cnc machining manufacturing has created considerable benefits for Honscn Co.,Ltd and its customers. The outstanding feature of this product lies in high performance. Although it is superior in materials and complicated in process, direct marketing reduces the price and makes the cost even lower. Therefore, it is highly competitive in the market and gets more popular for its superior performance and lower cost.
To maintain good sales, we promote HONSCN brand to more customers in the right way. First of all, we focuse on specific groups. We understood what they want and resonated with them. Then, we make use of the social media platform and gained a lot of following fans. In addition, we utilize analytical tools to ensure the effectiveness of marketing campaigns.
At Honscn, our customer service team always puts a relatively higher priority on customer's commands. We facilitate fast delivery, versatile packaging solutions, and product warranty for all products including cnc machining manufacturing.
In the field of machining, after CNC machining process methods and division of processes, the main content of the process route is to rationally arrange these processing methods and processing sequence. In general, CNC machining of mechanical parts includes cutting, heat treatment and auxiliary processes such as surface treatment, cleaning and inspection. The sequence of these processes directly affects the quality, production efficiency and cost of the parts. Therefore, when designing CNC machining routes, the order of cutting, heat treatment and auxiliary processes should be reasonably arranged, and the connection problem between them should be solved.
In addition to the basic steps mentioned above, factors such as material selection, fixture design and equipment selection need to be considered when developing a CNC machining route. Material selection is directly related to the final performance of parts, different materials have different requirements for cutting parameters; The fixture design will affect the stability and accuracy of the parts in the process of processing; Equipment selection needs to determine the type of machine tool suitable for its production needs according to the characteristics of the product.
What do we have to do before arranging the CNC machining process route?
1, the processing method of precision machinery parts should be determined according to the characteristics of the surface. On the basis of familiar with the characteristics of various processing methods, mastering the processing economy and surface roughness, the method that can ensure the processing quality, production efficiency and economy is selected.
2, select the appropriate drawing positioning reference, according to the principle of crude and fine reference selection to reasonably determine the positioning reference of each process.
3, When developing the machining process route of the parts, it is necessary to divide the rough, semi-fine and finishing stages of the parts on the basis of the analysis of the parts, and determine the degree of concentration and dispersion of the process, and reasonably arrange the processing sequence of the surfaces. For complex parts, several schemes can be considered first, and the most reasonable processing scheme can be selected after comparison and analysis.
4, determine the processing allowance and process size and tolerance of each process.
5, select machine tools and workers, clips, quantities, cutting tools. The selection of mechanical equipment should not only ensure the quality of processing, but also be economical and reasonable. Under the conditions of mass production, general machine tools and special jigs should generally be used.
6, Determine the technical requirements and inspection methods of each major process.Determining the cutting amount and time quota of each process is usually decided by the operator for a single small batch production plant. It is generally not specified in the machining process card. However, in the medium batch and mass production plants, in order to ensure the rationality of production and the balance of rhythm, it is required that the cutting amount must be specified, and must not be changed at will.
cnc machining process arrangement
First rough and then fine
The processing accuracy is gradually improved according to the order of rough turning - semi-fine turning - fine turning. The rough lathe can remove most of the machining allowance of the workpiece surface in a short time, thereby increasing the metal removal rate and meeting the requirement of the uniformity of the allowance. If the residual amount left after the rough turning does not meet the finishing requirements, it is necessary to arrange a semi-finishing car for finishing. The fine car needs to ensure that the outline of the part is cut according to the drawing size to ensure the processing accuracy.
Approach first and then far
Under normal circumstances, the parts close to the tool should be processed first, and then the parts far away from the tool to the tool should be processed to shorten the moving distance of the tool and reduce the empty travel time. In the process of turning, it is beneficial to maintain the stiffness of the blank or semi-finished product and improve its cutting conditions.
