cnc turned part bushing is one core product at Honscn Co.,Ltd. Carefully researched and developed by our technicians, it has several superior characteristics that fully meet the needs of customers in the market. It is characterized by stable performance and durable quality. Besides that, it is elaborately designed by professional designers. Its unique appearance is one of the most recognizable characteristics, making it stand out in the industry.
By virtue of the excellent quality, HONSCN products are well praised among purchasers and receive increasing favors from them. Compared with other similar products in the market now, the pricing offered by us is very competitive. Furthermore, all our products are highly recommended by the customers from domestic and overseas and occupy a huge market share.
We design and produce whatever customers require. We serve in the same way. 24-hour service for all product including cnc turned part bushing is available at Honscn. If you have any request about delivery and packaging, we are willing to help you.
CNC (Computer Numerical Control) custom machining services play a crucial role in the 3C (Computers, Communications, and Consumer Electronics) industry.
CNC (Computer Numerical Control) custom machining services
3C Industry
Here are some specific applications of CNC custom machining in 3C electronics:
1. Prototyping and Product Development: CNC machining is extensively used in the prototyping phase of 3C electronics. It allows for the creation of precise and custom components, facilitating rapid prototyping and iterative design improvements before mass production.
2. Customized Casings and Enclosures: CNC machining enables the production of intricate and precisely designed casings, housings, and enclosures for electronic devices. These casings can be tailor-made to fit specific components, ensuring optimal functionality and aesthetics.
3. Printed Circuit Boards (PCBs): CNC machining is used for creating PCBs with high precision. CNC milling and drilling machines can fabricate complex PCB designs, ensuring accurate placement of holes, traces, and components.
4. Heat Sinks and Cooling Systems: In electronic devices, managing heat is crucial for optimal performance and longevity. CNC machining helps create intricate heat sinks and cooling systems with specialized designs to dissipate heat effectively.
5. Connectors and Adapters: Custom CNC machining produces connectors, adapters, and specialized components that facilitate connectivity within electronic devices. These components can be tailored to meet specific device requirements.
6. Button and Control Interfaces: CNC machining enables the creation of precise and customized buttons, knobs, and control interfaces for electronic devices. This ensures ergonomic design and functionality.
The success or failure of aerospace operations depends on the accuracy, precision and quality of the components used. For this reason, aerospace companies utilize advanced manufacturing techniques and processes to ensure that their components fully meet their needs. While new manufacturing methods such as 3D printing are rapidly gaining popularity in the industry, traditional manufacturing methods such as machining continue to play a key role in the production of parts and products for aerospace applications. Such as better CAM programs, application-specific machine tools, enhanced materials and coatings, and improved chip control and vibration damping - have significantly changed the way aerospace companies manufacture critical aerospace components. However, sophisticated equipment alone is not enough. Manufacturers must have the expertise to overcome the material processing challenges of the aerospace industry.
Material requirements
The manufacture of aerospace parts first requires specific material requirements. These parts typically require high strength, low density, high thermal stability and corrosion resistance to handle extreme operating conditions.
Common aerospace materials include:
1. High strength aluminum alloy
High-strength aluminum alloys are ideal for aircraft structural parts because of their light weight, corrosion resistance and ease of processing. For example, 7075 aluminum alloy is widely used in the manufacture of aerospace parts.
2. titanium alloy
Titanium alloys have excellent strength to weight ratio and are widely used in aircraft engine parts, fuselage components and screws.
3. Superalloy
Superalloys maintain strength and stability at high temperatures and are suitable for engine nozzles, turbine blades and other high-temperature parts.
4. Composite material
Carbon fiber composites perform well in reducing structural weight, increasing strength and reducing corrosion, and are commonly used in the manufacture of casings for aerospace parts and spacecraft components.
What are the process characteristics of aerospace parts processing?
Process planning and design
Process planning and design are required before processing. At this stage, it is necessary to determine the overall processing scheme according to the design requirements of the parts and material characteristics. This includes determining the process of processing, the choice of machine tool equipment, the selection of tools, etc. At the same time, it is necessary to carry out detailed process design, including the determination of cutting profile, cutting depth, cutting speed and other parameters.
