With each passing day, you are getting familiar with new types of welding techniques. And this is quite convenient for your own sake because now, welding is not a difficult task as it used to be in the past. Here we are going to discuss a similar task which is CNC welding.
As we all are aware that welding requires a lot of mechanical work and equipment to work with. And it can be a hassle for you to manage and maintain all these workpieces together at the same time.
But in the case of CNC welding, you can rest your worries but here we are not asking to do any kind of difficult mechanical work. Because this welding technique was invented just to minimize the machinal work.
Now you must be curious about what exactly CNC welding is. Let us satisfy your curiosity by going into further details about the topic.
In CNC welding, we automize the welding machines and equipment in a special sequence by programming them to get the exact similar result when we do welding by hand.
How does CNC welding work?
Here, different equipment and tools are combined in a programmed and sequential way. Then the items to be welded are passed through different procedures one by one to get the work done.
Each step follows the other by first cutting metal, then shaping, welding, and assembling them. At last, you can see the final product perfectly similar to manual welding.
The best thing is that you don’t need human resources once the equipment is all set to perform its assigned functions. Until or unless you need to make any changes in the program and functions of the machines, machines are always ready to be used.
Why and how CNC welding was introduced?
With the latest advancement of the 21st century, two things that have been revolutionized are computers and welding machines. You will agree with this in the case of computers but when we said welding machines, you are confused and doubtful.
Let me clear your thoughts of doubt. Almost all types of machinery and working equipment are made using welding machines. Practically, welding machines are used in every aspect of life to make different devices, containers, and appliances.
Moreover, with the advancement in computer technology, now we can work with control systems automated. Most importantly, these machines are precisely designed to reduce the chances of errors. The same thing has been given birth to CNC welding machines as well.
CNC welding and control system
CNC welding system is an automated set of equipment where all the machinery is combined as a cell. All the work is controlled by the CNC control system and different tasks are performed just by giving instructions.
Mainly, these are some of the reasons why and how CNC welding was introduced in the first place.
CNC welding machines
Large welding space
These automated machines offer a large welding area where you can work on your welding piece easily. Just to increase and facilitate all the welding positions as well, some machines are introduced with rotatory tables to make the work convenient for you.
You will not need to move it around or use human assistance to weld because all these machines have built-in functions in them providing you full access to work in the way you want.
Which CNC machine to use?
The answer is the same in this case similar to other welding techniques and processes. You need to choose the machine according to the metals or substances you are working with.
It also depends if you are working on a low level or commercial level. In this way, you can decide to choose a bigger or smaller machine along with the functionality you want.
Welding path of CNC welding machine
A welding path is assigned to a CNC welder which is a set of patterns to follow the instructions while working on each piece.
But here in this case, if something unexpected happens during the process, then you have to deal with it manually. It’s because of the complications of the welding path.
In addition, when you are trying to assemble delicate pieces, then using a CNC welder is not advised because it can cause problems during the process. Also, there is a chance that your workpiece will be ruined.
Pre-programming of machines
During welding, the processes which are specific or to the point can be easily automated in CNC welding machines. For instance, during manual welding, a welder is using a welding gun to melt the metal and his other hand is working with the filler material to be placed in the joints of metals.
But in the case of CNC welding, we can do this automatically by pre-programming the welding gun to be turned on and off when needed. Also, we have access to a variety of functions because we store different programs easily in the CNC welding system.
When it comes to flexibility in work, these machines cannot work as humans do. But some of the most difficult and heavy tasks are difficult for humans can be done easily using CNC welding machines.
What are the requirements of CNC welding?
You need to have a keen knowledge of two things that are programming and computing. We use a G-code programming language to write functions and code to program a machine. If you don’t know how to code, then you must have some knowledge of computer-aided design.
First, we write the code and assign the functions to different machines. Then in the last step, it is tested to resolve any critical issues in it. We work in two different parts here:
- The open loop machining system
- The closed loop machining system
The open loop machining system
It is a one-way system where it receives instructions and runs the program by working the motor and controller. These systems are not advised to use because of their less accuracy.
The closed loop machining system
Here we use digital and analog systems to work. The system is highly accurate and capable of eliminating errors and mistakes automatically by identifying them.
These systems are highly recommended because they get feedback in real time and improve themselves by correcting errors.
Uses of CNC welding in industry
We can set different functions and assign them to machines depending upon the nature of the task. As the requirement for mechanical work is reduced, it is very easy to use in the following industries:
- Laser welding is used in the automobile industry by automated machinery and equipment. Proper tasks are assigned and programmed for each one of them like joining and cutting of pieces.
- As we know that plastics have low melting points, and it is quite difficult to weld them. Because we have to consider carefully which method to use for them. Using CNC welding is the best solution for this problem.
- In addition, CNC machines have wide use in electronics as well.
Other possibilities of CNC machines
Besides using CNC machines by automating them for welding, there are other aspects as well where you can use them. Some of these processes include water jet cutting, glass cutting, laser cutting, micro welding, etc.
3D printing using CNC machines
Another use of CNC machines that we will like to discuss here is 3D welding. 3D printing is a method of manufacturing products by stacking them on each other layer upon layer.
It is not very easy to arrange and assemble all the machinery, but when it’s done, the result can be quite astonishing. This process is very inexpensive and is mainly used to build prototypes.
3D printing with CNC machines can be used to build strong and quick prototypes and is quite popular in aerospace companies.
Above all, you will find infinite uses of CNC machines and welding to complete an infinite number of tasks. You can perform complex tasks depending on the complexity of the CNC cell.
As memory storage is not a problem now, you can store thousands of programs and instructions in a CNC controller and machine. Then you can assign them accordingly and also switch between functions as you want.
Now, all you have to do is assemble machinery and assign functions to get your work done at a massive level.