The principle of internal and external intersection
For parts that have both an inner surface (inner cavity) and an outer surface to be processed, when arranging the processing sequence, the inner and outer surfaces should be roughed first, and then the inner and outer surfaces should be finished. Must not be part of the surface of the part (outer surface or inner surface) after processing, then processing other surfaces (inner surface or outer surface).
Base first principle
Priority should be given to the surface used as the finishing reference. This is because the more accurate the surface of the positioning reference, the smaller the clamping error. For example, when machining shaft parts, the center hole is usually machined first, and then the outer surface and end face are machined with the center hole as the precision basis.
The principle of the first and the second
The main working surface and assembly base surface of the parts should be processed first, so as to find out the modern defects on the main surface in the blank early. The secondary surface can be interspersed, placed on the main machined surface to a certain extent, before the final finishing.
The principle of the face before the hole
The plane outline size of the box and bracket parts is large, and the plane is generally processed first, and then the hole and other sizes are processed. This arrangement of processing sequence, on the one hand with the processed plane positioning, stable and reliable; On the other hand, it is easy to process the hole on the machined plane, and can improve the processing accuracy of the hole, especially when drilling, the axis of the hole is not easy to deviate.
Conclusion
When developing the machining process of parts, it is necessary to select the appropriate processing method, machine tool equipment, clamp measuring tools, blank and technical requirements for workers according to the production type of parts.
The success or failure of aerospace operations depends on the accuracy, precision and quality of the components used. For this reason, aerospace companies utilize advanced manufacturing techniques and processes to ensure that their components fully meet their needs. While new manufacturing methods such as 3D printing are rapidly gaining popularity in the industry, traditional manufacturing methods such as machining continue to play a key role in the production of parts and products for aerospace applications. Such as better CAM programs, application-specific machine tools, enhanced materials and coatings, and improved chip control and vibration damping - have significantly changed the way aerospace companies manufacture critical aerospace components. However, sophisticated equipment alone is not enough. Manufacturers must have the expertise to overcome the material processing challenges of the aerospace industry.
Material requirements
The manufacture of aerospace parts first requires specific material requirements. These parts typically require high strength, low density, high thermal stability and corrosion resistance to handle extreme operating conditions.
Common aerospace materials include:
1. High strength aluminum alloy
High-strength aluminum alloys are ideal for aircraft structural parts because of their light weight, corrosion resistance and ease of processing. For example, 7075 aluminum alloy is widely used in the manufacture of aerospace parts.
2. titanium alloy
Titanium alloys have excellent strength to weight ratio and are widely used in aircraft engine parts, fuselage components and screws.
3. Superalloy
Superalloys maintain strength and stability at high temperatures and are suitable for engine nozzles, turbine blades and other high-temperature parts.
4. Composite material
Carbon fiber composites perform well in reducing structural weight, increasing strength and reducing corrosion, and are commonly used in the manufacture of casings for aerospace parts and spacecraft components.
What are the process characteristics of aerospace parts processing?
Process planning and design
Process planning and design are required before processing. At this stage, it is necessary to determine the overall processing scheme according to the design requirements of the parts and material characteristics. This includes determining the process of processing, the choice of machine tool equipment, the selection of tools, etc. At the same time, it is necessary to carry out detailed process design, including the determination of cutting profile, cutting depth, cutting speed and other parameters.
Material preparation and cutting process
In the process of aerospace parts processing, the first need to prepare working materials. Usually, the materials used in aviation parts include high-strength alloy steel, stainless steel, aluminum alloy and so on. After the material preparation is completed, the cutting process is entered.
This step involves the selection of machine tools, such as CNC machine tools, lathes, milling machines, etc., as well as the selection of cutting tools. The cutting process needs to strictly control the feed speed, cutting speed, cutting depth and other parameters of the tool to ensure the dimensional accuracy and surface quality of the parts.
