With the arrival of the world's fourth industrial revolution, and the continuous development of science and technology and social production, mechanical manufacturing technology has undergone profound changes, the structure of mechanical products is more and more reasonable, and its performance, accuracy and efficiency are increasingly improved, so the production equipment of processing mechanical products has put forward high performance, high precision and high automation requirements. In order to solve the problem that ordinary machine tools can not be produced, to achieve single and small batch production, especially the automatic processing of some complex parts, CNC machining came into being.

Although, at present, China has become a processing country, precision parts processing plants all over the country. According to the data of the General Administration of Customs of China, in January and February 2023, the cumulative export volume of China's machine tools reached 2364123 units (2,364,100 units), from high-end CNC customized precision parts to ordinary standard products can achieve standardized mass production, the application of CNC technology can realize the automatic processing of parts and improve production efficiency. Especially in the automotive manufacturing, aerospace, electronic equipment manufacturing and other fields, the application of CNC technology has great potential. The application of CNC technology can realize the automatic processing of parts and improve production efficiency. Especially in the automotive manufacturing, electronic equipment manufacturing and other fields, the application of CNC technology has great potential.

CNC machining is widely used in the field of automotive parts, involving the engine, transmission, chassis, braking system, steering system and other aspects. However, no matter in any field of precision machining, achieving high precision and high speed is an important competitive means to obtain user orders.



The following are some specific applications of CNC machining in the field of automotive parts:

Engine parts machining: CNC machining can be used to manufacture various parts of the engine such as cylinder block, crankshaft, connecting rod, valve seat, etc., which require high precision and high strength.



1.Transmission parts processing: CNC machining can be used to manufacture various parts of the transmission system such as transmission gears, clutches, transmission shafts, etc., which require high precision and high strength.

2.Brake parts processing: CNC machining can be used to manufacture various parts of the brake system such as brake discs, brake pads, brakes, etc., which require high precision and high quality.

3.Steering parts processing: CNC machining can be used to manufacture various parts of the steering system such as steering gear, steering rod, steering machine, etc., these parts need high precision and high strength.



With the continuous development of CNC machining technology and the expansion of application fields, whether it is automobile body design or automobile internal electronic parts processing, the application range of CNC custom machining technology in the field of automation will be more and more extensive. In the future, CNC machining technology will continue to play an important role in the automotive manufacturing field.

With the increasingly updated processing technology, CNC machining has also undergone a lot of changes. Many experts pointed out that in the future, CNC will be the mainstream processing mode. In the CNC machining process, the tool is the most important, today, we will understand the CNC tool in detail.




CNC machining tool concept



A tool is a tool used for cutting in mechanical manufacturing. Generalized cutting tools include both cutting tools and abrasive tools. The vast majority of knives are used for machines, but there are also hand tools. Since the tools used in mechanical manufacturing are basically used to cut metal materials, the term "tool" is generally understood as a metal cutting tool. The cutting tools used for cutting wood are called woodworking tools.


CNC machining tool



Tool classification

Cutting tools can be divided into five categories according to the form of the workpiece machined surface.

Cutting tools for processing various outer surfaces, including cutting tools for processing various outer surfaces, including turning tools, planing knives, milling cutters, outer surface broach and file, etc.

Hole processing tools, including drill, reaming drill, boring cutter, milling cutter and internal surface broach, etc.

Thread processing tools, including tap, die, automatic opening thread cutting head, thread turning tool and thread milling cutter.

Gear processing tools, including hob, gear shaper cutter, shaving cutter, bevel gear processing tool, etc.

Cutting tools, including inserted circular saw blade, band saw, bow saw, cutting tool and saw blade milling cutter, etc.

In addition, there are combination tools.


Hole cutting tool



Tool structure

The structure of various tools is composed of a clamping part and a working part. The clamping part and working part of the overall structure of the tool are done on the tool body; The working part of the tool (the tooth or blade) is mounted on the tool body.

The clamping part of the tool has two kinds of holes and handles. The tool with hole relies on the inner hole set on the spindle or mandrel of the machine tool, and transmits the torsional torque with the help of the axial key or the end key, such as the cylindrical milling cutter and the sleeve face milling cutter.

