Shop Best 5 Axis Cnc Machining in HONSCN
It is universally acknowledged that 5 axis cnc machining stands as Honscn Co.,Ltd's main and featured product. We have gained wide recognition and high appraises from all over the world for the product with our pro-environment adherence and strong dedication to sustainable development. Research and development and comprehensive market research have been thoroughly conducted before it is launched so that it highly meets the market demand.
As social media has emerged as a valuable platform for marketing, HONSCN pays increasing attention to reputation building online. By giving top priority to quality control, we create products with a more stable performance and greatly reduce the repair rate. The products are well received by the customers who are also active users in social media. Their positive feedback helps our products spread around the Internet.
We pride ourselves with outstanding services that make our relationship with customers as easy as possible. We are constantly putting our services, equipment, and people to the test in order to better serve customers at Honscn. The test is based on our internal system which proves to be high efficiency in the improvement of service level.
In the field of machining industry, the precision size control of drawings plays a vital role, which directly affects the assembly performance and quality of mechanical equipment. The main factor affecting the size of precision machining is the error problem, because the error problem is affected by a variety of factors, in the machine precision machining will inevitably appear a variety of error problems, so only the use of various technical measures, the precision control in a scientific range. This requires technical personnel to strictly process according to the production drawings, and strictly require the machining process flow, so as to ensure the accuracy of the size of the precision machining production drawings to the greatest extent.
Today, with the rapid development of social economy and industrial reform, the role played by precision machining has become more and more important, and China's machining industry has also made great progress, not only the quality has been greatly improved, but also greatly expanded in the scale of production. With the development of the industrialization process, the precision of precision machining is also more and more attention, therefore, it is necessary to strengthen the control of precision in the process of machining (precision machining process, the control of precision must be attached great importance, and take reasonable technical measures to solve the problems.
Content of machining and influencing factors
1
/
Understand the content of machining
In the field of mechanical processing in China, there is a clear definition of the accuracy of mechanical processing, which refers to the professional and technical personnel after the completion of the processing of mechanical parts, the use of instruments to detect the position of the parts, shape, size and related data, so as to determine the degree of compliance of the parts. Generally speaking, the main factor affecting the accuracy of machining is the various errors generated in machining, and the operators and technical units of technical processing must attach great importance to this problem. In machining, the control and grasp of precision are obviously related to the error problem of machining. Machining error is mainly reflected by the shape, size and position, it is through the use of mechanical size control to achieve the purpose of controlling the precision of machining, in ensuring the surface quality of machining, the machining size error control within a reasonable range. In the process of machining, due to the impact of the benchmark and the machining surface, it will cause the deviation of the position of the precision parts, so the verticality, position and parallelism of the precision machining must be strictly controlled.
2
/ Factors affecting precision machining accuracy
In the process of precision machining, there are strict requirements for various production technologies and production processes, so as to reduce or even eliminate the purpose of machining technology errors. In machining, the error between the spindle rotation is an important factor affecting the accuracy. In the process of modern mechanical production and processing, the error caused by the spindle rotation problem is very obvious, which is more obvious in high-tech and high-precision products, which is also an important factor affecting the processing. For the resulting error, the error can be reduced by processing and transforming the machinery. In addition, bearings with higher precision can also be used, which can also significantly reduce the resulting error.
In addition to the error caused by the spindle rotation, the error caused by the problem of the fixture and the tool can not be ignored. Due to the requirements of production, machining manufacturers will renovate the size, type and model of fixtures and tools to a certain extent, which will have a greater impact on the accuracy of machining. In the actual processing process, the size of the fixture and the tool are fixed, which makes it impossible to adjust the size of the fixture and the tool in the process of production and processing. This will cause a certain error flow in the mechanical processing when the technical parameters and the working environment change.
In addition, due to the process of using and installing fixtures and tools, the position of fixtures and tools will be changed, resulting in errors. Of course, the cutting force will also have a certain impact on the machining, resulting in the generation of errors, and ultimately the accuracy of the machining. Due to the influence of the external environment and temperature, the machined parts can easily affect the cutting force. The greater accuracy error is caused by the local change of the process system and the overall deformation. In the process of mechanical production and processing, if the change of the direction of the tightening degree and the insufficient stiffness of the parts are affected, the deformation of the machined parts will be caused, and the machining will produce a lot of errors, which will affect the precision control of the machining.
Technical measures to control machining accuracy
In the process of mechanical production and processing, the problem of processing accuracy must be strictly controlled, and the accuracy problem must be comprehensively considered, so the processing accuracy of each part must be greatly improved, so as to improve the accuracy of the entire mechanical equipment. In the process of machining, the original error plays an important role in ensuring the quality of machining. For mechanical components, it is necessary to classify them according to the requirements of relevant regulations, according to the material, type, model, size and use, and then develop a certain accuracy range, and control the precision error of the machined parts within this range. For the technical staff, it is necessary to determine a reasonable range of the error generated in the machining, and make reasonable adjustments to the fixture and the tool, so as to control the error within this reasonable range, and ultimately reduce the error of the part to the greatest extent. Only by controlling the errors in machining, can the precision control of machining be achieved to the maximum extent, so as to achieve the purpose of improving the precision of machining.
Compensating error method
Error compensation method refers to the use of processing means to achieve error compensation after the machining of mechanical parts, so as to achieve the purpose of reducing the error in the processing of parts. Compensation error method is a very important technical measure to solve the stiffness problem of the process. The main principle is to compensate the original error by creating a new error, so as to improve the precision control level in precision machining. Error compensation method is an important means to reduce the machining error, which has been widely used in practice at home and abroad. In domestic regulations, the original error is generally represented by a negative number, and the compensation error is specified as a positive number, so that when the original error and the compensation error are closer to zero, the smaller the machining error.
Of course, the methods of reducing errors and improving precision control are not only these two, but also the transfer error method is a more commonly used method of reducing errors. Therefore, in the actual production process, it is necessary to choose a reasonable method to reduce the error according to different situations, so as to achieve the best precision control and promote the continuous and stable development of precision machining.
Today, with the rapid development of social economy and industrial reform, the role played by precision machining has become more and more important, and China's machining industry has also made great progress, not only the quality has been greatly improved, but also greatly expanded in the scale of production. With the development of the industrialization process, the precision of precision machining is also more and more attention, therefore, it is necessary to strengthen the control of precision in the process of machining (precision machining process, the control of precision must be attached great importance, and take reasonable technical measures to solve the problems.
Content of machining and influencing factors
1
/
Understand the content of machining
In the field of mechanical processing in China, there is a clear definition of the accuracy of mechanical processing, which refers to the professional and technical personnel after the completion of the processing of mechanical parts, the use of instruments to detect the position of the parts, shape, size and related data, so as to determine the degree of compliance of the parts. Generally speaking, the main factor affecting the accuracy of machining is the various errors generated in machining, and the operators and technical units of technical processing must attach great importance to this problem. In machining, the control and grasp of precision are obviously related to the error problem of machining. Machining error is mainly reflected by the shape, size and position, it is through the use of mechanical size control to achieve the purpose of controlling the precision of machining, in ensuring the surface quality of machining, the machining size error control within a reasonable range. In the process of machining, due to the impact of the benchmark and the machining surface, it will cause the deviation of the position of the precision parts, so the verticality, position and parallelism of the precision machining must be strictly controlled.
2
/ Factors affecting precision machining accuracy
In the process of precision machining, there are strict requirements for various production technologies and production processes, so as to reduce or even eliminate the purpose of machining technology errors. In machining, the error between the spindle rotation is an important factor affecting the accuracy. In the process of modern mechanical production and processing, the error caused by the spindle rotation problem is very obvious, which is more obvious in high-tech and high-precision products, which is also an important factor affecting the processing. For the resulting error, the error can be reduced by processing and transforming the machinery. In addition, bearings with higher precision can also be used, which can also significantly reduce the resulting error.
In addition to the error caused by the spindle rotation, the error caused by the problem of the fixture and the tool can not be ignored. Due to the requirements of production, machining manufacturers will renovate the size, type and model of fixtures and tools to a certain extent, which will have a greater impact on the accuracy of machining. In the actual processing process, the size of the fixture and the tool are fixed, which makes it impossible to adjust the size of the fixture and the tool in the process of production and processing. This will cause a certain error flow in the mechanical processing when the technical parameters and the working environment change.