Precision machining process
Aerospace components are usually very demanding in terms of size and surface quality, so precision machining is an indispensable step. At this stage, it may be necessary to use high-precision processes such as grinding and EDM. The goal of the precision machining process is to further improve the dimensional accuracy and surface finish of the parts, ensuring their reliability and stability in the aviation field.
Heat treatment
Some aerospace parts may require heat treatment after precision machining. The heat treatment process can improve the hardness, strength and corrosion resistance of the parts. This includes heat treatment methods such as quenching and tempering, which are selected according to the specific requirements of the parts.
Surface coating
In order to improve the wear resistance and corrosion resistance of aviation parts, surface coating is usually required. Coating materials can include cemented carbide, ceramic coating, etc. Surface coatings can not only improve the performance of parts, but also extend their service life.
Assembly and testing
Do parts assembly and inspection. At this stage, the parts need to be assembled in accordance with the design requirements to ensure the accuracy of the match between the various parts. At the same time, rigorous testing is required, including dimensional testing, surface quality testing, material composition testing, etc., to ensure that parts meet aviation industry standards.
Process characteristics
Strict quality control: The quality control requirements of aviation parts are very strict, and strict testing and control are required at each processing stage of aviation parts to ensure that the quality of parts meets the standards.
High precision requirements: Aerospace components typically require very high accuracy, including dimensional accuracy, shape accuracy and surface quality. Therefore, high-precision machine tools and tools need to be used in the processing process to ensure that the parts meet the design requirements.
Complex structure design: Aviation parts often have complex structures, and it is necessary to use multi-axis CNC machine tools and other equipment to meet the processing needs of complex structures.
High temperature resistance and high strength: aviation parts usually work in harsh environments such as high temperature and high pressure, so it is necessary to choose high temperature resistance and high strength materials, and carry out the corresponding heat treatment process.
Overall, aerospace parts processing is a highly technology-intensive, precision demanding process that requires strict operating processes and advanced processing equipment to ensure that the quality and performance of the final parts can meet the stringent requirements of the aviation sector.
Processing difficulties
Aerospace parts processing is challenging, mainly in the following areas:
Complex geometry
Aerospace parts often have complex geometrics that require high-precision machining to meet design requirements.
Super alloy processing
The processing of superalloys is difficult and requires special tools and processes to handle these hard materials.
Large parts
The parts of the spacecraft are usually very large, requiring large CNC machine tools and special processing equipment.
Quality control
The aerospace industry is extremely demanding on part quality and requires rigorous quality control and inspection to ensure that every part meets the standards.
In aerospace parts processing, precision and reliability are key. A deep understanding and fine control of materials, processes, precision and machining difficulties is the key to manufacturing high-quality aerospace parts.
1 Tool change of hat type magazineThe fixed address tool change mode is mostly adopted, and the tool number is fixed corresponding to the tool seat number. The tool change action is realized by the lateral movement of the tool magazine and the up and down movement of the spindle, which is referred to as the spindle tool change mode for short. Because it has no tool change manipulator, the tool selection action cannot be preselected before the tool change action. The tool change instruction and tool selection instruction are generally written in the same program segment, and the instruction format is as follows:M06 T
When the command is executed, the tool magazine first turns the tool holder corresponding to the tool number on the spindle to the tool change position, and switches the tool on the spindle back to the tool holder, and then the tool magazine turns the tool specified in the command to the tool change position and changes the spindle.For this tool magazine, even if TX x is executed before M06, the tool cannot be preselected, * the action of final tool selection is still executed when M06 is executed. If there is no TX X in front of M06, the system will give an alarm.2 Tool change of disc and chain magazine
Most of them use random address tool change mode. The corresponding relationship between tool number and tool seat number is random, but its corresponding relationship can be remembered by NC system. The tool change of this tool magazine depends on the manipulator. The action of the command and tool change is: the tool command TX controls the rotation of the tool magazine and turns the selected tool to the tool change working position, while the tool change command M06 controls the action of the tool change manipulator to realize the tool exchange between the spindle tool and the tool change position of the tool magazine. The tool selection command and tool change command can be in the same program segment or written separately. The actions corresponding to tool selection and tool change command can also be operated simultaneously or separately. The instruction format is as follows:
Tx x M06;When the command is executed, the tool magazine first turns the TX tool to the tool change position, and then the manipulator exchanges the tool of the tool magazine with the tool of the spindle to realize the purpose of changing the TX tool to the spindle.After reading the above two methods, it can be seen that method 2 overlaps the tool selection action with the machining action, so that when changing the tool, it is not necessary to select the tool and change the tool directly, which improves the work efficiency.