Material preparation and cutting process
In the process of aerospace parts processing, the first need to prepare working materials. Usually, the materials used in aviation parts include high-strength alloy steel, stainless steel, aluminum alloy and so on. After the material preparation is completed, the cutting process is entered.
This step involves the selection of machine tools, such as CNC machine tools, lathes, milling machines, etc., as well as the selection of cutting tools. The cutting process needs to strictly control the feed speed, cutting speed, cutting depth and other parameters of the tool to ensure the dimensional accuracy and surface quality of the parts.
Precision machining process
Aerospace components are usually very demanding in terms of size and surface quality, so precision machining is an indispensable step. At this stage, it may be necessary to use high-precision processes such as grinding and EDM. The goal of the precision machining process is to further improve the dimensional accuracy and surface finish of the parts, ensuring their reliability and stability in the aviation field.
Heat treatment
Some aerospace parts may require heat treatment after precision machining. The heat treatment process can improve the hardness, strength and corrosion resistance of the parts. This includes heat treatment methods such as quenching and tempering, which are selected according to the specific requirements of the parts.
Surface coating
In order to improve the wear resistance and corrosion resistance of aviation parts, surface coating is usually required. Coating materials can include cemented carbide, ceramic coating, etc. Surface coatings can not only improve the performance of parts, but also extend their service life.
Assembly and testing
Do parts assembly and inspection. At this stage, the parts need to be assembled in accordance with the design requirements to ensure the accuracy of the match between the various parts. At the same time, rigorous testing is required, including dimensional testing, surface quality testing, material composition testing, etc., to ensure that parts meet aviation industry standards.
Process characteristics
Strict quality control: The quality control requirements of aviation parts are very strict, and strict testing and control are required at each processing stage of aviation parts to ensure that the quality of parts meets the standards.
High precision requirements: Aerospace components typically require very high accuracy, including dimensional accuracy, shape accuracy and surface quality. Therefore, high-precision machine tools and tools need to be used in the processing process to ensure that the parts meet the design requirements.
Complex structure design: Aviation parts often have complex structures, and it is necessary to use multi-axis CNC machine tools and other equipment to meet the processing needs of complex structures.
High temperature resistance and high strength: aviation parts usually work in harsh environments such as high temperature and high pressure, so it is necessary to choose high temperature resistance and high strength materials, and carry out the corresponding heat treatment process.
Overall, aerospace parts processing is a highly technology-intensive, precision demanding process that requires strict operating processes and advanced processing equipment to ensure that the quality and performance of the final parts can meet the stringent requirements of the aviation sector.
Processing difficulties
Aerospace parts processing is challenging, mainly in the following areas:
Complex geometry
Aerospace parts often have complex geometrics that require high-precision machining to meet design requirements.
Super alloy processing
The processing of superalloys is difficult and requires special tools and processes to handle these hard materials.
Large parts
The parts of the spacecraft are usually very large, requiring large CNC machine tools and special processing equipment.
Quality control
The aerospace industry is extremely demanding on part quality and requires rigorous quality control and inspection to ensure that every part meets the standards.
In aerospace parts processing, precision and reliability are key. A deep understanding and fine control of materials, processes, precision and machining difficulties is the key to manufacturing high-quality aerospace parts.
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.
5-axis CNC machining is an advanced manufacturing process that adds two rotating axes (A, B or A, C) to the three linear axes (X, Y, Z). This type of processing has many advantages. It can realize the multi-sided machining of complex shape parts, greatly improve the machining accuracy and efficiency, and reduce the number of clamping and error. For parts with deep cavity, reverse buckle, complex surface and other features, 5-axis CNC machining can easily cope with. In the aerospace, automotive, mold and other industries, 5-axis CNC machining is widely used in the manufacture of high-precision key parts, such as engine impellers, aviation structural parts, automotive molds and so on.
How to optimize 5-axis cnc machining？
1. Tool path planning:
- Efficient tool path algorithm to reduce empty travel and unnecessary tool movement.
- Optimize the cutting and cutting mode of the tool, avoid sudden stop and turn, reduce tool wear and machine vibration.
2. Tool selection:
- Select the appropriate tool material, geometry and size according to the machining material and process requirements.
- Consider using multi-edge tools to improve cutting efficiency.
