title Illustration: "What is a CNC Information System? 🤔 Why Does Your Factory Need One?"


Illustration for "What is a CNC Information System?"


Illustration for "Why Does Your Factory Need One? - Benefits"


Illustration for "Conclusion: Transition to a Smart Factory"

Tracing G-Code and M-Code: Basic Commands Every CNC Programmer Needs to Know

 1. What is G-Code (Geometric Code)?

This section explains G-Code, the heart of CNC programming:

  • Definition: G-Code is the primary command set used to define tool motion or geometric actions of a machine.

  • Primary Function: Tells the machine "where to go and how to move."

  • Example Basic Commands:

  • G00: Rapid Traverse without Cutting. Used for free movement.

  • G01: Linear Interpolation with Cutting.

  • G02/G03: Circular Interpolation. Clockwise/Counterclockwise.

  • G90/G91: Defines absolute or incremental coordinate systems. (Incremental)

  • G40/G41/G42: Cutter Radius Compensation


2. What is M-Code (Miscellaneous Code)?

This section describes M-Code, which are additional commands used to control machine operations:

  • Definition: M-Code is a set of additional commands used to control machine functions that are not directly related to movement.

  • Primary Function: Tells the machine what to do, such as turning various functions on/off.

  • Example Basic Commands:

  • M03/M04: Turn the spindle clockwise/counterclockwise (turn on the cutter head).

  • M05: Stop the spindle.

  • M08/M09: Turn the coolant on/off.

  • M06: Change the cutting tool.

  • M30: End the program and return to the starting point.


3. Program Structure and Applications

This content links G-Code and M-Code together to create a complete program:

  • Command Block Structure: Explains how a CNC program consists of command blocks (Block/Line), each of which can contain a G-Code, M-Code, and coordinates.

  • Relationship: G-Code indicates position (X, Y, Z), while M-Code commands the machine to perform other functions necessary for cutting (e.g., turning on coolant or changing cutter heads).

  • Importance for Programmers: Emphasizes that understanding both codes is essential for writing, editing, and verifying CNC programs to ensure accurate and safe production.

Principles:
  • G-Code, M-Code, CNC Programmer

Level:
  • Basic, CNC Commands, Command Codes

Technology:
  • CNC Programming, CNC Control, Machine Language

Specialized Knowledge:
  • Machine Control, Geometric Code, Miscellaneous Code

G-Code, M-Code, CNC Programming, Basic Commands, CNC Programmer


Here is the first image, illustrating the core concept of G-Code: 1. G-Code: Geometric Commands An illustration showing a computer screen displaying blocks of G-Code (e.g., G00 X10 Y5 Z2, G01 X20 Y10 F100). Next to it, a simplified diagram of a cutting tool moving along a defined path (rapid traverse, linear cut, arc) on a workpiece. The visual should clearly link the code to geometric movement.


Here is the second image, illustrating the core concept of M-Code: 2. M-Code: Miscellaneous Functions An illustration depicting a computer screen showing blocks of M-Code (e.g., M03 S1500, M08, M05). Alongside, simple icons or small diagrams representing machine functions: a spinning spindle (M03), a coolant nozzle spraying (M08), a tool changing arm (M06), and a program end symbol (M30).


Here is the third image, demonstrating how G-Code and M-Code work together in a program: 3. G-Code & M-Code Working Together A visual representation of a CNC machine's control panel or interface, showing a snippet of a CNC program where G-Code and M-Code commands are interspersed (e.g., N10 G00 X0 Y0, N20 M03 S1000, N30 G01 Z-5 F50). Arrows or highlights should connect specific lines of code to their corresponding actions on a simplified machine diagram (e.g., G00 to rapid movement, M03 to spindle rotation).


And here is the fourth image, highlighting the importance for CNC programmers: 4. Why G-Code & M-Code are Essential for Programmers A stylized image of a CNC programmer (human figure) at a computer, looking confident and in control, with a backdrop of a complex CNC machine or a finished precision part. Text overlay: "Empowering Precision" or "Mastering Machine Language."



CNC Milling 101: Getting to Know CNC Milling Machines from the Start

 

1. Get to Know CNC Milling

  • What is CNC?: Explain the meaning of CNC, which stands for Computer Numerical Control, a system for controlling machine operations using a computer.

  • What is CNC Milling?: Explain that it is a machine that uses CNC technology to control the movement of a milling cutter to precisely and automatically cut, drill, or shape a workpiece according to desired design.