In addition, due to the process of using and installing fixtures and tools, the position of fixtures and tools will be changed, resulting in errors. Of course, the cutting force will also have a certain impact on the machining, resulting in the generation of errors, and ultimately the accuracy of the machining. Due to the influence of the external environment and temperature, the machined parts can easily affect the cutting force. The greater accuracy error is caused by the local change of the process system and the overall deformation. In the process of mechanical production and processing, if the change of the direction of the tightening degree and the insufficient stiffness of the parts are affected, the deformation of the machined parts will be caused, and the machining will produce a lot of errors, which will affect the precision control of the machining.
Technical measures to control machining accuracy
In the process of mechanical production and processing, the problem of processing accuracy must be strictly controlled, and the accuracy problem must be comprehensively considered, so the processing accuracy of each part must be greatly improved, so as to improve the accuracy of the entire mechanical equipment. In the process of machining, the original error plays an important role in ensuring the quality of machining. For mechanical components, it is necessary to classify them according to the requirements of relevant regulations, according to the material, type, model, size and use, and then develop a certain accuracy range, and control the precision error of the machined parts within this range. For the technical staff, it is necessary to determine a reasonable range of the error generated in the machining, and make reasonable adjustments to the fixture and the tool, so as to control the error within this reasonable range, and ultimately reduce the error of the part to the greatest extent. Only by controlling the errors in machining, can the precision control of machining be achieved to the maximum extent, so as to achieve the purpose of improving the precision of machining.
Compensating error method
Error compensation method refers to the use of processing means to achieve error compensation after the machining of mechanical parts, so as to achieve the purpose of reducing the error in the processing of parts. Compensation error method is a very important technical measure to solve the stiffness problem of the process. The main principle is to compensate the original error by creating a new error, so as to improve the precision control level in precision machining. Error compensation method is an important means to reduce the machining error, which has been widely used in practice at home and abroad. In domestic regulations, the original error is generally represented by a negative number, and the compensation error is specified as a positive number, so that when the original error and the compensation error are closer to zero, the smaller the machining error.
Of course, the methods of reducing errors and improving precision control are not only these two, but also the transfer error method is a more commonly used method of reducing errors. Therefore, in the actual production process, it is necessary to choose a reasonable method to reduce the error according to different situations, so as to achieve the best precision control and promote the continuous and stable development of precision machining.
Long long agoOnce upon a time, people said that the country is an important weaponIt refers to the imperial jade seal handed down by Qin Shihuang on behalf of the heavenly power
Later, it generally refers to the jade seal carved by emperors of all dynastiesOn October 5, 2016, Sotheby's auction house auctioned the Hotan green jade seal "the treasure of the supreme emperor" used by one party after the reign of Emperor Qianlong in Hong Kong for HK $91.48 million. At that time, the auction aroused fierce opposition from many parties in China.Nowadays, the title of national heavy weapon refers to manufacturing equipment
Manufacturing equipment determines the level of processing and manufacturingThe level of processing and manufacturing is an intuitive expression of a country's national strengthHowever, what we are talking about today is only this kind of national manufacturing equipment
CNC machining centerIt can not only process and manufacture precision workpieces full of mechanical beautyCNC itself is also an exquisite and elegant industrial creation
(just a little loud)DMG GM 16|6 series six axis automatic turning centerThat's so bad
What can this CNC machining center do?Let's say soIt is known as the top industrial manufacture with the highest difficulty in R & D and manufacturing
Which can best reflect the highest level of industrial development of a countryTurbofan engineIt is polished with CNC bit by bit
As for various high-precision metal partsThere are too many to enumerateThere are turning, boring and milling, grinding and grooving
There are punching, gear shaper and testingThe tools that appear are not completely duplicatedA large CNC machining center
CNC can shape the precision and shape of complex workpieces at one time. What you eat is iron, and what you spit out is different work with high precision. However, the time is hundreds of times shorter than before, and the precision yield has been improved exponentially. The most irritating thing is that it also has adaptability and can be updated at any time.For example, in the past, if a master of worm gear wanted to make a good worm, you had to practice it for ten years and eight years. Hey, now if you want to process a completely different part and make a new process, you can sit and drink coffee. All this needs the support of equipment (tools), that is, it depends on how the manufacturing equipment of this manufacturing equipment plays with the equipmentCNC equipment: all kinds of machining tools
A CNC machining centerBe responsible for tool storage and tool change equipmentIt is called tool holder, also known as tool magazine
We all know the English word: tool magazine(in fact, the original meaning of the word magazine comes from the warehouse)To improve the working ability of CNC
In addition to pursuing more precise controlIt is also necessary to increase the capacity of the tool magazine and speed up the efficiency of tool changeThere are many ways to achieve this
According to the number of tools stored in the tool magazine and the tool taking methodCan be divided into different typesThe common ones are linear type, hat type, disc type, chain type magazine and so on
The power turret should be regarded as the smallest and most portable CNC tool magazineThe utility model is composed of a rotary cutter head and a box bodyA motor is installed in the box
The motor rotor is connected to the central shaft of the NC machine toolThe stator is fixed on the box for tool changeDMG BMT power turret with motor
A CNC machining center can install multiple power turretsThe upgraded version of the power turret is a hat type magazineIt is similar to the integration of turret and spindle head
It is a hat type tool magazine that automatically changes tools by moving the spindle up and downWhen the tool on the spindle enters the clamping slot of the hat magazineThe spindle moves up out of the tool
At the same time, the magazine rotates rapidlyWhen the tool to be replaced is aligned below the spindleThe spindle moves down so that the tool enters the spindle taper hole
After clamping the tool, the magazine returns to its original positionThe tool position of hat magazine is still limited (generally 16 34 tool positions)And it's always up and down
It takes up a lot of time and is not efficientIt also affects the working stroke of the spindleHowever, for a universal manufacturing equipment
It is not enough to add several independent tool holdersAfter all, a high-precision CNC machining center needs to coverLathe worker, milling worker, grinder worker, line drawing worker, heat treatment and other links
If you want to finish so much work at one timeDon't hide hundreds of knives with you. I'm sorry to leave the factory, okay!For CNC machining center
Linear magazine and chain magazine are its armed beltsChain magazineLarge CNC machining centers often need to carry hundreds of tools
If you don't agree, you have to take out dozens or hundreds of fancy tools to connect ironChain magazine of traditional armed belt typeStill not all competent
So there is a large combined extended automatic tool changing chain tool magazine(does such a long name seem particularly corrupt?)It is also called central warehouse tool magazine
The motor drives the winding chain at high speedQuickly send the required tool to the specified positionThen it is taken out by the mechanical arm and sent to the main shaft
Exchange positions with the tools that have been removed at the same timeTo save tool change timeWheel magazine of DMG mori
The disc magazine has been developed to the extremeThe cutter bases are evenly arranged around the huge hollow runnerOne cutter wheel can hold 40 60 cutters
In the assembly workshop of DMG moriYou can see the spectacular installation process of five or even six layer cutter wheelsOriginal title: the beauty of tool magazine: the arsenal of CNC machining center
The source of the article: official account of WeChat: motor technology and application] welcome to add attention! Please indicate the source of the article.