The tool with the handle is usually rectangular handle, cylindrical handle and conical handle three kinds. Turning tools, planing tools, etc. are generally rectangular handles; The conical handle withstands the axial thrust with the taper and transmits the torque with the help of friction. Cylindrical shank is generally suitable for smaller twist drill, end mill and other tools, cutting with the help of the friction generated when clamping torque transfer. The shank of many tools with handles is made of low alloy steel, and the working part is made of high speed steel welded to each other.



The basic properties that the tool material should have

1. High hardness

The hardness of the tool material must be higher than the hardness of the workpiece material to be machined, which is the basic feature that the tool material should have.

2. Sufficient strength and toughness

The material of the cutting part of the tool must withstand great cutting force and impact force when cutting. The bending strength and impact toughness reflect the ability of tool material to resist brittle fracture and edge breakage.

3. High wear resistance and heat resistance

The wear resistance of tool materials refers to the ability to resist wear. The higher the hardness of the tool material, the better the wear resistance; The higher the high temperature hardness, the better the heat resistance, the tool material at high temperature resistance to plastic deformation, anti-wear ability is also stronger.

4. Good thermal conductivity

Large thermal conductivity means good thermal conductivity, and the heat capacity generated during cutting is easily transmitted out, thereby reducing the temperature of the cutting part and reducing tool wear.

5. Good technology and economy

In order to facilitate manufacturing, the tool material is required to have good machinability, including forging, welding, cutting, heat treatment, grindability and so on. Economy is one of the important indexes to evaluate and promote the application of new tool materials.

6. Resistance to bonding

Prevent the workpiece and the tool material molecules under the action of high temperature and high pressure adsorption bond.

7. Chemical stability

It means that the tool material is not easy to react chemically with the surrounding medium at high temperature.

Tool coating

Aluminum alloy indexable inserts are now coated with hard or composite layers of titanium carbide, titanium nitride, alumina by chemical vapor deposition. The physical vapor deposition method that is being developed can be used not only for aluminum alloy tools, but also for high-speed steel tools such as drills, hobs, taps and milling cutters. As a barrier that prevents chemical diffusion and heat conduction, the hard coating slows down the wear rate of the tool during cutting, and the life of the coated blade is about 1 to 3 times higher than that of the uncoated blade.




How to choose a tool



Tool selection is carried out in the human-machine interaction state of NC programming. The tool and handle should be correctly selected according to the machining capacity of the machine tool, the performance of the workpiece material, the processing procedure, the cutting amount and other relevant factors.

The general principle of tool selection: easy installation and adjustment, good rigidity, high durability and accuracy. On the premise of meeting the processing requirements, try to choose a shorter tool handle to improve the rigidity of the tool processing. When selecting the tool, the size of the tool should be adapted to the surface size of the workpiece to be machined.

1. End milling cutter is often used to process the peripheral outline of plane parts.

2. When milling the plane, carbide blade milling cutter should be selected.

3. When processing convex and grooves, choose high-speed steel end milling cutter.

4. When processing the blank surface or roughing the hole, you can choose the corn milling cutter with cemented carbide blade.

5. For the processing of some vertical surface and variable bevel contour, ball end milling cutter, ring milling cutter, conical milling cutter and disk milling cutter are often used.

6. In the processing of free-form surface, because the cutting speed of the end of the ball head tool is zero, so in order to ensure the processing accuracy, the cutting line spacing is generally very dense, so the ball head is often used in the finishing of the surface.

7, flat head tool in the surface processing quality and cutting efficiency are better than the ball head knife, therefore, as long as the premise of ensuring but cutting, whether it is rough surface machining or finishing, should be preferred to choose flat head knife.

8. In the machining center, various tools are installed on the tool library, and the tool selection and tool change are carried out at any time according to the procedure. Therefore, the standard tool handle must be used in order to make the standard tool for drilling, boring, expanding, milling and other processes quickly and accurately installed on the machine spindle or tool library. The number of tools should be reduced as far as possible; After a tool is installed, it should complete all the processing parts that it can carry out; Rough finishing tools should be used separately, even if the same size specifications of the tool; Milling before drilling; Surface finishing is carried out first, and then 2D contour finishing is carried out. Where possible, the automatic tool change function of CNC machine tools should be used as much as possible to improve production efficiency.