  • Benefits: Emphasize key advantages such as high accuracy, speed, and consistent production. It can produce workpieces with complex shapes better than traditional milling machines.


2. Working Principles and Workflow

  • Workflow: Explains how CNC milling machines operate using computer-generated commands to control the movement of the cutting tool in various directions (X, Y, Z, and other axes).

  • Basic Process:

  • CAD Model Design: Create a 3D model of the workpiece using CAD (Computer-Aided Design) software.

  • CAM Conversion: Import the model into CAM (Computer-Aided Manufacturing) software to define the cutting path (toolpath) and generate G-code, or command code, for the CNC machine.

  • Command Input: Enter the G-code into the CNC milling machine's control system.

  • Start Operation: The machine automatically operates according to the received commands to mill the workpiece according to the design.

3. Components and Types of Milling Machines

  • Main Components: Introduces the essential parts of the machine, such as the spindle, the milling head holder, the worktable for holding the workpiece, and the controller, which is the brain of the machine.
  • Machine Types: Introduces common types of CNC milling machines, such as:
  • Vertical CNC Milling Machine: The milling head rotates vertically, suitable for milling flat surfaces, drilling, and grooving.
  • Horizontal CNC Milling Machine: The milling head rotates horizontally, suitable for large workpieces and mass production.

4. Materials and Cutting Tools
  • Available Materials: Demonstrate that CNC milling machines can work on a wide variety of materials, including metals (steel, aluminum), plastics, and wood.
  • Cutting Tools: Briefly explain the types of milling heads (end mills, face mills, drill bits) and the importance of selecting the appropriate tool for the material and application.


Course:
  • CNC Milling, CNC Milling Machines, CNC 101

Level:
  • Beginner, Basic, Introductory

Technology:
  • CAM, CAD, G-Code, Computer-Aided

Industry:
  • Metalworking, Manufacturing, Machining, Technical

CNC Milling, CNC Milling Machines, Beginner, CAM, G-Code, Basic Machining


Here is the first illustration, depicting the core concept of a CNC milling machine at work, showing precision and automation: 1. CNC Milling Machine in Action A modern CNC milling machine with a robotic arm precisely cutting a metal workpiece, surrounded by a clean, high-tech workshop environment. Emphasize the precision and automated nature.


Here is the second illustration, explaining the workflow from design to manufacturing: 2. CNC Workflow Diagram An infographic illustrating the sequential steps of the CNC process: CAD design (a 3D model on a computer screen), CAM software (showing tool paths), G-code generation (lines of code), and finally, the CNC machine producing the part. Use arrows to show the flow.


Here is the third illustration, showing the main components and types of CNC machines: 3. CNC Machine Components and Types A split image or collage showing key components (Spindle with a cutting tool, control panel, workpiece on a table) on one side, and two distinct types of CNC machines (a Vertical Machining Center and a Horizontal Machining Center) on the other. Label the components and types.


And finally, here is the fourth illustration, focusing on materials and cutting tools: 4. Materials and Cutting Tools for CNC An image showcasing various raw materials (a block of aluminum, wood, and plastic) on one side, and a diverse set of CNC cutting tools (end mills, drills, face mills) arranged neatly on the other side. Label the materials and tools.


5:59 AM

Mold forming process using CNC milling machine

  










Machine: Three-axis machining center brand UDM-2216 CAD/CAM software: Cimatron 2025 My video editor:Movavi Video Editor Plus If you're interested in learning more about cnc milling, then be sure to check out this video! I used tools from companies dat nguyen cnc cnc machine operator in hindi cnc machine job work vmc machine operator training millwright cnc programmer kaise bane cnc programming for mechanical engineering machine operator bmc machine cnc machine operator training g code nc laser cutting vmc cnc frezar Mold component production (CNC Milling)

How does an EDM machine work?

 Electrical Discharge Machining (EDM), also known as electrical discharge machining or spark machining, is a non-contact machining process that uses electrical spark erosion to remove conductive material from the workpiece.

1. Basic working principles of EDM

The operation of an EDM machine relies on the rapid and repeated release of a high-voltage electric current between the electrode and the workpiece. The key components and steps are as follows:

1.1 Key components

  1. Electrode: Acts as a cutting tool and can be a copper rod, graphite, or brass wire (in the case of Wire EDM). The electrode is connected to one terminal of the power supply.