Later, it generally refers to the jade seal carved by emperors of all dynastiesOn October 5, 2016, Sotheby's auction house auctioned the Hotan green jade seal "the treasure of the supreme emperor" used by one party after the reign of Emperor Qianlong in Hong Kong for HK $91.48 million. At that time, the auction aroused fierce opposition from many parties in China.Nowadays, the title of national heavy weapon refers to manufacturing equipment
Manufacturing equipment determines the level of processing and manufacturingThe level of processing and manufacturing is an intuitive expression of a country's national strengthHowever, what we are talking about today is only this kind of national manufacturing equipment
CNC machining centerIt can not only process and manufacture precision workpieces full of mechanical beautyCNC itself is also an exquisite and elegant industrial creation
(just a little loud)DMG GM 16|6 series six axis automatic turning centerThat's so bad
What can this CNC machining center do?Let's say soIt is known as the top industrial manufacture with the highest difficulty in R & D and manufacturing
Which can best reflect the highest level of industrial development of a countryTurbofan engineIt is polished with CNC bit by bit
As for various high-precision metal partsThere are too many to enumerateThere are turning, boring and milling, grinding and grooving
There are punching, gear shaper and testingThe tools that appear are not completely duplicatedA large CNC machining center
CNC can shape the precision and shape of complex workpieces at one time. What you eat is iron, and what you spit out is different work with high precision. However, the time is hundreds of times shorter than before, and the precision yield has been improved exponentially. The most irritating thing is that it also has adaptability and can be updated at any time.For example, in the past, if a master of worm gear wanted to make a good worm, you had to practice it for ten years and eight years. Hey, now if you want to process a completely different part and make a new process, you can sit and drink coffee. All this needs the support of equipment (tools), that is, it depends on how the manufacturing equipment of this manufacturing equipment plays with the equipmentCNC equipment: all kinds of machining tools
A CNC machining centerBe responsible for tool storage and tool change equipmentIt is called tool holder, also known as tool magazine
We all know the English word: tool magazine(in fact, the original meaning of the word magazine comes from the warehouse)To improve the working ability of CNC
In addition to pursuing more precise controlIt is also necessary to increase the capacity of the tool magazine and speed up the efficiency of tool changeThere are many ways to achieve this
According to the number of tools stored in the tool magazine and the tool taking methodCan be divided into different typesThe common ones are linear type, hat type, disc type, chain type magazine and so on
The power turret should be regarded as the smallest and most portable CNC tool magazineThe utility model is composed of a rotary cutter head and a box bodyA motor is installed in the box
The motor rotor is connected to the central shaft of the NC machine toolThe stator is fixed on the box for tool changeDMG BMT power turret with motor
A CNC machining center can install multiple power turretsThe upgraded version of the power turret is a hat type magazineIt is similar to the integration of turret and spindle head
It is a hat type tool magazine that automatically changes tools by moving the spindle up and downWhen the tool on the spindle enters the clamping slot of the hat magazineThe spindle moves up out of the tool
At the same time, the magazine rotates rapidlyWhen the tool to be replaced is aligned below the spindleThe spindle moves down so that the tool enters the spindle taper hole
After clamping the tool, the magazine returns to its original positionThe tool position of hat magazine is still limited (generally 16 34 tool positions)And it's always up and down
It takes up a lot of time and is not efficientIt also affects the working stroke of the spindleHowever, for a universal manufacturing equipment
It is not enough to add several independent tool holdersAfter all, a high-precision CNC machining center needs to coverLathe worker, milling worker, grinder worker, line drawing worker, heat treatment and other links
If you want to finish so much work at one timeDon't hide hundreds of knives with you. I'm sorry to leave the factory, okay!For CNC machining center
Linear magazine and chain magazine are its armed beltsChain magazineLarge CNC machining centers often need to carry hundreds of tools
If you don't agree, you have to take out dozens or hundreds of fancy tools to connect ironChain magazine of traditional armed belt typeStill not all competent
So there is a large combined extended automatic tool changing chain tool magazine(does such a long name seem particularly corrupt?)It is also called central warehouse tool magazine
The motor drives the winding chain at high speedQuickly send the required tool to the specified positionThen it is taken out by the mechanical arm and sent to the main shaft
Exchange positions with the tools that have been removed at the same timeTo save tool change timeWheel magazine of DMG mori
The disc magazine has been developed to the extremeThe cutter bases are evenly arranged around the huge hollow runnerOne cutter wheel can hold 40 60 cutters
In the assembly workshop of DMG moriYou can see the spectacular installation process of five or even six layer cutter wheelsOriginal title: the beauty of tool magazine: the arsenal of CNC machining center
The source of the article: official account of WeChat: motor technology and application] welcome to add attention! Please indicate the source of the article.
"CNC machining often has many advantages. From the perspective of automotive, aerospace and consumer applications, it is widely used in the manufacturing of components in these fields. And, in a way, it has similar properties to metal."
Polyformaldehyde, or POM, is a fascinating plastic resin that is widely used in various industrial fields. The aerospace, automotive and electronics industries are important consumers of this polymer. The processing of polyformaldehyde, especially when used in the manufacturing field, can achieve fast and efficient processing. In addition, it benefits users due to its high mechanical strength, stiffness, machinability and variety of grade choices.
This article contains the following key details of POM CNC machining, as well as its basic characteristics in terms of functions, applications, advantages, etc. Let's get started.
What is POM?
POM, a homopolymer, is also known as Delrin. It is widely adopted as an engineering grade thermoplastic for manufacturing prototypes for industrial use. It usually comes in two forms: copolymers or homopolymers. From complex prototypes to flexible machine parts, it brings economic benefits to manufacturing.
Product designers can benefit from its structural integrity, color diversity and stiffness characteristics. In addition, its reliability and resilience in wet environments make it suitable for Marine, medical and aerospace applications. POM, usually has some other name, such as; Acetal (acetal), polyacetal (polyacetal), polyformaldehyde, etc.
Why use POM for CNC machining?
POM formaldehyde or polyacetal has significant advantages when used in machining. Benefit from leading technologies such as precision machining POM or CNC machining; For example; Milling, drilling, punching and punching. In addition, its versatility in various grades is very beneficial for machining experts. Delrin is also compatible with advanced cutting technologies; Examples include laser cutting and extrusion processes.
Some of the main features of CNC machining include:
It is lightweight, wear-resistant and has low friction properties.
POM's low friction capability means it can be used in high-precision rotating parts, such as automotive bushings, bearings and gears.
POM is similar to acrylic because of its inherent optical transparency and crystallinity.
Delrin comes in a variety of textures, colors and grades.
POM CNC machining is essential for high volume production and runs efficiently.
It has a lower heat absorption rate compared to other grade polymers such as nylon and polyethylene.
Evolved into CNC POM prototyping, CNC machining plays a key role in prototyping.
Delrine or POM is also known as metallic plastic or super steel because of its high rigidity and strength.
POM can be efficiently milling, drilling, grooving and cutting with CNC machining.
Manufacturers can use it for a variety of applications such as aerospace, automotive and consumer goods.
Design engineers can benefit from its dimensional stability and achieve tighter tolerances of ±0.0005 inches.
Rapid prototyping with CNC machining is feasible.
CNC lathes are also available for POM machining.
It describes low-cost solutions and offers economic benefits when produced in large volumes.
POM is a common technique; For example; CNC machining, injection molding, and 3D printing.
Prototypes and complex geometric shapes are easier to manufacture with POM CNC machining.
POM numerical control machining method
Plastic CNC machining can be deployed through various technologies; For example; CNC milling, CNC drilling, lathes, grinding, blanking and punching. Its ease of processing greatly affects its use in these processes. In addition, it has also received a lot of attention for its high elongation. Now, let's discuss the method to get the best results POM CNC machining.
The process begins with computer-aided design and programming to improve accuracy, quality, and optimization levels. After the virtual configuration, the instructions are forwarded to the CNC machine in the following form: G code for further processing prospects.
A cutting operation is then performed on the workpiece material (POM) to obtain the optimal dimensions and dimensions. It is recommended to use coolant when machining Delrin at high speed to prevent ineffective processing operations such as chip buildup or overheating.
The following are some of the techniques commonly used to process strong polyformaldehyde or POM.
1.POM CNC milling
CNC milling is often used to machine POM parts. Tools with sharp edges help to get the best Angle, as well as surface finish. Therefore, it is reasonable to use a single slot milling cutter to process Delrin. These cutters prevent chip buildup during machining operations.
2.POM CNC drilling
Standard twist and center drills are best suited for processing polyformaldehyde resins. These materials have strong, sharpened edges that ultimately allow for smooth milling operations on Delrin. The optimal cutting speed of the drilled POM must be approximately 1500rpm and the lip torsion Angle 118°.
3.POM CNC turning
POM CNC turning operation is similar to brass turning operation. The best results can be achieved by maintaining high speed turning at the same rate as the medium feed rate. In order to prevent interference and excessive chip accumulation problems, a chip-breaker must be used for precision turning operations.
4. Blanking and punching
Blanking and stamping, both methods are preferred for small and medium-sized complex parts. During operation, cracks in the sheet can lead to major problems of improper processing. To eliminate this problem, it is best to preheat the Delrin plate and use a manual or high punch.