3. Cutting parameters optimization:
- Precise setting of parameters such as cutting speed, feed speed and cutting depth to achieve the best cutting results and efficiency.
- Combine tool and material characteristics to determine optimal parameters through testing and simulation.
4. Clamping method:
- Ensure that the workpiece is firmly mounted, reducing displacement and vibration during machining.
- The use of appropriate fixtures to improve clamping efficiency and accuracy.
5. Programming optimization:
- Simplify programming code, reduce redundant instructions, and improve program execution efficiency.
- Use macros and subroutines to improve programming flexibility and versatility.
6. Machine maintenance:
- Regular maintenance and calibration of the machine to ensure the accuracy and performance of the machine.
- Replace the worn parts in time to ensure the normal operation of the machine.
7. Processing sequence:
- Reasonable arrangement of processing procedures, first rough processing, then semi-finishing and finishing.
- Avoid repeated clamping and positioning errors.
8. Simulation and verification:
- Perform tool path simulation before machining to check for interference and errors.
- Verify the feasibility and rationality of the processing technology.
9. Personnel training:
- Improve the skill level and process knowledge of the operators so that they can skillfully operate the machine and optimize the machining process.
10. Adopt advanced control system:
- Upgrade the machine control system to support more advanced machining functions and optimization algorithms.
We can use the above methods to optimize 5-axis CNC machining according to the actual situation.
What factors should be considered to optimize 5-axis cnc machining?
-
Workpiece design and geometry: including complexity, feature size and tolerance requirements, which affect machining strategy and tool path selection.
-
Material characteristics: the hardness, toughness, thermal conductivity and other properties of the material determine the selection of cutting parameters and tools.
-
Tool selection: The material, geometry, blade number, diameter, etc. of the tool should be matched with the processing task to ensure cutting efficiency and quality.
-
Cutting parameters: such as cutting speed, feed rate, cutting depth, etc., need to be optimized according to material and tool characteristics to improve processing efficiency and avoid excessive tool wear.
-
Machine tool performance: including the accuracy, rigidity, stroke, speed range of the machine tool, etc., to give full play to the advantages of the machine tool and avoid exceeding its capacity.
-
Clamping method: to ensure that the workpiece clamping is stable, accurate, and will not interfere with the processing, and to facilitate loading and unloading, improve production efficiency.
-
Tool path planning: Optimize the feed and retreat mode of the tool, reduce empty travel and unnecessary movement, and reduce processing time.
-
Cooling and lubrication: Suitable cooling and lubrication methods can reduce the cutting temperature, extend the tool life, and improve the surface quality.
-
Programming technology: Efficient and accurate programming code helps to reduce errors and improve machine operation efficiency.
-
Post-processing program: ensure that the generated CNC code can be executed accurately by the machine tool.
-
Processing sequence: reasonable arrangement of roughing, semi-finishing and finishing sequence to improve processing efficiency and ensure processing quality.
-
Processing cost: under the premise of ensuring quality, minimize tool loss, energy consumption and processing time to control costs.
-
Production batch: Batch size will affect the processing strategy and the selection of tooling fixtures.
-
Quality requirements: Strict surface roughness, dimensional accuracy and form and position tolerances require finer processing parameters and process control.
These factors are related to each other, and comprehensive consideration can achieve the optimization of 5-axis CNC machining.
What performance can be improved by optimizing 5-axis CNC machining?
-
Machining accuracy: Through more accurate tool path planning, optimized cutting parameters and good machine tool calibration, machining errors can be significantly reduced, and dimensional accuracy and form and position tolerance accuracy of parts can be improved.
-
Surface quality: Suitable tool selection, cutting parameter adjustment and effective cooling lubrication can obtain a smoother and lower roughness surface to meet higher surface quality requirements.
-
Processing efficiency: reducing empty stroke, optimizing tool path, improving cutting speed and feed speed and other measures can greatly shorten processing time and improve production efficiency.
-
Tool life: Reasonable cutting parameters and tool path can reduce tool wear and damage, extend the service life of the tool, reduce the cost of the tool.
-
Machine tool stability: Optimizing the processing process can reduce the vibration and shock of the machine tool, enhance the stability of the machine tool operation, and reduce the incidence of failure.