Problems encountered in processing aluminum and solutions



Problems encountered in processing aluminum and solutions when processing pure aluminum, easy to stick knife analysis and solutions:

1. Aluminum material is soft in texture and easy to stick at high temperature;

2. Aluminum is not resistant to high temperature, easy to open;

3. Related to processing cutting fluid: good oil lubrication performance; Good water-soluble cooling performance; High dry cutting cost;

4. When processing pure aluminum, the end mill dedicated to aluminum processing should be selected: positive front Angle, sharp cutting edge, large chip discharge slot, 45 degrees or 55 degrees helix Angle;

5. The material of the workpiece and the CNC tool has a greater affinity.

6. Rough front tool processing soft materials.

Recommendation: Machine tool conditions are poor to good requirements are low to high, please use high-speed steel, coated polished carbide, PCD polycrystalline diamond and single crystal diamond.

7. Low speed can be avoided by cutting fluid, high speed oil mist lubrication, the effect can be improved, aluminum alloy suitable


Tool future development direction



Due to the high temperature, high pressure, high speed, and the parts working in the corrosive fluid medium, the application of difficult to process more and more materials, the automation level of cutting processing and the processing accuracy requirements are getting higher and higher. In order to adapt to this situation, the development direction of the tool will be the development and application of new tool materials; Further develop the vapor deposition coating technology of the tool, and deposit higher hardness coating on the matrix of high toughness and high strength, so as to better solve the contradiction between hardness and strength of the tool material; Further development of indexable tool structure; Improve the manufacturing accuracy of the tool, reduce the difference in product quality, and optimize the use of the tool.How to choose CNC aluminum alloy machining tool.

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.

Nowadays, smart phones have changed from plastic back cover to thin metal body. Although the smart appearance attracts consumers, the production process of mobile phone case parts suppliers is more difficult. Only because the cutting and processing of the case requires quite high precision, even if it is only a small deviation, it may cause workpiece scrapping and erode profits.


In order to improve the yield of CNC processing, mobile phone box manufacturers are often forced to change tools frequently to ensure that CNC machines maintain a normal production beat, but this leads to an increase in the cost of consumables and also affects profits. In addition, the mobile phone case processing industry attaches great importance to the production rate, for fear that the sudden failure of CNC cutting machine will lead to negative chain reactions such as production capacity decline and delivery delay, which will damage customer satisfaction and goodwill. Therefore, it allocates manpower to carry out regular inspection and entrusts outsourcers to provide second-line maintenance support, but these methods are passive, It is difficult to effectively deal with abnormal conditions at the first time.
Mobile phone case is one of the cases of CNC machine application. CNC cutting is widely used in various processing and manufacturing, and various suppliers are facing a similar profit defense war. Xu Changyi, manager of Linghua technology measurement and automation products division, believes that whether you want to improve the machining accuracy or increase the productivity, the axe bottom salary drawing plan is to monitor the cutting process, especially the vibration monitoring, mainly because once the vibration value of the machine rises beyond the reasonable range due to imbalance, resonance or misalignment, It is easy to affect the operation of the machine, resulting in fault shutdown.
PC based monitoring solution is better than PLC solution to capture fine vibration signals
If the CNC processing machine can be endowed with intelligence and built with a set of full-time vibration monitoring mechanism, it can diagnose the health state of the machine at any time. Instead of waiting for the output of the final finished product and judging the cause of the abnormality afterwards, it can detect the unusual state of the processing machine in real time through preventive detection in advance and take corresponding treatment measures quickly, Including optimizing and adjusting processing parameters (such as changing spindle speed), or changing tools, etc. to solve small deviations immediately and avoid causing major disasters in the future.
It can not be denied that the cutting vibration monitoring of CNC machining machines is not a new topic at this moment. In the past, there were some PLC solutions with the demand of simplicity and convenience, which boasted that as long as the CNC machine was connected, it could produce utility quickly; Therefore, it is inevitable that some people wonder why PC based monitoring scheme is needed since PLC is available to assist in cutting vibration monitoring?
The so-called devil lies in the details. Some subtle vibration signals or high-frequency signals reflect some facts to some extent. It may be that the connecting mechanism begins to be unbalanced, the rotating spindle bearing ball breaks and affects the transmission power, or the fasteners become loose, which means that the CNC machining machine begins to "get sick", and the symptoms are different with the different machine characteristics; These subtle and changeable signs are not easy to capture by virtue of the PLC solution with the characteristics of low sampling rate, supporting limited bandwidth range and fixed algorithm. If the CNC monitoring solution can capture small changes and help users quickly grasp the key factors that may lead to reduced accuracy or capacity decline, they can respond as soon as possible.
In view of this, Linghua launched a cutting vibration monitoring scheme called mcm-100, which boasts that it can carry out 24-hour continuous data acquisition and vibration measurement for rotating transfer machinery and equipment under the condition of high precision and high sampling rate, and integrate the functions of data collection, vibration analysis and calculation, operation, Internet access and so on, Assist CNC machine users to successfully solve various challenges faced by traditional cutting process, and endow CNC machine with intelligence in the most relaxed and burden-free way.Achieve the wonderful effect of preventive maintenance through high-precision monitoring
Xu Changyi explained that generally speaking, there are three detection situations that CNC machines most want to establish. One is "spindle vibration detection", which aims to monitor the vibration of the spindle during cutting. The method is to directly measure the RMS value of the time domain signal. If it exceeds the critical value, reduce the speed or stop running; The second is "bearing quality diagnostic tic", which is intended to diagnose the health status of bearings. It is carried out when CNC does not perform cutting and only idles at high speed; The third is "spindle collision detection", which is used to detect the spindle collision. When the vibration wave pattern meets some default conditions, it is judged that the collision has occurred, and the spindle movement is stopped immediately.
The above situations 1 and 2 are closely related to the accuracy and bandwidth range of vibration signals. PLC solutions can capture very little information, which is difficult to help users establish contingency strategies; In contrast, mcm-100 not only has 24 bit high resolution capability (generally falling in the range of 12 or 16 bit), but also can capture high-frequency signals with a sampling rate of up to 128ks / S (generally only supporting 20Ks / s or even lower), so as to provide users with more vibration analysis materials.New business opportunities for CNC machine equipment manufacturers
On the other hand, the cutting vibration monitoring scheme can also create new business opportunities for CNC machine equipment manufacturers. As CNC machine equipment suppliers are exposed to a large amount of vibration information, once combined with big data analysis, they have a more thorough understanding of the correlation between signal changes and machine failures. CNC machine equipment suppliers can make good use of the accumulated knowledge assets, give birth to value-added services, and even adjust their business model from selling out equipment to selling machine operation hours, Establish long-term stable income. According to Linghua technology, the operator of PC based cutting vibration monitoring scheme, the vibration monitoring scheme has entered the landing stage and has been adopted by various well-known CNC tool machine manufacturers, and its demand has increased significantly in 2017, which shows that both CNC processors and CNC tool machine manufacturers have increasingly keen demand for CNC cutting vibration monitoring scheme.