Highlights: "During POM CNC machining, it is important to keep the POM tight or hold the POM and use a hard steel or carbide tool.
List of Delrin grades for CNC machining
The two most common acetal grades are very useful for CNC machining; Polyformaldehyde resin 150, polyformaldehyde resin; 100 (AF). Let's evaluate their compatibility;
1. Delrin 150
Derlin 150 belongs to the acetal homopolymer family. It has high mechanical strength, stiffness and wear resistance. Thanks to these unique features, it is ideal for CNC machining of gears, bushings, gaskets and automotive interior and exterior finishes. In addition, its stability under high temperature conditions makes it ideal for irrigation and conveyor parts.
2. Delrin 100(A)
Delrin 100 A is integrated with polytetrafluoroethylene (PTFE) for enhanced mechanical stability and viscosity. It is widely used in gear systems or components that require low friction characteristics. In addition, it has strong moisture and chemical resistance. In addition, it eliminates the self-lubricating (oil or grease) characteristic, making it different from other Delrin grades.
Surface treatment options for POM
The desired surface finish plays a key role in the machining process. When it comes to surface treatment, two options are usually employed: machining and sandblasting. Here is a brief introduction to these;
After processing
CNC machining often leaves a bumpy surface or texture on the surface of the acetal part. When rough or textured parts are needed to improve the frictional properties of the parts, the surface treatment is preferred. The typical roughness range that can be achieved by machining is about 32 to 250 microinches (0.8 to 6.3 microns).
Pearl burst
In most cases, machining tools leave marks on acetal parts. Sandblasting is often used to prevent tool marks and enhance the visual effect of Delrin machined parts. It works by releasing glass beads or fine particles onto the surface of machined parts under high pressure. In addition, it improves durability and provides a valuable, smooth, matte, aesthetically pleasing and satin-polished appearance to polyformaldehyde resin machine parts.
There are other techniques; For example; Anodizing, polishing, painting and stamping. However, most design engineers prefer the above two options due to economic feasibility.
What are the limitations of Delrin CNC machining?
However, there are huge benefits to using Delrin for CNC machining. Besides, it also has some disadvantages. Here are Delrin's limitations;
Adhesion: Although acetal has excellent chemical resistance, it often presents challenges in bonding with strong adhesives. To overcome this problem, designers may need to employ post-treated surface options for best results.
Thermal sensitivity: Thermal sensitivity is a noteworthy issue for design manufacturers. The ability of acetone alcohols to withstand high temperature conditions is very significant. However, it is well suited for applications where mechanical stability is critical. But in some cases, when it is exposed to high temperature conditions, there will be deformation or distortion problems. Compared with nylon, nylon shows higher strength and structural strength even in harsh environments.
High flammability: The processing of polyformaldehyde resin faces the challenge of flammability. It is sensitive to temperatures above 121 degrees Celsius. It is recommended to always use a coolant, such as air coolant, to maintain the temperature during the processing operation. In order to overcome or control flammability problems, it is also necessary to use A Class A fire extinguisher when processing POM.
Delrin NC machining applications
From automotive interiors to aerospace components, Drin is used in a wide range of applications. Let's take a look at some of its key applications in manufacturing;
Medical industry
POM is an important material for medical components or equipment. As an engineered thermoplastic, it meets the strict quality standards of the FDA or ISO. Its applications range from enclosures and housings to complex functional components; For example; Disposable syringes, surgical tools, valves, inhalers, prosthetics and medical implants.
Automobile industry
Derlin supplies a wide range of automotive components to the automotive industry. Its high mechanical strength, low friction, and wear resistance allow engineers to use it to make important car, motorcycle, and electric vehicle parts. Some common examples include: articulated housings, locking systems, and fuel transmitter units.
Consumer appliances
When it comes to convenient applications, polyformaldehyde processing describes several significant benefits. Manufacturing experts use it to make zippers, cooking utensils, washing machines and clips.
Industrial machinery parts
Derlin's great strength enables it to be used in industrial parts manufacturing. Its ability to withstand wear and low friction characteristics makes it ideal for components such as springs, fan wheels, gears, housings, scrapers and rollers.
As an industry pioneer, Honscn is always at the forefront of market developments. We know that in the fierce market competition, only by constantly honing ourselves can we create indestructible competitiveness. Therefore, we adhere to technological innovation and integrate scientific management into every production link to ensure that every step is accurate. We not only focus on the pulse of the domestic market, but also in line with international standards, with a global perspective to examine the industry trend, grasp the pulse of The Times. With an open mind, embrace the world, with excellent quality, win the future!
Please feel free to contact us to discuss your project needs!
Polyformaldehyde, or POM, is a fascinating plastic resin that is widely used in various industrial fields. The aerospace, automotive and electronics industries are important consumers of this polymer. The processing of polyformaldehyde, especially when used in the manufacturing field, can achieve fast and efficient processing. In addition, it benefits users due to its high mechanical strength, stiffness, machinability and variety of grade choices.
This article contains the following key details of POM CNC machining, as well as its basic characteristics in terms of functions, applications, advantages, etc. Let's get started.
What is POM?
POM, a homopolymer, is also known as Delrin. It is widely adopted as an engineering grade thermoplastic for manufacturing prototypes for industrial use. It usually comes in two forms: copolymers or homopolymers. From complex prototypes to flexible machine parts, it brings economic benefits to manufacturing.
Product designers can benefit from its structural integrity, color diversity and stiffness characteristics. In addition, its reliability and resilience in wet environments make it suitable for Marine, medical and aerospace applications. POM, usually has some other name, such as; Acetal (acetal), polyacetal (polyacetal), polyformaldehyde, etc.
Why use POM for CNC machining?
POM formaldehyde or polyacetal has significant advantages when used in machining. Benefit from leading technologies such as precision machining POM or CNC machining; For example; Milling, drilling, punching and punching. In addition, its versatility in various grades is very beneficial for machining experts. Delrin is also compatible with advanced cutting technologies; Examples include laser cutting and extrusion processes.
Some of the main features of CNC machining include:
It is lightweight, wear-resistant and has low friction properties.
POM's low friction capability means it can be used in high-precision rotating parts, such as automotive bushings, bearings and gears.
POM is similar to acrylic because of its inherent optical transparency and crystallinity.
Delrin comes in a variety of textures, colors and grades.
POM CNC machining is essential for high volume production and runs efficiently.
It has a lower heat absorption rate compared to other grade polymers such as nylon and polyethylene.
Evolved into CNC POM prototyping, CNC machining plays a key role in prototyping.
Delrine or POM is also known as metallic plastic or super steel because of its high rigidity and strength.
POM can be efficiently milling, drilling, grooving and cutting with CNC machining.
Manufacturers can use it for a variety of applications such as aerospace, automotive and consumer goods.
Design engineers can benefit from its dimensional stability and achieve tighter tolerances of ±0.0005 inches.
Rapid prototyping with CNC machining is feasible.
CNC lathes are also available for POM machining.
It describes low-cost solutions and offers economic benefits when produced in large volumes.
POM is a common technique; For example; CNC machining, injection molding, and 3D printing.
Prototypes and complex geometric shapes are easier to manufacture with POM CNC machining.
POM numerical control machining method
Plastic CNC machining can be deployed through various technologies; For example; CNC milling, CNC drilling, lathes, grinding, blanking and punching. Its ease of processing greatly affects its use in these processes. In addition, it has also received a lot of attention for its high elongation. Now, let's discuss the method to get the best results POM CNC machining.
The process begins with computer-aided design and programming to improve accuracy, quality, and optimization levels. After the virtual configuration, the instructions are forwarded to the CNC machine in the following form: G code for further processing prospects.
A cutting operation is then performed on the workpiece material (POM) to obtain the optimal dimensions and dimensions. It is recommended to use coolant when machining Delrin at high speed to prevent ineffective processing operations such as chip buildup or overheating.
The following are some of the techniques commonly used to process strong polyformaldehyde or POM.
1.POM CNC milling
CNC milling is often used to machine POM parts. Tools with sharp edges help to get the best Angle, as well as surface finish. Therefore, it is reasonable to use a single slot milling cutter to process Delrin. These cutters prevent chip buildup during machining operations.
