Bad runout can happen during the rotational movements of the CNC milling operations, which indicates a big deviation from the normal or expected runout value. Each milling operation will use a rotational axis that won't always be accurately rotating. Runout can occur occasionally, but it should be controlled at certain values. Various factors can contribute to the runout error based on the machine configuration and how you handle the CNC milling machining operation.It is always best for you to keep the runout error at a minimum and avoid bad runout problems as much as possible.
Here are the common mistakes that can cause bad runout in CNC milling and how to prevent them:
1. Bad Setup for the Milling Components
Set up the CNC milling components the right way. These components are the ones that will do the full work during your manufacturing operation. These CNC milling components need to be well-fitted with each other. So, set them up properly before each milling process. Any deviation in the setup preparation might cause bad runout problems, which will affect your overall production result.
Preventing the bad setup for the milling components can be done by making sure that each component is in the best working condition. You can also perform regular maintenance work for the component before and after any milling operation. Damaged components, especially in their axis area, can cause bad runout and should be replaced immediately.
2. Not Checking the Fitting between the Chuck and the Tools
Each tool that you use for the CNC milling operation needs to fit snugly with the corresponding chuck. Any bad fitting or unstable fitting can inevitably cause various problems during the CNC milling process, including bad runout. It is very common for manufacturers to get bad runout problems because of the bad fitting of the chucks and tools they use for the milling operation.
To prevent this bad runout problem, you need to ensure that the chuck and tool you use correspond perfectly with each other. Make sure that you are using compatible models for the chucks and tools you use during CNC machining. Check the snug fitting of the chucks and tools before beginning your machining operation to avoid any bad runout that might negatively affect your production result.
3. Not Adjusting the Machining Configuration for Different Workpiece Materials
Different workpiece materials have different characteristics, such as hardness, strength, durability, and machinability. The most common mistake you can make is not adjusting your CNC milling tools for different workpiece materials. This can cause a range of problems, including bad runout during CNC milling operations. Not adjusting the machining configuration for different workpiece materials can also potentially damage the corresponding tools. This can cause further runout problems for your production and low volume manufacturing services plan.
To prevent this bad runout problem from happening, it's necessary for you to configure your CNC milling machine to work in the best way with different materials. You also need to use some specialized tools and components when using some special workpiece materials during the milling operation. It can help reduce your chance of getting bad runout errors that can jeopardize your entire production run.
4. Bad Quality Components for the Machining Process
Using third-party components for your CNC milling machine might be necessary to do when you need to replace the old or damaged machine parts. Using third-party generic components for your milling machine might end up causing problems for your machining operation, such as bad runout. Low-quality third-party components for CNC milling might be more difficult to adjust and cause runout problems over time.
To prevent this issue, use only officially compatible components for the CNC machining services equipment. Match the parts you want to replace with the parts from the original manufacturer for the milling equipment. This will ensure the best compatibility for your CNC milling machine and prevent any bad runout problems when you operate it.
5. Too Much Friction for the Components During Machining Operation
During CNC milling operations, each component works together along with the cutting tools. During this working process, each component will apply friction against the other components. The tools will apply friction against the axis as the milling machine rotates to cut the material workpiece. This is often where the problem of bad runout can happen. Too much friction might disturb how the rotation axis works on the CNC milling machine and cause a bad runout over time. Without fixing this issue, you might have a runout problem that causes certain inconsistencies or damages to the end product you are trying to make with CNC milling.
To prevent this problem, you need to reduce the amount of friction received by each component during the milling operation. You can reduce the risk of a bad runout problem by smoothening the applied friction in each component. You can use lubricants on your CNC milling components to keep the friction low during operation. Don't forget to change the lubricants occasionally to keep a smooth-running CNC milling operation and avoid a bad runout. Also, using sharp cutting tools can help reduce the friction between your CNC milling components and the material workpiece.
Conclusion
Avoid these mistakes in your manufacturing and CNC milling process if you want to get the best result for your machined products. Runout is always to be expected in any CNC milling operation. But a bad runout can turn your production plan upside down. You need to prevent bad runout problems as much as possible by following the advice given in this guide. Before the bad runout problem wreaks havoc in your production process, it is always better for you to prevent it.
Configure your CNC milling machine to control the runout value to be as low as possible. Perform maintenance work on all the tools and components you use in your milling operation to avoid any bad runouts and other issues in your production.