Shenzhen, China With an array of advanced machining equipments and a team of qualified and experienced technicians and engineers, Runsom Precision boasts of supplying custom machined parts to their industrial clients in a timely manner. According to the spokesperson of the company, they can ship the custom machining parts within 48 hours of receiving the order from the client.
The spokesperson reveals that they maintain a streamlined machining process that makes them capable of shipping China machining parts that precisely meet the specifications supplied by a client. By supplying precision and custom parts in a timely and regular manner, they allow their industrial clients to keep innovating and producing new goods to gain a competitive advantage in the market. They deliver precision machined components within the scheduled time for industries to carry out their production work continually and without any interruption.
According to the spokesperson, they enjoy an excellent reputation in the industry for their outstanding China machining service . They maintain high precision of all machined components, including the holes, axis and the center distance. Moreover, they employ multiple machines for different types of components to help achieve the highest possible degree of precision. The multiple-machining technique proves very important to reduce the production cost and also shortens the project duration. This also gives them the ability to process complex components that need to pass through different machining processes.
Not only cost and customization, but Runsom Precision also focuses on the quality when it comes to supplying CNC Machining parts . The spokesperson maintains that their machining process is strictly according to the ISO 9001:200 standards and the machining of each component is monitored for their quality. According to him, with a stringent quality control measure, they take extra care to make sure that defect free machined parts are delivered to the clients. Their custom machining ensures that clients get the product that exactly meets their specification.
To know more about their machining process, one can visit their website
About Runsom Precision
Runsom Precision Co. Ltd, established since 2005, is a professional, customized, high precision machined components manufacturer based in Shenzhen, China. With years of experience in the manufacturing and services of CNC machined parts, precision engineering components, custom machined parts, Precision CNC machining service, injection molding parts and die casting parts, the company has established a high reputation for their high quality and nice service. They are able to provide one-stop services from initial concept to finished products.
Contact:
Lucy Zhang (sales)
Company: Runsom precision co.,ltd
Phone no: 86-755-3309675