2.POM CNC drilling
Standard twist and center drills are best suited for processing polyformaldehyde resins. These materials have strong, sharpened edges that ultimately allow for smooth milling operations on Delrin. The optimal cutting speed of the drilled POM must be approximately 1500rpm and the lip torsion Angle 118°.
3.POM CNC turning
POM CNC turning operation is similar to brass turning operation. The best results can be achieved by maintaining high speed turning at the same rate as the medium feed rate. In order to prevent interference and excessive chip accumulation problems, a chip-breaker must be used for precision turning operations.
4. Blanking and punching
Blanking and stamping, both methods are preferred for small and medium-sized complex parts. During operation, cracks in the sheet can lead to major problems of improper processing. To eliminate this problem, it is best to preheat the Delrin plate and use a manual or high punch.
Highlights: "During POM CNC machining, it is important to keep the POM tight or hold the POM and use a hard steel or carbide tool.
List of Delrin grades for CNC machining
The two most common acetal grades are very useful for CNC machining; Polyformaldehyde resin 150, polyformaldehyde resin; 100 (AF). Let's evaluate their compatibility;
1. Delrin 150
Derlin 150 belongs to the acetal homopolymer family. It has high mechanical strength, stiffness and wear resistance. Thanks to these unique features, it is ideal for CNC machining of gears, bushings, gaskets and automotive interior and exterior finishes. In addition, its stability under high temperature conditions makes it ideal for irrigation and conveyor parts.
2. Delrin 100(A)
Delrin 100 A is integrated with polytetrafluoroethylene (PTFE) for enhanced mechanical stability and viscosity. It is widely used in gear systems or components that require low friction characteristics. In addition, it has strong moisture and chemical resistance. In addition, it eliminates the self-lubricating (oil or grease) characteristic, making it different from other Delrin grades.
Surface treatment options for POM
The desired surface finish plays a key role in the machining process. When it comes to surface treatment, two options are usually employed: machining and sandblasting. Here is a brief introduction to these;
After processing
CNC machining often leaves a bumpy surface or texture on the surface of the acetal part. When rough or textured parts are needed to improve the frictional properties of the parts, the surface treatment is preferred. The typical roughness range that can be achieved by machining is about 32 to 250 microinches (0.8 to 6.3 microns).
Pearl burst
In most cases, machining tools leave marks on acetal parts. Sandblasting is often used to prevent tool marks and enhance the visual effect of Delrin machined parts. It works by releasing glass beads or fine particles onto the surface of machined parts under high pressure. In addition, it improves durability and provides a valuable, smooth, matte, aesthetically pleasing and satin-polished appearance to polyformaldehyde resin machine parts.
There are other techniques; For example; Anodizing, polishing, painting and stamping. However, most design engineers prefer the above two options due to economic feasibility.
What are the limitations of Delrin CNC machining?
However, there are huge benefits to using Delrin for CNC machining. Besides, it also has some disadvantages. Here are Delrin's limitations;
Adhesion: Although acetal has excellent chemical resistance, it often presents challenges in bonding with strong adhesives. To overcome this problem, designers may need to employ post-treated surface options for best results.
Thermal sensitivity: Thermal sensitivity is a noteworthy issue for design manufacturers. The ability of acetone alcohols to withstand high temperature conditions is very significant. However, it is well suited for applications where mechanical stability is critical. But in some cases, when it is exposed to high temperature conditions, there will be deformation or distortion problems. Compared with nylon, nylon shows higher strength and structural strength even in harsh environments.
High flammability: The processing of polyformaldehyde resin faces the challenge of flammability. It is sensitive to temperatures above 121 degrees Celsius. It is recommended to always use a coolant, such as air coolant, to maintain the temperature during the processing operation. In order to overcome or control flammability problems, it is also necessary to use A Class A fire extinguisher when processing POM.
Delrin NC machining applications
From automotive interiors to aerospace components, Drin is used in a wide range of applications. Let's take a look at some of its key applications in manufacturing;
Medical industry
POM is an important material for medical components or equipment. As an engineered thermoplastic, it meets the strict quality standards of the FDA or ISO. Its applications range from enclosures and housings to complex functional components; For example; Disposable syringes, surgical tools, valves, inhalers, prosthetics and medical implants.
Automobile industry
Derlin supplies a wide range of automotive components to the automotive industry. Its high mechanical strength, low friction, and wear resistance allow engineers to use it to make important car, motorcycle, and electric vehicle parts. Some common examples include: articulated housings, locking systems, and fuel transmitter units.
Consumer appliances
When it comes to convenient applications, polyformaldehyde processing describes several significant benefits. Manufacturing experts use it to make zippers, cooking utensils, washing machines and clips.
Industrial machinery parts
Derlin's great strength enables it to be used in industrial parts manufacturing. Its ability to withstand wear and low friction characteristics makes it ideal for components such as springs, fan wheels, gears, housings, scrapers and rollers.
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Computer Numerical Control (CNC) machining is a common technique that is contemporarily utilized in the metalworking industry. As opposed to conventional machines, CNC machining makes use of computerized systems which facilitate superior output in complicated shapes for a range of materials. A renowned example is the CNC milling machine.
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.
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.
Seven diverse wood products application reflect the diverse capabilities of CNC machining centers.
For a machine that not so long ago did not even exist, the uses for CNC machining centers have quickly become vast and continue to grow.
Woodworkers today are using these versatile machines for a variety of uses ranging from high-speed, flat-panel production work to very intricate carvings. Combining high speed boring with routing, profiling, cutting and other features, these computer-controlled marvels are being successfully utilized in shops that produce everything from beautiful high-end architectural woodwork to flanges for take up reels.
In the following pages, WOOD & WOOD PRODUCTS interviews woodworkers from around the country who have increased their productivity and accuracy while reducing labor costs through investments in CNC technology. Following are their stories.
SPEAKER MAKER USES CNC MACHINERY TO MAKE IT'S DIVERSE PRODUCT As an OEM supplier of audio speakers, the products that Tiffin, Ohio-based Ameriwood Industries International Inc. manufactures vary in size from small bookshelf-size speakers to large symphonic speakers.
Jim Harrington, plant manager of Ameriwood, said, "We do a variety of sizes and styles. We work with different types of materials, with different thicknesses and locations of holes. No two things are alike." Because of this product diversity, Ameriwood Industries (formerly Tiffin Enterprises) used to perform multiple machining operations for every item. Multiple operations meant that several workers had to handle each part, "and the more you handle it, the more opportunity there is for the product to be damaged," Harrington said.
To minimize parts handling -- and thus reduce their labor costs -- the company made an investment in a CNC machining center from Roger Stiles & Associates.
MACHINING CENTERS Vinyl overlayed particleboard is trimmed, cut-to-size, drilled and routed on the machining center. Computer programs are downloaded from a computer system directly into the machine's controller.
"We used CNC routers for a number of years," Harrington said. "The machining center is taking the place of routing and vertical-type drills." The machining center allows the company to do up to 12 workpieces at a time, Harrington said. After all the machining operations have been completed it is a "totally finished part" without need of further machining, Harrington added.
EFFICIENT PLANT HELPS COMPANY CONTROL COSTS In the past two years, Warvel Products-North Carolina has experienced dramatic price increases for the raw materials used to produce curved plywood components. These components are then sold to contract furniture manufacturers such as Haworth.
"We had 30 percent increases in our raw material costs," said sales manager Robbie Wiltcher, "so we have improved plant efficiency by purchasing machinery and technology that would allow us to absorb as much (of the price increase) as possible without passing these costs on. It is important for us as a vendor to help our customers be as competitive in their markets as possible." One of the ways Warvel did this was through the purchase of a multiple-station, four-axis CNC machining center from C.M.S North America. The machining center allows the company to mount up to six components at a time, and complements the company's existing three and five axis machining centers, Wiltcher said.
This is important, considering the amount of product which is shipped from the company's plant in Linwood, N.C. Approximately 100,000 parts a month are produced at the facility, the majority of which are customized. The company has a catalog with standard components, but Wiltcher said that 80 percent of the company's orders are made per customers specifications.
"The machine is capable of multiple machining tasks," Wiltcher said. "In most cases all that's left to do is light sanding and tee-nut installation where required." Another benefit, Wiltcher added, is the very tight tolerances obtained with the machine. The company supplies curved plywood which must integrate with plastic and steel components in ergonomic chairs.
