What CNC Machining Engineering services are supplied by machine shops?
Novel concepts in the engineering world are coming at an unprecedented pace. Behind the scenes of these remarkable concepts are countless manhours, numerous prototypes, and assistance from one-stop solution providers in the CNC machining engineering world. Companies heavily rely on CNC (Computer Numerical Control) processes for their precision machining, versatile possibilities, and rapid solutions.
It helps to test ideas at a lower financial risk. As a reader, you might also be on the lookout for a one-stop engineering service provider. Without further delay, let us walk you through which range of services a good solution provider must offer for your growing business.
What is a CNC Machining Engineering Service?
To understand what a CNC Machining Engineering service is, the following flowchart can help you establish what it offers for you as a customer:
With these traits, CNC machining service providers are actively working with top inventors, researchers, and engineers to provide rapid prototyping services. It helps market players to gain cutting-edge market competitiveness. The road map of turning a concept into a producible part involves several steps from the CNC industry including:
- Multi Axis Machining
- CNC Inspection Services including CAD file evaluation
- Surface Finishing
- Design for Assembly
- Optimization for mass production and costs
- Prototyping Services
Without accurate following of the above steps, companies will neither be able to have clarity on design process nor will they be able to sell their ideas to major stakeholders for building trust and attracting investments.
A good CNC machining engineering service provider will ensure that a part gets formulated from the raw material to a finished product right within their facility. In terms of life cycle cost, the following chart summarizes how 85 percent of costs are involved within the first two phases.
Let us now walk you through the main services offered by CNC machining services.
Multi-axis machining
Multi-axis Computer numerical control (CNC) machining employs advanced machining equipment and tooling that accommodates motion in various directions to facilitate the machining of complex geometries with precision.
Multi-axis CNC machining includes:
- 3-axis CNC machining
- 4-axis CNC machining
- 5-axis CNC machining (the most efficient, fast, and modern technology)
3 axis CNC machining:
3-axis CNC machining implies that the workpiece remains in the same position as set up, where the cutting tool operates along in XYZ plane to remove material. This is beneficial for the part that does not require depth and detailing.
The 3 axis machine is great for:
- Automatic operations
- Milling slots
- Drilling holes
- Cutting sharp edges
- Parts with less complicated geometries
4 axis CNC machining:
4 axis machining implies that a workpiece is processed the same way as in the 3 axis machine but with the additional rotary movement around the x-axis, named A-axis. This method is beneficial when holes or cuts need to be made on the sides of the workpiece. The fourth axis allows the workpiece to flip over to remove material from both sides.
Some of the uses are as follows:
- Intermittent cutting
- Continuous cutting
- Engraving curved surface
5 axis CNC machining:
Computer numerical control (CNC) with 5 axis machining capabilities refers to simultaneously moving cutting tools or parts along 5 axes. The cutting tool continuously moves by maintaining the tip perpendicular to the part. This type of machining allows you to deal with a wide variety of complicated parts.
Configuration of 5 axis CNC machines:
The main configuration of 5 axes is as follows:
- Trunnion-style: Trunnion machines are efficient in machining because this style allows the table to move, which helps in machining large volumes and the spindle doesn’t take any space.
- Swivel-rotate-style: Efficient configuration due to the utilization of rotary axes by using the rotating spindle. This style is very beneficial in heavier parts because the table is constantly horizontal.
Benefits of 5 axis CNC machining:
Some of the benefits of 5 axis CNC machining are as follows:
- Single setup: With 5 axes machining, you can machine complicated shapes in a single setup. This improves efficiency saves time and prevents operator error.
- Shorter cutting tools: Shorter cutting tools can be incorporated in 5 axis CNC machining because you can orient the cutter as per your machining needs i.e. head and cutter adjustment. This helps achieve higher cutting speed without putting much pressure on the cutter.
- Complex parts: This process allows you to machine complex parts that would require casting.