As mentioned earlier, the tool change command of the tool magazine is related to the machine tool manufacturer. For example, some tool magazines require that not only the Z axis must return to the tool change point, but also the Y axis must return to the tool change point. The program format is as follows:
When writing the instructions of tool selection and tool change in the same program section, the execution rules of tools from different manufacturers may also be different. If any, regardless of the writing order, the rules of tool selection and tool change shall be followed. Some rules stipulate that the tool selection command must be written before the tool change command is executed. Otherwise, the action is to change the tool first and then select the tool, as shown in the above program. In this case, if the tool selection command is not written before the M06 command is executed, the system will give an alarm.
CNC metalworking is replacing other manufacturing technologies in multiple industries. The medical field is considered an area where mistakes are rare, and the same rules apply when it comes to manufacturing medical parts, because human lives are at stake in this field, and even small mistakes can lead to serious health problems or even death. Therefore, the machining techniques that machinists use to produce medical parts must support tight tolerances and high-precision measurements.
CNC metalworking is growing in popularity due to its ability to mass-produce detailed and precise results, which has led to an increase in the number of producers using CNC machines in the industry.
CNC machining is a manufacturing method in which the tool movement is controlled by pre-programmed computer software. All medical products can be manufactured accurately and quickly with the help of CNC milling and turning. Let's look at the main advantages of CNC machining demand in the healthcare industry:
No fixed tool
CNC machining is unmatched in terms of fast turnaround and minimal investment in small batch production, even in disposable products. Parts for the medical industry often have to be manufactured quickly and in small batches. At the same time, CNC metalworking allows parts to be manufactured without dedicated tools, which can extend the manufacturing process but provide excellent quality and precision even without the use of tools.
No quantity limit
After you create a digital CAD (Computer Aided Design) file, you can easily build a cutting program from it at the touch of a button. The coding application can manufacture a single part or any number of parts with the highest precision and accuracy. This is a huge benefit when creating disposable or disposable custom parts, such as highly specialized medical devices, appliances, equipment, prosthetics, and other medical or surgical products. Other procedures require a minimum order size to obtain the required raw materials, making certain projects impractical, while CNC machining does not require a minimum order size.
High tolerance
Many medical types of equipment require a large tolerance range, and with CNC machines, this is easily achieved. The surface finish is usually very good and requires minimal post-treatment, saving time and money, but this is not the most important consideration. In general, the most important thing to remember about medical supplies and equipment is that they must be fit for their purpose, and any deviation from the standard can mean disaster.
Fast machine
CNC machines are faster and can work 24 hours a day, 365 days a year. Apart from routine maintenance, repairs and upgrades are the only time manufacturers stop using equipment.
Digital CAD files are lightweight and flexible
Product designers, medical specialists, and manufacturing professionals can quickly and easily transfer digital programs from one location to another. The technology significantly improves CNC machining capabilities to produce high-quality specialty medical devices and equipment solutions, regardless of geographic location, whenever and wherever they are needed. This feature of CNC machining is very convenient, especially in time-critical medical environments.
How is CNC Machining changing the healthcare industry
CNC machining has revolutionized the way medical devices and devices are designed, manufactured, personalized, and used. The precision, customization and speed of CNC machining transform patient care, enabling personalized treatment and improving surgical outcomes.