-
Material utilization: More accurate processing and reasonable layout planning can reduce the waste of materials and improve the utilization rate of materials.
-
Production flexibility: can adapt to the processing needs of different parts more quickly, adjust the processing technology and parameters, and improve the flexibility and response speed of production.
-
Energy consumption: By improving processing efficiency and reducing unnecessary machine tool actions, reduce energy consumption, achieve energy saving and reduce production costs.
To sum up, optimizing 5-axis CNC machining is of great significance for improving product quality, reducing costs, and enhancing the competitiveness of enterprises.
Honscn has obvious advantages in CNC aluminum processing. First of all, the precision is high, can make aluminum parts with accurate size and complex shape, and the quality is barbar. Then there is high efficiency, automatic processing, saving manpower and time. Complex shapes are no problem, anything can be done. Full use of materials, no waste, cost can be reduced. And the processed things have good repeatability and stable quality. It is also easy to modify the design, and it is flexible to change the procedure.
In the field of modern manufacturing, CNC (computer numerical control) processing technology has become a powerful tool for shaping various materials, and plastic materials have shown a unique charm in them. Today, let's take a closer look at the beauty of CNC-machined plastics and the significant advantages that this process brings to factory production.
The magic charm of CNC machining technology
CNC machining is a manufacturing process in which a machine tool is digitally controlled by a computer to precisely remove material to obtain the desired shape and size. When applied to plastic materials, it shows amazing precision and flexibility.
High precision: CNC machines are able to process plastic parts with micron precision, ensuring that every detail meets the design requirements. Whether it's complex geometry, tiny holes or tight tolerances, the CNC can handle it with ease. This high precision allows plastic parts to play a key role in areas such as electronic devices and medical devices that require high precision.
For example, when manufacturing mobile phone cases, CNC machining can precisely shape ergonomic curves and exquisite key holes, providing a comfortable feel and perfect appearance. For example, in the medical field, the precision requirements for instrument parts used in minimally invasive surgery are almost strict, and CNC machining can perfectly manufacture these fine plastic parts to ensure the safety and success of the surgery.
The shaping of complex shapes: The plasticity of plastics combined with the power of CNC technology allows designers to unleash their creativity. From smooth curves to three-dimensional structures, from hollow patterns to multi-layer nesting, almost any imaginable shape can be achieved on plastic materials through CNC machining.
Imagine the exquisite plastic trim in the interior of a car, with its unique textures and intricate shapes, created by CNC machining, adding an atmosphere of luxury and comfort to the interior environment. Not only that, in the aerospace sector, complex plastic structural parts inside aircraft, such as ventilation ducts and interior panels, are also highly customized and lightweight through CNC machining.
Repeatability and consistency: In mass production, CNC machining ensures that every plastic part has the same high quality and specifications. This is of critical importance for products that require a large number of the same parts, such as auto parts, consumer electronics, etc.
Taking the plastic parts in the automobile engine as an example, through CNC machining, the size and performance of each part can be guaranteed to be completely consistent, thereby improving the reliability and stability of the entire engine. Similarly, in the electronics industry, such as the plastic fasteners on computer motherboards, whose consistency is crucial for the stability of product assembly and performance, CNC machining ensures that each fastener can be accurately matched, improving production efficiency and product quality.
CNC can process plastic process flow
CNC machining of plastics usually involves the following major steps:
Design and programming
- First, according to the requirements and design requirements of the product, the three-dimensional model of the part is created using computer aided design (CAD) software.
- Then, the computer aided manufacturing (CAM) software is used to convert the 3D model into a numerical control program that can be recognized by the machine tool to determine the tool path, cutting parameters, etc.
Material preparation
- Select the appropriate plastic material, common such as acrylic, polycarbonate, nylon, etc., and prepare the corresponding blank according to the size and number of parts.
- Ensure that the surface quality and dimensional accuracy of the material meet the processing requirements.
Clamp positioning
- The plastic blank is installed on the machine table and fixed with a suitable fixture to ensure that the material does not move or deform during processing.
- Precisely adjust the position of the material so that it is aligned with the coordinate system in the program to ensure the accuracy of the processing.