- Improve tool life: You can achieve optimum cutting position, which improves the cycle time and tool life.
- Collision avoidance: This can tilt the table or cutting tool to prevent collision with the holder of the tool.
Next on the list are CNC turning facilities.
Horizontal CNC turning
Horizontal computer numerical control (CNC) includes lathes that integrate drilling and machining capabilities. Some of the facilities which CNC turning provides to its operator are as follows:
- Travelling tool turret
- More tooling axes
- Coolant flooding
- Sometimes conveyor belt
Turning tools which are widely used in CNC machining of different features are as follows:
- Drills
- Reamers
- Broachers
- Taps
- Dyes
- Knurling tools
Benefits of Horizontal CNC turning
- Horizontal CNC turning centers are very flexible and have longer beds, which makes them more suitable for longer pieces like shafts and pipes. This gives them more efficacy and adaptability.
- They have unique parts like bar feeders and tailstocks which are less introduced in vertical CNC lathes.
- Horizontal lathes can adapt various types of heads installed on a horizontal clamp. These machines accommodate a wide variety of shapes and sizes, and gravity works to keep the workpiece clean during machining.
- Most horizontal CNC turning machines can incorporate automatic bar-stock feeders for ease of operation.
Vertical CNC turning
- As the name suggests that in vertical CNC turning the spindle moves up and down to place it in line with the appropriate tool necessary for the desired operation.
- A vertical CNC turning machine is less complex than a horizontal CNC machine.
- It provides the best option for projects that focus on a single side, like large metal plates and sinking dyes.
- It holds an advantage over horizontal CNC machine where workpiece sagging is concerned due to large part size.
- Vertical CNC turning machine is ideally suited for large diameters and heavy weights.
- It can save time in loading and unloading workpieces.
- An automatic tool changer makes the operation faster and saves lead time for every part.
Along with turning, CNC milling is also one of the key offerings. Let us discuss it next.
Vertical CNC milling
As the name suggests that vertical milling has a vertical spindle axis. There are two common types of CNC vertical mills and these are:
- Bed mill: Material is placed on a bed that can move in the horizontal direction but the spindle can be guided up and down.
- Turret mill: This includes a fixed spindle and a bed that moves both vertically and horizontally to position the workpiece.
The advantages of vertical CNC milling are as follows:
- Visibility: Visibility is increased in vertical CNC milling due to openness provided by orientation. This can be useful in a project which requires higher attention.
- Ease: CNC controls for vertical machines are very user-friendly, and the appropriately skilled labor for this type of machine is easy to find.
- Precision: CNC vertical machines ensure precise cuts and reduce the risk of human error found in conventional machines.
Horizontal CNC milling
As the name suggests that spindle is in a horizontal direction with the workpiece. The horizontal CNC milling machine is more like a circular saw. Horizontal milling centers come with various customizations such as multiple cutters or rotating universal beds that let user cuts at various angles.
The advantages of horizontal CNC milling are as follows:
- Speed: Horizontal Computer numerical control (CNC) milling removes material from the workpiece at a faster speed and can make multiple cuts simultaneously.
- Capacity: Because of increased speed and precision, horizontal milling machines are ideal for large production projects.
- Durability: Horizontal milling machines are built to last. Their size and durable construction enable them to handle larger and heavier materials without risking damage to the machine.
- Precision: CNC horizontal milling machines drastically reduce random errors by automating cutting processes resulting in tight tolerancing.
With machining services covered, inspection services come next in line.
CNC Inspection service
In Computer numerical control (CNC) inspection service is essential to ensure that manufactured products meet the standards of industries and customers. Mainly inspection is done by following methods:
- Testing of machine tool’s accuracy: In this method, the alignment and kinematic accuracy of machine tools are to be examined. A number of parameters are inspected including:
a)Orientation of spindle
b)Holders
b)Holders - Product testing: In this method, the part dimensions and features’ locations are checked. This also includes inspecting the surface finish in addition to inspecting tolerances based on the area of application.