"It is essential to be able to maintain tight tolerances in the various required operations such as drilling on angles, profiling and notching so that all of the different chair components fit together the way they were engineered. This machine provides all of these things," Wiltcher said.
To increase productivity even further, the company purchased machines and software that complement the machining center, including a digitizing machine. The digitizer will read a template part and the software will create a program which is downloaded into the machining center. The company also uses the system to internally produce its own compound tooling.
"The system has reduced the lead time on new tooling from months to days," said Wiltcher. "All of these capabilities assists our customers in bringing many new products to market rapidly and competitively." HIGH-TECH HELPS HIGH-END ARCHITECTURAL FIRM Powell Cabinet & Fixtures of Sparks, Nev., is a high-end architectural woodworking company whose work ranges from luxurious residences to glistening casinos.
The 42-year-old company, which bills itself as the oldest architectural woodworking company in the state of Nevada, is owned by the father/son team of Roger and Bill Powell.
One of the company's most recent projects was for the new Luxor Casino and Hotel in Las Vegas. The company did a variety of work at the hotel, including a 3 1/2-inch thick, 13-inch wide, solid-mahogany handrail that was built on a 255-foot radius. The handrail also featured solid-cast bronze support pieces and etched glass.
The handrail was manufactured utilizing a Komo VR 512 CNC machining center the company got in January 1993. Prior to that, the company had been doing everything with multiple machines. "The machining center is exceptional on irregular shapes and curves," Bill Powell said.
"It is more adaptable than to have a journeyman do it by hand. The radius work takes more time to program, but instead of having a journeyman woodworker spend several days on something, the machine will produce the same product in significantly less time." Powell added that there is a learning curve to the machine. "The purchase of the machine is just the first step," Powell said.
"The time that it takes to learn how to program and operate it is a major expense, as is the tooling and all the programming updates that are needed to keep up-to-speed." But while these factors need to be taken into account, Powell said he thinks it is becoming essential for companies to invest in high-technology equipment. According to Powell, one of the reasons the company purchased the machining center was because "the quantity of qualified, journeyman cabinetmakers that can produce this type of work is diminishing. You have to rely on the technical aspects of the industry to help fill that void," he said.
COMPANY GROWS A STEP AT A TIME When Denny Beuter and Bob Bloss formed Diamond Cut Inc. eight years ago they had a plan. The two men wanted their South Bend, Ind.-based company to become a leader in the field of commercial sound equipment. A daunting task made all the more difficult considering they did not own any sophisticated equipment.
"We went on the premise that we needed extremely good equipment to make a really good product," said Beuter. "But in order to get good equipment you have to have a product with enough volume to keep the machine running." What Beuter and Bloss did was to start slowly, acquiring equipment and producing parts for other companies. "We would do cutting and edging, anything to get work into the plant," Beuter said. "To sell machine time you have to do everything a little bit better than what the (source) companies can do in their own shop. We got real good, real fast, because otherwise we had to eat the cost of the job." From doing this job-shop-type-work, the next step was doing contract work. "My partner (Bloss), whose background is in the speaker business, went out (to speaker companies) and said, 'We can make speakers boxes for you and we can do them with high precision,'" Beuter said.
Diamond Cut began producing speaker cabinets for such companies as JBL and Panasonic. The product Panasonic wanted the company to produce necessitated an equipment upgrade. "The Panasonic people wanted a (speaker) box that was trapezoid shape," Beuter said. "This product would have been almost impossible to make with the router we were using." Beuter and Bloss chose a U-26 Morbidelli machining center from Tekna Machinery. The machine not only allows them to produce the trapezoidal shapes, it also has reduced labor costs. "For example, we had one full-time worker on the payroll whose only job was to make jigs, Beuter said. "I have no more jigs." While Diamond Cut has grown, with sales projected to reach around $2 million in 1994, the company continues to move toward that plan. In 1993, the company started a proprietary line of heavy-duty commercial sound equipment under the moniker, Bull Frog.
The Bull Frog equipment is sold throughout the United States and a number of countries around the world. "For 24-hours a day, for the last three months, we have been so busy with our own proprietary work that we have not been able to do any outside work, Beuter said.
"Hopefully by the end of the year we will be completely out of contract work." BOOTH MAKER FINDS SIGN TO SUCCESS Utilizing a variety of materials, Farmington Displays of Farmington, Conn., creates trade show displays for companies in industries as diverse as food, computers and guns.
Farmington Displays, which was founded in 1973 by Paul DiTommaso Sr., counts 278 companies as its clients. On average, Farmington Displays' clients update their booths every three to five years.
"We have a pretty good job flow," said general manager Sal DiTommaso, son of Paul Sr. and one of three sons and a daughter currently working for the company. "Not everybody is building their booth at the same time." Farmington Displays boasts an impressive client list, including General Electric, NEC and gun manufacturer Smith & Wesson. In the traditionally very labor-intensive field of display manufacturing, the company stands out for its use of high-technology equipment. More than three years ago, after extensive research on available machinery, the company began its investment in CNC machinery.
"The first thing that sparked my interest in obtaining CNC machinery was watching one of my men cutting out an eight-foot circle," said Sal DiTommaso. "It was so archaic, I just said there had to be another way to do it." Farmington Display's plant now features two Heian CNC routers and a computerized panel saw from Stiles Machinery, as well as a computerized graphic/design laboratories linked together as a Local Area Network.
The Heian machining centers have allowed the company to branch out into areas such as manufacturing signage and store fixtures. Farmington Displays had always created graphics for signs, but the CNC routers allow the company to manufacture them in-house. Additionally, the company is now doing contract machining for other, non-competing manufacturers.
To create their distinctive products, the company utilizes a variety of materials. On its CNC routers, the company utilizes everything from acrylics to solid woods. On a separate metal machining center the company works with brass and other metallic alloys. "We don't farm anything out," DiTommaso said. "We try to keep everything in-house so that we have complete quality control over the finished product." FAMILY-OWNED LUMBER YARD SEIZES CHANCE TO DIVERSIFY ITS BUSINESS In 1922, Hans Lars founded Hansen Lumber in Galesburg, Ill. Over the next 70 or so years, the business would be handed down from family-member to family-member, and would remain a traditional lumber yard.
It remained solely a lumber yard until two years ago when Hansen Lumber seized an opportunity to diversify. The company was asked to do some circular panel cutting for a Galesburg-based manufacturer of wooden reels. Approximately a year later that manufacturer, who believed the reel industry was going to dominated by the use of plastics, first contemplated shuttering the facility and then offered to sell the business -- and its client list -- to Hansen Lumber.
The family-owned company, currently being run by Shard Hansen, the founder's grandson, with help from his daughter Karen (the fourth-generation family member in the business), decided to purchase the company, and quickly realized the need to upgrade its equipment.
"Taking up wire or rope around a reel must be done at very high feed rates, especially if it is a small diameter wire, because unless your doing it at a 1,000 feel a minute it would take forever to wind," said Hansen, "so the arbor hole has to be exact. If the arbor hole is off center the whole thing will be jerking." A little more than a year ago the company purchased a CNC machining center from Accu-Router. The machine features two vertical routers, which can machine 1 1/2 inch southern yellow pine industrial grade plywood used for the flanges on the reels and maintains tight tolerances.
Prior to working with the machining center, the company would have to cut out a square and in subsequent steps radius the panel down to the required size and shape.
Having a high-technology machining center not only provides for accuracy, it also helps to utilize the plywood. "Our flanges range in size from eight inches to 48 inches round," said Hansen.
"When we are cutting the circles, we can nest them in such a fashion that we get great yield and waste is very nominal." CNC EQUIPMENT HELPS CARVING COMPANY MAKE BEAUTIFUL MUSIC Investing, not only in new equipment, but also in the training of its workforce has helped this Thomasville, N.C.-based carving company increase its capacity while reducing its overhead.
Founded in 1968, Piedmont Carving carves furniture parts -- specializing in chair parts -- and parts for such musical instruments as the cello and guitar.
Over the last few years, the company has sold some of its older carving machines and invested that money in computerized machinery including CNC Robot Carvers from Thermwood Corp.
