Our world is surrounded by complex technology evolving at a rapid rate. In everyday life, we see a lot of intricate parts, such as gears and components inside machinery, which makes one wonder what goes into manufacturing them.
Well, for most of these products and to the question of how they are made, the answer is the same –CNC precision machining.
Computer numerical control (CNC) processes have been the foundation stone for modern industries, producing parts in an automated fashion at unimaginable production speeds. CNC precision machining has taken it even further, adding accuracy and simplifying the manufacturing process.
This article will discuss precision machining, Process, Advantage, and Applications and much more.
What is precision machining?
Precision machining is the process wherein the raw material is removed an object to create a smaller, finished product utilizing cutting machines, software applications, and human engineering to meet very exacting specifications. A company that offers contract precision machining services can usually assist with minor modifications during the prototyping process to meet design and/or industry standards.
What are the Steps in the Precision Machining Process?
Most precision machining companies work through a series of similar steps for various types of parts.
1. Design the Graphical Model
A graphical model is required to create any part. This is accomplished with the help of Computer-Aided Design (CAD) software. The CAD software enables the designer to create 2D and 3D models of any part for manufacturing.
It is common for designs to start as hand-drawn sketches to understand the basic concepts of the part. The Computer-Aided Design (CAD) designer then refers to these sketches to create the graphical model with accuracy in dimensions. For Computer-Aided Design, there are many popular software programs, both free and paid. Manufacturers can also outsource the design process for any complex design development.
2. Convert CAD to CAM
Computer-Aided Design creates a graphical representation of the part in a digital format. This representation is easy for the designers, operators, and manufacturers to understand. However, CNC machines used to create the part do not understand this digital format directly.
The machine understands coordinates where it can move the cutting tool or shift the workpiece. Therefore, CNC machines require the part design to be in a suitable format that provides the necessary manufacturing instructions. Computer Aided Manufacturing (CAM) software is used to create the readable format for CNC machining. The CAM software takes the CAD model and converts it into CAM format that the CNC machines can understand.
Computer Aided Manufacturing (CAM) software uses two types of codes-the G and M codes. The G code controls the coordinates of the cutting tool. The M code controls the auxiliary functions of the machine, such as turning the coolant flow on or off.
3. Material Selection and Preparation
The choice of material primarily depends on the part’s requirements, machinability, and cost. In most applications where hardness and strength are required, usually steel is the first choice. When weight is a concern, for instance in aerospace applications, manufacturers may choose lightweight aluminum. A subsequent section highlights this point in detail.
4. Setup of Precision Machinery
The machine setup includes selecting and precisely calibrating the precision machine tools, checking the fluid and coolant levels, and possibly running a dry run to ensure everything is set correctly.
5. Execution of Machining
Once everything is set up, the machining process can begin. During the process, monitor the initial stages of the process. Some machines may require a technician’s attention for adjustments, for instance, calibrating tool positions or modifying feed rates to accommodate variations in material hardness or tool wear.
6. Post-Processing Steps
Although precision machined parts often emerge from the machine close to their final form, some may require additional finishing, such as polishing or grinding. The last step is quality assurance checks to confirm that each part adheres to the specified precise dimensions.
Advantages of CNC Precision Machining
Industry today is moving at a breakneck pace. Keeping up to speed or ahead of the curve is vital for your business in order to meet the demands of today’s customers.
Here are 7 advantages to using and outsourcing precision machining in your business model.
1. Low Error
By using CNC machines, once the correct specifications are keyed in, the automated precision machining process takes over. The chances for error is extremely low as compared to human machining. When you outsource this work, you avoid the need to recruit and hire the highly skilled staff needed to run these machines.
2. Less Material Waste
As the core concept of precision machining is subtraction, there is enormous potential for material waste start to finish on a single product. CNC precision machining helps reduce material costs due to wastage human error. Contract companies may also be buying the material needed for your job is bulk, and pass the savings on to you.
3. Consistent Product Quality
Precision machining via CNC machines leads to consistent output time after time. Consistently producing quality product runs leads to customer confidence and enhances your brand’s awareness.
4. Improved Workflow
When looking at how to manage opportunity costs, it’s key that engineers’ time and skills are spent on actual product development and not tiny design changes. A company that offers contract precision machining services can usually assist with minor modifications during the prototyping process to meet design and/or industry standards.
5. Reduced Turnaround Time
The opportunity exists to improve your existing factory workflow (either with in-house precision machines if you can afford the machine investment and the skilled labor to operate it), or, by using contract machining services. A contract company is experienced in this type of work and have the system in place to get the job done as efficiently as possible.
6. Faster Production Cycles
Being able to offer your product to market faster gives you an edge over facilities that are still using older methodologies. You’re also likely to be more flexible with changes due to industry regulations or customer requests.
7. Easier Prototype Testing
Precision machining offers your business an opportunity to explore smaller niche markets with the potential for high returns. Precision CNC machining can allow for a flexible product-development phase as the niche opportunity is determined. If the market has a demand, the machining can be shifted into a full-scale production mode.
What are the Applications of Precision Machining?
Precision machining forms the basis of many industries, whether for tooling or making the final product. Some of the applications of precision CNC machining are:
Prototypes
Precision machining is utilized for making prototypes for all industries. Prototypes require a highly accurate reproduction of an intended design to depict product features. Precision machining is the ideal way to fulfill these criteria.
Automobiles
Automotive industries require intricate gears and components for engine parts, axles, nuts, and more. These components for two-wheelers, cars, trucks, ships, and airplanes are made with precision machining tools.
Medical Industry
Medical technology is becoming more and more complex. There are automated tools and equipment in the medical industry that can even perform surgeries. This equipment requires intricate machining on a micro level, made possible by precision machining.
Aerospace
The aerospace industry utilizes some of the most advanced equipment, materials, and technology. It requires a machining process that is not only highly accurate but can also work on the hardest materials. Precision machining provides a simple solution to create all kinds of parts in the aerospace industry, from prototypes to full-scale parts.
Defense Industry
The defense industry has requirements similar to the aerospace industry. It calls for the most rugged materials requiring quality precision machining. The applications are wide and varied, from new weapons prototypes to entire missile systems.
Outsourcing Your Precision Machined Products
Producing precision-machined products in-house can be challenging, especially when the demand for these products is infrequent. Outsourcing the machining of precise products is the most practical option.
Xtmachining provides a one-stop solution for all precision machining services. We are an ISO 9001, ISO13485 and IATF16949 certified company, ensuring that each component meets stringent quality standards.
Our services include 3D printing, Precision CNC milling, turning, grinding, and EDM with tolerances up to 0.01mm. Whether you need precision prototype machining or large-scale production, we handle projects of any size using the best materials and cutting-edge technology.
Conclusion
Today’s machines are intricate assemblies made up of numerous micro-parts, each of which must synchronize perfectly to function as a unified whole. Precise machining is crucial in this context-it ensures that every component is manufactured to exact dimensions.
There are multiple CNC machining equipment options available to perform specific cutting tasks. As the world continues to shift towards more advanced technologies, the significance and use of CNC precision machining will only increase.
Contact us at Xtmachining to learn how we can support your manufacturing goals with precision and reliability.