The technology paves the way for breakthrough innovations in prosthetics, devices, and therapeutics, and drives advances in many areas of healthcare.
CNC machining brings many advantages to the medical field, including:
Precision and accuracy
The operation precision of CNC machine tools is extremely high. This level of precision is essential for the production of surgical instruments, implants and micro-devices used in minimally invasive surgery. The precision and consistency provided by CNC machining improves performance during medical procedures and reduces the risk of complications.
This is especially important for surgeons who rely on ultra-sophisticated and reliable instruments to perform delicate tasks. From scalpel handles to robotic surgical assistants, CNC machining provides high-quality tools that improve accuracy and patient safety.
Customization and personalization
CNC machining enables the creation of personalized medical parts and devices based on a patient's unique anatomy. This ability makes it possible to create personalized orthopedic implants, dentures, hearing AIDS and other devices.
Using patient-specific data such as 3D scans or MRI images, CNC machines can precisely create items that fit perfectly to the patient's body. This improves comfort, function and treatment effectiveness, and accelerates patient recovery.
Complex shape and structure
CNC machining can produce complex geometries and complex internal structures that are often difficult to achieve with other manufacturing methods. The ability to precisely carve internal cavities, channels, and delicate features is especially valuable when manufacturing implants, microdevices, and surgical instruments.
Rapid prototyping
Prototyping allows medical engineers and designers to create functional models of parts and devices, enabling them to evaluate design, assembly, and functionality before starting production. The combination of computer-aided design (CAD) software and CNC machine tools allows digital designs to be quickly translated into physical prototypes.
This allows for iterative design improvements and helps ensure that medical devices are thoroughly tested and optimized prior to release. In an evolving field, rapid prototyping can enhance innovation and help bring new medical advances to market faster.
Process optimization
The integration of CNC machining with advanced technologies such as automation and artificial intelligence (AI) minimizes errors and enables automated quality control processes. This increases efficiency, reduces production time and improves product quality, all of which contribute to improved patient outcomes.
In addition, automated CNC systems can operate continuously with minimal human-machine interaction between operations. Some CNC machines are also capable of multi-axis machining and performing tasks on different surfaces of parts at the same time.
By reprogramming machines, manufacturers can quickly switch between producing one type of part and another. This reduces conversion times and means that different parts can be made on the same machine in a single shift. These features help speed up production cycles, reduce downtime, and increase overall production.
Flexible material selection
CNC machining is suitable for a wide range of materials, including metals, plastics and composites. This versatility enables manufacturers to consider factors such as biocompatibility, durability and functionality to select the most appropriate material for a specific medical application.
Cost saving
Although industrial CNC machines can be expensive, they offer significant cost saving opportunities in the long run. By eliminating the need for dedicated jigs, fixtures, and dedicated tools for each part, CNC machining helps minimize setup time, simplify production, and reduce manufacturing costs.
The technology also reduces waste and costs through material optimization. This is especially important in the medical field, as implants are often made with high-value materials such as titanium and platinum. The increased efficiency and productivity of CNC machining also contribute to cost savings over time.
What are CNC processed medical products?
Due to the critical nature of medical devices and components, the medical industry requires high-quality and high-precision products. Therefore, CNC machining is widely used in medical applications. Below, we will introduce what CNC machining medical products are?
1. Medical implants
Orthopedic implants: CNC machining is commonly used to manufacture orthopedic implants, such as hip and knee replacements.
Dental implants: Use CNC machining to manufacture precise and customized dental implants.
2. Electronic medical equipment
MRI components: Some components of magnetic resonance imaging (MRI) machines, such as structures, brackets, and housings, are often machined using CNC.
Diagnostic equipment enclosures: CNC machining is used to manufacture enclosures and housings for a wide range of medical diagnostic equipment, ensuring precise dimensions, durability, and compatibility with electronic components.