"We used to have 13 carving machines and we would run all of them in one shift," said Gay Jones, who along with her twin brother Ray, and her father, company-founder Jimmy, own the business. "We sold three carving machines and still are projecting to triple our capacity with the robotic carvers." The company has reduced its labor costs in part by computerizing its carving, but also by cross training its 29 employees so that they can work on other machines in the shop.
Learning to efficiently use the CNC robot was a difficult challenge for the company, Gay Jones said, "but I'm glad we did because it gives us an advantage over companies who are just now getting into robotic carving." Piedmont Carving bought its first robotic carver four years ago. The company is planning to purchase additional machines.
One of the benefits of computerized machinery is consistency. This is important when Piedmont is crafting its furniture and musical instrument components.
"Chair parts have to fit together perfectly when they're sent to the manufacturer," Jones said. "With the robotic carving everything stays so consistent. This consistency is also very important when we are doing the musical instruments because the craftsmanship that goes into the part can affect the sound." CARVING WOOD PARTS 20 AT A TIME Intricate handcarvings are being quickly and accurately duplicated by Carving Research Inc. of Huntersville, N.C., using a 20-head Kitako CNC Machining Center distributed by Tekmatex Inc.
Carving Research is a 2-year-old, 12-employee company with projected 1994 sales of $840,000. The company supplies intricate wood carvings to such major residential furniture makers as Henredon Furniture Industries Inc. and Baker Furniture Co.
What once had to be done one at a time by master handcarvers can now be done 20 at a time by the company. This results not only in time savings but cost savings as well, without sacrificing the look of the product, according to company owner Tom Bowker. An example of the speed of the machine is a rice carved bed post; typically it would take a master handcarver approximately six to eight hours to complete, "while we can do it in an hour," Bowker said.
To produce the carvings, an initial handcarved template is made. This carving is sent to Tekmatex, where a digitizing machine creates a computer program which can be downloaded into the machining center. Once this program is completed, an infinite number of a given carving can be created with precision.
There are certain "essential ingredients" to creating the carvings, said Bowker. Tooling is one of the most important. Because of the nature of the product, the Carving Research utilizes unique tooling, including a razor-sharp veining bit developed by Oertli Woodworking Tools Inc. that leaves such a clean cut, that secondary carvings are not necessary, Bowker said. Another example is a 1/16-inch flat-bottom or straight router bit which is used on many of the carvings.
"Nobody else uses anything like that," Bowker said.
"Because of the intricacies of many of the carvings, we have to use a wider variety of tooling including some carbide tooling, than what you would use if running a normal carving operation. Many of our bits have to be small because you have to get in and do a cut and make it look like it was done with a chisel.
For a machine that not so long ago did not even exist, the uses for CNC machining centers have quickly become vast and continue to grow.
Woodworkers today are using these versatile machines for a variety of uses ranging from high-speed, flat-panel production work to very intricate carvings. Combining high speed boring with routing, profiling, cutting and other features, these computer-controlled marvels are being successfully utilized in shops that produce everything from beautiful high-end architectural woodwork to flanges for take up reels.
In the following pages, WOOD & WOOD PRODUCTS interviews woodworkers from around the country who have increased their productivity and accuracy while reducing labor costs through investments in CNC technology. Following are their stories.
SPEAKER MAKER USES CNC MACHINERY TO MAKE IT'S DIVERSE PRODUCT As an OEM supplier of audio speakers, the products that Tiffin, Ohio-based Ameriwood Industries International Inc. manufactures vary in size from small bookshelf-size speakers to large symphonic speakers.
Jim Harrington, plant manager of Ameriwood, said, "We do a variety of sizes and styles. We work with different types of materials, with different thicknesses and locations of holes. No two things are alike." Because of this product diversity, Ameriwood Industries (formerly Tiffin Enterprises) used to perform multiple machining operations for every item. Multiple operations meant that several workers had to handle each part, "and the more you handle it, the more opportunity there is for the product to be damaged," Harrington said.
To minimize parts handling -- and thus reduce their labor costs -- the company made an investment in a CNC machining center from Roger Stiles & Associates.
MACHINING CENTERS Vinyl overlayed particleboard is trimmed, cut-to-size, drilled and routed on the machining center. Computer programs are downloaded from a computer system directly into the machine's controller.
"We used CNC routers for a number of years," Harrington said. "The machining center is taking the place of routing and vertical-type drills." The machining center allows the company to do up to 12 workpieces at a time, Harrington said. After all the machining operations have been completed it is a "totally finished part" without need of further machining, Harrington added.
EFFICIENT PLANT HELPS COMPANY CONTROL COSTS In the past two years, Warvel Products-North Carolina has experienced dramatic price increases for the raw materials used to produce curved plywood components. These components are then sold to contract furniture manufacturers such as Haworth.
"We had 30 percent increases in our raw material costs," said sales manager Robbie Wiltcher, "so we have improved plant efficiency by purchasing machinery and technology that would allow us to absorb as much (of the price increase) as possible without passing these costs on. It is important for us as a vendor to help our customers be as competitive in their markets as possible." One of the ways Warvel did this was through the purchase of a multiple-station, four-axis CNC machining center from C.M.S North America. The machining center allows the company to mount up to six components at a time, and complements the company's existing three and five axis machining centers, Wiltcher said.
This is important, considering the amount of product which is shipped from the company's plant in Linwood, N.C. Approximately 100,000 parts a month are produced at the facility, the majority of which are customized. The company has a catalog with standard components, but Wiltcher said that 80 percent of the company's orders are made per customers specifications.
"The machine is capable of multiple machining tasks," Wiltcher said. "In most cases all that's left to do is light sanding and tee-nut installation where required." Another benefit, Wiltcher added, is the very tight tolerances obtained with the machine. The company supplies curved plywood which must integrate with plastic and steel components in ergonomic chairs.
"It is essential to be able to maintain tight tolerances in the various required operations such as drilling on angles, profiling and notching so that all of the different chair components fit together the way they were engineered. This machine provides all of these things," Wiltcher said.
To increase productivity even further, the company purchased machines and software that complement the machining center, including a digitizing machine. The digitizer will read a template part and the software will create a program which is downloaded into the machining center. The company also uses the system to internally produce its own compound tooling.
"The system has reduced the lead time on new tooling from months to days," said Wiltcher. "All of these capabilities assists our customers in bringing many new products to market rapidly and competitively." HIGH-TECH HELPS HIGH-END ARCHITECTURAL FIRM Powell Cabinet & Fixtures of Sparks, Nev., is a high-end architectural woodworking company whose work ranges from luxurious residences to glistening casinos.
The 42-year-old company, which bills itself as the oldest architectural woodworking company in the state of Nevada, is owned by the father/son team of Roger and Bill Powell.
One of the company's most recent projects was for the new Luxor Casino and Hotel in Las Vegas. The company did a variety of work at the hotel, including a 3 1/2-inch thick, 13-inch wide, solid-mahogany handrail that was built on a 255-foot radius. The handrail also featured solid-cast bronze support pieces and etched glass.
The handrail was manufactured utilizing a Komo VR 512 CNC machining center the company got in January 1993. Prior to that, the company had been doing everything with multiple machines. "The machining center is exceptional on irregular shapes and curves," Bill Powell said.
"It is more adaptable than to have a journeyman do it by hand. The radius work takes more time to program, but instead of having a journeyman woodworker spend several days on something, the machine will produce the same product in significantly less time." Powell added that there is a learning curve to the machine. "The purchase of the machine is just the first step," Powell said.
"The time that it takes to learn how to program and operate it is a major expense, as is the tooling and all the programming updates that are needed to keep up-to-speed." But while these factors need to be taken into account, Powell said he thinks it is becoming essential for companies to invest in high-technology equipment. According to Powell, one of the reasons the company purchased the machining center was because "the quantity of qualified, journeyman cabinetmakers that can produce this type of work is diminishing. You have to rely on the technical aspects of the industry to help fill that void," he said.
COMPANY GROWS A STEP AT A TIME When Denny Beuter and Bob Bloss formed Diamond Cut Inc. eight years ago they had a plan. The two men wanted their South Bend, Ind.-based company to become a leader in the field of commercial sound equipment. A daunting task made all the more difficult considering they did not own any sophisticated equipment.