  2. Workpiece: The material to be cut, which must be an electrically conductive material . The workpiece is connected to the other terminal of the power supply.

  3. Dielectric Fluid: The workpiece and electrode are immersed in this fluid (usually EDM oil or distilled water). This fluid acts:

    • Insulated: Prevents short circuits.

    • Controls spark generation: It breaks down into a conductive medium when the voltage is high enough.

    • Cooling: Absorbs heat from sparks.

    • Scrap Removal: Flush molten metal particles out of the cutting gap.

1.2 Spark Erosion Process

  1. Spark Gap Control: The servo system controls the electrodes to move as close to the workpiece as possible (but not touching it) to create a micro-gap between them.

  2. Dielectric Breakdown: As the voltage applied between the electrode and the workpiece increases, the electric field in the gap increases, causing the dielectric fluid to ionize.

  3. Electrical Discharge: A rapid flow of electric current in the form of a spark across a gap.

  4. Melting and Evaporation: This spark creates very high heat (up to8,000to12,000  ºCOr more20,000 °F) which will cause the small pieces of material in the area where the spark occurs on the workpiece to melt and evaporate, turning into vapor.

  5. Flushing: When the spark is extinguished, the circulating dielectric fluid rapidly flushes molten metal particles (slag or Debris) out of the gap.

  6. Repetition: This entire process is repeated rapidly (thousands of times per second) as the CNC system controls the movement of the electrode, continuously and precisely "eroding" the material into the desired shape.

2. Main types of EDM machines

The specific operation varies depending on the type of EDM machine:

EDM machine typeElectrodeWorking characteristicsGeneral use
Sinker EDM (Ram/Die Sinking EDM)Electrodes that are fabricated to a specific shape (e.g., graphite or copper rods)The electrode is "sunk" into the workpiece to create a cavity, channel, or negative 3D shape.Plastic injection molding, casting molding, complex cavity creation
Wire EDM (Wire-Cut EDM)Thin wire (usually brass) that is fed continuously.The wire acts like an electric band saw, cutting through the workpiece, creating straight cuts or cutting complex 2D shapes.Metal stamping die work, high-precision parts, thin-walled shape cutting
Hole Drilling EDM (Fast Hole Drilling)Hollow Tube ElectrodeUsed to create small, deep, and precise holes quickly.Drilling the initial hole for Wire EDM, creating cooling holes in the turbine

Advantages of EDM

  • Can cut very hard materials (such as hardened steel) that are difficult to cut with conventional methods.

  • It is a cutting process that does not use mechanical force (No Mechanical Force), allowing delicate parts to be cut without distortion or deformation.

  • Provides high precision and good quality surface finish.

  • It can create complex geometric shapes, small holes and sharp internal corners that cannot be achieved with conventional milling.

How does a CNC waterjet machine work?

 A CNC waterjet cutter is an automated cutting tool that uses the principle of mechanical erosion, injecting a high-pressure stream of water (often mixed with an abrasive) to cut precisely through almost any material. It is a cold cutting process.

1. Basic operating principles

The operation of a waterjet machine relies on converting water pressure into very high speeds for cutting, which is divided into three main steps as follows:

1.1 Ultra High-Pressure Generation

  • High-Pressure Pump (or Intensifier Pump): This is the heart of the system. It takes filtered tap water and intensifies it to a very high pressure, typically around60,000to94,000PSI (pounds per square inch) or approximately4,000to6,480bar

1.2 Pressure to Velocity Conversion

  • Orifice: High-pressure water is directed through a metal tube to the cutting head. As the water is forced through a tiny hole called an "orifice" (usually made of diamond or sapphire), which is much smaller than a human hair, the laws of physics convert the water pressure into a jet of water that travels at supersonic speeds (higher than sonic ).2,500miles per hour, or about 3-4 times the speed of sound)

1.3 Cutting Mechanism

Waterjet cutting is divided into two types depending on the material:

  • Pure Waterjet Cutting: Used for cutting soft materials such as rubber, foam, plastic, wood or food. The high-speed water jet cuts the material by the force generated when it hits the surface.

  • Abrasive Waterjet Cutting: Used for cutting hard materials such as metal (steel, stainless steel, aluminum), stone, glass, or ceramics.

    • In the mixing chamber of the cutting head, abrasives such as garnet, a natural sand, are sucked into the pure water stream through the principle of vacuum (Venturi effect).