3. Medical surgical instruments
Scalpels and blades: CNC machining is used to produce surgical instruments such as scalpels and blades.
Tweezers and clamps: Surgical instruments with complex designs, such as tweezers and clamps, are usually CNC machined to achieve the desired accuracy.
4. Prosthetics and orthotics
Custom prosthetic components: CNC machining is used to manufacture custom prosthetic components, including acceptance chamber components, joints, and connectors.
Orthopedic brackets: Components of orthopedic brackets that provide support and alignment to various parts of the body can be CNC machined.
5. Endoscope assembly
Endoscope housings and parts: CNC machining is used to produce parts of endoscope equipment, including housings, connectors, and structural parts.
6. Prototype medical equipment
Prototyping components: CNC machining is widely used for rapid prototyping of various medical devices.
Finally, machining medical devices is a process that requires a high level of precision and accuracy. Therefore, the technology is very suitable for CNC machining.
Honscn Precision is a reliable manufacturer of medically critical components for surgical instruments and tools as well as medical device prototyping. With 20 years of experience in CNC manufacturing, we are driven by the need to ensure the closest tolerances and accuracy for each machined part. Our skilled mechanics can tailor machined parts designs to the highest standards for all aspects of the medical industry. Do you want to start your CNC machining project at Honscn Precision?Click here to start your custom service
Why CNC machining stands out?
Previous machines which were known as numerical control machines (NC) located their positions via G-codes. These G-codes were manipulated manually by the user unlike in CNC machining whereby this task is computerized. In the most recent versions known as the parametric program, logical commands have been fixed in a manner that they can work together with these G-codes. This modified version allows users to regulate and manipulate system parameters effortlessly.
Benefits of using CNC machines:
The improvement in technology used in the manufacturing of these machines has brought about a number of benefits.
These include the following:
- There is improved speed, accuracy, productivity and efficiency of tasks - They significantly reduce the incidents of accidents since computerized systems minimize the contact between the tools and the user. This makes the metalworking process a more comfortable undertaking.
CNC Milling Machines:
CNC milling machines function by using a computerized system to transmit signals to a stepper motor controller. This system instructs the stepper motor on the direction to follow and the number of steps it is supposed to take. The motor is linked to the drive mechanism of the mill in the X, Y and Z axes. Some CNC milling machines are known to utilize a servo motor as a replacement for the stepper motor. They have below mentioned advantages:
- Metals can be cut at higher rates - Servo motors have a feedback loop which enables the machine to accurately resume to its initial position.
How to find the best CNC milling machines?
These machines have become essential in very many facets of life especially in the running of our businesses. The purchasing of this machines entail that you have to find the right kind of supplier or dealer. The following are tips to assist you in identifying the most ideal place where the machines can be obtained from:
- Check the quality of the milling machine. Visit online forums to get information on the available brands in the market and the most reliable brands according to customer reviews.
- Choose a supplier or dealer with professional staff and highly skilled personnel to repair your milling machine if it breaks down - If you are looking for a cost cutting option, some suppliers deal with second hand milling machines so, pursue such options.
Maintaining your CNC milling machine:
Once you have your milling machine purchased, some important tips can be followed to keep it in top condition. These machines are usually maintained by a set up process. This includes the below procedures:
- Wipe the table to the T-holder to keep it free it from fragments and rust.
- Place its vise down and tighten it with bolts. Straighten the vices using an indicator - Place every tool into collects and ensure they are safely locked.
- Set the collets into the changer of the tool as per to the manual of the machine.
- Confirm if the machine "knows" where it ought to stop. This is to guarantee that the machine makes an accurate cut. - Set the spindle on the zero point then ignite the machine again on the X and Y axes - Next, locate the Z point by lowering the spindle to the top of material. This point will be used as a reference in cutting other materials.
This simple setting up process guarantees that the CNC machining machine works efficiently for years on end. This process is to be repeated whenever the machine is heavily used.