- Process monitoring and control: At every stage of the CNC machining process, checking prevents the whole process from errors, which could result in unnecessary delays in the CNC manufacturing process.
Parameters to be inspected during CNC machining processes:
- Feasibility study
- Analysis
- Pilot production phase
- Aim for tight tolerances
- Make sure the machine is highly calibrated
- Record inspection results for future reference
- Final inspection of finished products including internal features
Aesthetics for any machined parts play a key role in value addition. Let us discuss this next.
CNC Surface finishing services
Before we go into CNC surface finishing detail, let’s understand what surface finish is. It is defined by:
- Surface roughness: The measure of total spaced irregularities on the surface.
- Waviness: Waviness is the measure of a rigid surface whose irregularities are greater than surface roughness.
Importance of CNC surface finishing:
- Prevents corrosion and chemical-resistant effects
- High-quality finishing improves the part’s aesthetics and functioning
- Helps with the adhesion of coating and paints
- Overcome surface defects
- Improve conductivity in metal finished products
- Increase product strength by minimizing effects
Different techniques for metal surface finishing:
All metal prototyping and CNC machined parts will leave behind a pattern of scratches or burs on the workpiece. To make high-quality finished products some of the finishing processes are as follows:
- Sanding
- Ultrasonic polishing
- Rumbling and tumbling
- Magnetic polishing
- Sandblasting
- Lapping
- Filing
With part machining, finishing, and inspection discussed above, let us walk you through the next stage i.e., assembling of parts.
Assembly services
Assembly includes the steps for constructing a completed product made up of components or semi-knock-down units (SKD). Product assembly services include:
- Mechanical assembly: Mechanical assembly involves the process of combining mechanical components to form a final product using different tools and types of equipment. These are generally joined with fasteners such as bolts, nuts, and screws.
- As a service provider, we guide you through various aspects of fitments including:
1.Gauges
2.Fits
3.Tolerancing - Electro-mechanical assembly: Electro-mechanical assembly involves the process of combining electrical and mechanical components to make a product or system that uses electrical current to perform a specific task or set of tasks.
Design Guidelines to Optimize Part Machining and Reduce Cost
CNC machining is a versatile machining method that produces high-quality results. To optimize part machining, you just need to design your part by getting guidelines from computer aided manufacturing (CAM) techniques.
A professional engineer from the CNC machining service provider can evaluate your provided CAD in any file format for optimal machining operations. The optimization is mostly resulting from the simulation of machining beforehand. G code and M code are generated automatically from simulation based programs to avoid wastage of material, cost and time. Parameters that we can optimize using industrial CAM software for the reduction in time and cost incurred include:
- Spindle speed
- Feed rate
- Utilization of types of tools
- Tooling strategies
- Path strategies
Prototyping Service
Seasoned CNC machining service providers are not only capable of providing individual offerings but also combine various services to provide you a one-stop solution.
As we discussed earlier, 85 percent of total product lifecycle cost is incurred in the first 2 phases, accurate prototyping and testing is key for major market players. To reduce testing costs, attract investments from major stakeholders and present ideas in an interactive way, prototyping is vital.
During the prototyping cycle, expert advice on the following aspects is vital:
- Types of machining processes required on part
- Material requirement
- Types of tooling
- Optimization of design, cost and time
- Conversion of prototypes to mass production
Conclusion
Therefore, it is very clear from this informative article that a good CNC machining service provider can positively benchmark your product. Data from earlier experience gives service providers the versatility to guide you through the lifecycle of novel products.
Hence, always choose the right service provider to give you a jump start for your unique ideas and innovation.
Worthy Hardware is a CNC manufacturing and sheet metal fabrication company,including CNC machining services,CNC milling services, CNC turning services, laser cutting services and stamping services.Call us +86-76989919645 or email us [email protected] for more discounts for your projects.