    • The abrasive-mixed water stream is accelerated and projected out of the focusing tube as high-speed "liquid sandpaper" that erode, or grinds, away material in small, microscopic amounts.

2. The role of the CNC system

CNC (Computer Numerical Control) systems are crucial in controlling the entire process to produce precise and complex workpieces:

  1. Programming: The user enters 2D or 3D drawings created from a CAD program into the CNC system.

  2. Motion Control: The CNC software converts the design into G-code to control the movement of the cutting head in the X and Y axes (and the Z axis or other rotational axes for 3-5 axis machines) to cut along the desired line.

  3. Parameter Management: The CNC system controls water valve opening/closing, pressure adjustment, and abrasive feed rate to suit the material type and thickness, which affects cutting speed and edge quality.

Main advantages of Waterjet CNC

  • No Heat Generation: Since it is a cold cutting process, there is no material distortion (Thermal Distortion) or heat affected zone (HAZ) generation.

  • Material versatility: Can cut almost any material, from soft to very hard.

  • High precision: It can cut complex shapes with high precision and has a very narrow Kerf, reducing material waste.

How does a CNC plasma cutting machine work?

 A CNC plasma cutter is an automated tool that uses the principle of heat cutting, relying on the fourth state of matter called plasma , to cut all types of conductive metals (such as steel, stainless steel, aluminum) quickly and precisely under the control of a computer system.

1. Principles of plasma generation and cutting

The main process of plasma cutting consists of four important steps:

1.1 Gas Flow

  • The machine injects gas (such as compressed air, nitrogen, oxygen, or an argon/hydrogen mixture) into the plasma torch at high pressure and speed.

1.2 Electric Arc and Plasma Creation

  • Inside the cutting head are electrodes and nozzles.

  • When a high voltage current is applied between the electrode and the injector, a spark is created, which ionizes the gas flowing through that area.

  • The ionized gas becomes a plasma, a very high temperature conductor (up totoor more)

1.3 Cutting Action

  • Once plasma is generated, the system transfers the primary current to the metal workpiece (the workpiece acts as the positive terminal in the circuit).

  • A highly heated plasma jet is forced out at very high speed through a tiny orifice in the nozzle.

  • The intense heat of the plasma causes the metal in contact to melt instantly .

  • The pressure and high velocity of the still flowing gas blows away the molten metal from the Kerf, causing the workpiece to continuously break apart.

1.4 CNC control system

  • The CNC (Computer Numerical Control) system precisely controls the movement of the plasma cutting head along the X, Y, and Z axes according to the shape the user has designed in the computer program.

  • CNC controls parameters such as cutting speed, amperage, and torch height control (THC) to achieve the best possible cut quality.

2. Working steps of CNC plasma cutting machine

  1. Design: The user creates the shape of the workpiece in a CAD (Computer-Aided Design) program.

  2. G-code Generation: Use Computer-Aided Manufacturing (CAM) software to convert design files into G-code instructions to tell the machine where to move and when to start cutting.

  3. Setup:

    • Place the metal sheet on the cutting table and connect the ground wire to the workpiece.

    • Set cutting parameters (current, gas type, pressure) in the CNC system.

  4. Arc Initiation:

    • The CNC system will command the cutting head to lower to the pierce height.

    • The machine will start the plasma creation process (Pilot Arc) and send the current to the workpiece.

  5. Piercing:

    • The high-heat plasma beam penetrates through the thickness of the metal sheet.

  6. Cutting:

    • Once the cut is made, the CNC system commands the cutting head to start moving along the path specified in the G-code.

    • The Automatic Cutter Head Height Control (THC) system works to maintain a constant height between the cutter head and the workpiece to produce a consistent quality cut.

  7. Completion: When the workpiece has been cut to the specified shape, the system will stop supplying power and stop the gas flow.

Summary of main components

componentduty
CNC systemThe brain controls the movement in the X, Y and Z axes to cut according to the designed shape.
Power supplyConverts alternating current (AC) to direct current (DC) and provides the high current required to create the plasma arc.
Plasma cutting torchIt is the origin of plasma, consisting of electrodes, nozzles and rotating gas rings.
Gas (Gas/Compressed Air)It is a medium for creating plasma and uses high pressure to blow away the molten metal.
Altitude Control (THC) SystemAutomatically adjusts the distance between the cutting head and the workpiece to maintain the quality of the cut.

CNC CODE

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