"We went on the premise that we needed extremely good equipment to make a really good product," said Beuter. "But in order to get good equipment you have to have a product with enough volume to keep the machine running." What Beuter and Bloss did was to start slowly, acquiring equipment and producing parts for other companies. "We would do cutting and edging, anything to get work into the plant," Beuter said. "To sell machine time you have to do everything a little bit better than what the (source) companies can do in their own shop. We got real good, real fast, because otherwise we had to eat the cost of the job." From doing this job-shop-type-work, the next step was doing contract work. "My partner (Bloss), whose background is in the speaker business, went out (to speaker companies) and said, 'We can make speakers boxes for you and we can do them with high precision,'" Beuter said.
Diamond Cut began producing speaker cabinets for such companies as JBL and Panasonic. The product Panasonic wanted the company to produce necessitated an equipment upgrade. "The Panasonic people wanted a (speaker) box that was trapezoid shape," Beuter said. "This product would have been almost impossible to make with the router we were using." Beuter and Bloss chose a U-26 Morbidelli machining center from Tekna Machinery. The machine not only allows them to produce the trapezoidal shapes, it also has reduced labor costs. "For example, we had one full-time worker on the payroll whose only job was to make jigs, Beuter said. "I have no more jigs." While Diamond Cut has grown, with sales projected to reach around $2 million in 1994, the company continues to move toward that plan. In 1993, the company started a proprietary line of heavy-duty commercial sound equipment under the moniker, Bull Frog.
The Bull Frog equipment is sold throughout the United States and a number of countries around the world. "For 24-hours a day, for the last three months, we have been so busy with our own proprietary work that we have not been able to do any outside work, Beuter said.
"Hopefully by the end of the year we will be completely out of contract work." BOOTH MAKER FINDS SIGN TO SUCCESS Utilizing a variety of materials, Farmington Displays of Farmington, Conn., creates trade show displays for companies in industries as diverse as food, computers and guns.
Farmington Displays, which was founded in 1973 by Paul DiTommaso Sr., counts 278 companies as its clients. On average, Farmington Displays' clients update their booths every three to five years.
"We have a pretty good job flow," said general manager Sal DiTommaso, son of Paul Sr. and one of three sons and a daughter currently working for the company. "Not everybody is building their booth at the same time." Farmington Displays boasts an impressive client list, including General Electric, NEC and gun manufacturer Smith & Wesson. In the traditionally very labor-intensive field of display manufacturing, the company stands out for its use of high-technology equipment. More than three years ago, after extensive research on available machinery, the company began its investment in CNC machinery.
"The first thing that sparked my interest in obtaining CNC machinery was watching one of my men cutting out an eight-foot circle," said Sal DiTommaso. "It was so archaic, I just said there had to be another way to do it." Farmington Display's plant now features two Heian CNC routers and a computerized panel saw from Stiles Machinery, as well as a computerized graphic/design laboratories linked together as a Local Area Network.
The Heian machining centers have allowed the company to branch out into areas such as manufacturing signage and store fixtures. Farmington Displays had always created graphics for signs, but the CNC routers allow the company to manufacture them in-house. Additionally, the company is now doing contract machining for other, non-competing manufacturers.
To create their distinctive products, the company utilizes a variety of materials. On its CNC routers, the company utilizes everything from acrylics to solid woods. On a separate metal machining center the company works with brass and other metallic alloys. "We don't farm anything out," DiTommaso said. "We try to keep everything in-house so that we have complete quality control over the finished product." FAMILY-OWNED LUMBER YARD SEIZES CHANCE TO DIVERSIFY ITS BUSINESS In 1922, Hans Lars founded Hansen Lumber in Galesburg, Ill. Over the next 70 or so years, the business would be handed down from family-member to family-member, and would remain a traditional lumber yard.
It remained solely a lumber yard until two years ago when Hansen Lumber seized an opportunity to diversify. The company was asked to do some circular panel cutting for a Galesburg-based manufacturer of wooden reels. Approximately a year later that manufacturer, who believed the reel industry was going to dominated by the use of plastics, first contemplated shuttering the facility and then offered to sell the business -- and its client list -- to Hansen Lumber.
The family-owned company, currently being run by Shard Hansen, the founder's grandson, with help from his daughter Karen (the fourth-generation family member in the business), decided to purchase the company, and quickly realized the need to upgrade its equipment.
"Taking up wire or rope around a reel must be done at very high feed rates, especially if it is a small diameter wire, because unless your doing it at a 1,000 feel a minute it would take forever to wind," said Hansen, "so the arbor hole has to be exact. If the arbor hole is off center the whole thing will be jerking." A little more than a year ago the company purchased a CNC machining center from Accu-Router. The machine features two vertical routers, which can machine 1 1/2 inch southern yellow pine industrial grade plywood used for the flanges on the reels and maintains tight tolerances.
Prior to working with the machining center, the company would have to cut out a square and in subsequent steps radius the panel down to the required size and shape.
Having a high-technology machining center not only provides for accuracy, it also helps to utilize the plywood. "Our flanges range in size from eight inches to 48 inches round," said Hansen.
"When we are cutting the circles, we can nest them in such a fashion that we get great yield and waste is very nominal." CNC EQUIPMENT HELPS CARVING COMPANY MAKE BEAUTIFUL MUSIC Investing, not only in new equipment, but also in the training of its workforce has helped this Thomasville, N.C.-based carving company increase its capacity while reducing its overhead.
Founded in 1968, Piedmont Carving carves furniture parts -- specializing in chair parts -- and parts for such musical instruments as the cello and guitar.
Over the last few years, the company has sold some of its older carving machines and invested that money in computerized machinery including CNC Robot Carvers from Thermwood Corp.
"We used to have 13 carving machines and we would run all of them in one shift," said Gay Jones, who along with her twin brother Ray, and her father, company-founder Jimmy, own the business. "We sold three carving machines and still are projecting to triple our capacity with the robotic carvers." The company has reduced its labor costs in part by computerizing its carving, but also by cross training its 29 employees so that they can work on other machines in the shop.
Learning to efficiently use the CNC robot was a difficult challenge for the company, Gay Jones said, "but I'm glad we did because it gives us an advantage over companies who are just now getting into robotic carving." Piedmont Carving bought its first robotic carver four years ago. The company is planning to purchase additional machines.
One of the benefits of computerized machinery is consistency. This is important when Piedmont is crafting its furniture and musical instrument components.
"Chair parts have to fit together perfectly when they're sent to the manufacturer," Jones said. "With the robotic carving everything stays so consistent. This consistency is also very important when we are doing the musical instruments because the craftsmanship that goes into the part can affect the sound." CARVING WOOD PARTS 20 AT A TIME Intricate handcarvings are being quickly and accurately duplicated by Carving Research Inc. of Huntersville, N.C., using a 20-head Kitako CNC Machining Center distributed by Tekmatex Inc.
Carving Research is a 2-year-old, 12-employee company with projected 1994 sales of $840,000. The company supplies intricate wood carvings to such major residential furniture makers as Henredon Furniture Industries Inc. and Baker Furniture Co.
What once had to be done one at a time by master handcarvers can now be done 20 at a time by the company. This results not only in time savings but cost savings as well, without sacrificing the look of the product, according to company owner Tom Bowker. An example of the speed of the machine is a rice carved bed post; typically it would take a master handcarver approximately six to eight hours to complete, "while we can do it in an hour," Bowker said.
To produce the carvings, an initial handcarved template is made. This carving is sent to Tekmatex, where a digitizing machine creates a computer program which can be downloaded into the machining center. Once this program is completed, an infinite number of a given carving can be created with precision.
There are certain "essential ingredients" to creating the carvings, said Bowker. Tooling is one of the most important. Because of the nature of the product, the Carving Research utilizes unique tooling, including a razor-sharp veining bit developed by Oertli Woodworking Tools Inc. that leaves such a clean cut, that secondary carvings are not necessary, Bowker said. Another example is a 1/16-inch flat-bottom or straight router bit which is used on many of the carvings.
"Nobody else uses anything like that," Bowker said.
"Because of the intricacies of many of the carvings, we have to use a wider variety of tooling including some carbide tooling, than what you would use if running a normal carving operation. Many of our bits have to be small because you have to get in and do a cut and make it look like it was done with a chisel.
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