Tool selection and installation
- According to the characteristics of plastic materials, processing requirements and process parameters, select the appropriate tool, such as end milling cutter, drill, ball cutter and so on.
- Install the tool correctly on the tool library or spindle of the machine tool, and measure and compensate the length and radius of the tool.
Cutting process
- Start the machine tool, according to the pre-written numerical control program, the machine tool control system drives the tool along the predetermined path for cutting.
- During processing, the tool gradually removes excess plastic material to form the desired shape and structure.
Process monitoring
- Real-time monitoring of cutting force, temperature, vibration and other parameters during processing to ensure the stability and safety of processing.
- Observe the tool wear, if necessary, replace the tool in time to ensure the quality of machining.
Quality inspection
- After processing is completed, measuring tools such as calipers, micrometers and coordinate measuring machines are used to detect the size and shape accuracy of the parts.
- Check the surface quality of the parts, such as roughness, defect, etc., to ensure that the design requirements are met.
Follow-up treatment
- According to the needs, the processed parts are deburring, polishing, painting and other follow-up treatment to improve the appearance and performance of the parts.
CNC can process a variety of plastic choices
A wide variety of plastic materials, each with unique properties and characteristics, offer a wealth of possibilities for CNC machining.
Acrylic (PMMA) : with excellent transparency and optical properties, often used in the manufacture of display stands, light boxes, optical lenses, etc. CNC machining can shape acrylic into a variety of beautiful shapes while maintaining its high transparency and smooth surface.
In the display cabinet of the shopping mall, you can often see CNC processed acrylic products, which attract the attention of customers with its clear display effect. In addition, in the eyewear industry, the high-precision processing of acrylic lenses is also achieved through CNC, providing consumers with a clear and comfortable visual experience.
Polycarbonate (PC) : high strength, good heat resistance, suitable for the manufacture of electronic equipment shell, protective mask, car lamp shade, etc. CNC machining is able to take full advantage of its performance to produce strong and durable parts with complex shapes.
For example, the case of the laptop computer, through the CNC processing of polycarbonate material, not only provides good protection, but also shows a stylish design. At the same time, in the field of outdoor lighting, the lamp shade made of polycarbonate, after CNC processing, can withstand a variety of adverse weather conditions, while ensuring good light transmission.
Nylon (PA) : with excellent wear resistance and mechanical strength, it is often used in the manufacture of gears, bearings, mechanical parts, etc. CNC machining can precisely manufacture the tooth shape and structure of nylon parts, ensuring efficient operation in the drive system.
In industrial machinery, the gear made of nylon is CNC processed and can withstand high load operation to ensure the normal operation of the equipment. In addition, in the field of sports equipment, such as certain parts of bicycles, nylon materials are machined by CNC to provide reliable performance and comfortable use experience for athletes.
The factory uses CNC processing plastic advantages
In modern factories, the choice of CNC machining plastics brings a series of significant advantages, providing a strong guarantee for the improvement of production efficiency and product quality.
Improve production efficiency: CNC machine tools can realize automatic processing, reducing manual operation time and error. Through pre-programmed instructions, the machine can run continuously, greatly shortening the production cycle. At the same time, the multi-axis CNC machine can complete the machining of multiple faces in a single clamping, further improving the processing efficiency.
In an electronic equipment manufacturing plant, CNC machining of plastic shells significantly reduced the time from raw materials to finished products, meeting the market demand for fast delivery. Moreover, the automated production process reduces the downtime and adjustment time caused by human factors, so that the utilization rate of the machine tool has been greatly improved.
Cost reduction: Although the initial investment in CNC equipment is high, the long-term cost savings are significant. High-precision processing reduces scrap rates and rework times, saving material and labor costs. In addition, automated production reduces the reliance on skilled workers and reduces labor costs.
Taking a plastic products factory as an example, through the use of CNC processing technology, the rejection rate is reduced from the original 10% to 2%, which greatly saves the production cost. At the same time, due to the improvement of production efficiency, the processing cost of unit products is also reduced correspondingly, which enhances the price competitiveness of enterprises in the market.
Improve product quality: The high precision and consistency of CNC machining ensures that every plastic part is of exceptional quality. Strict tolerance control and surface finish make the product reach a higher standard in appearance and performance, enhancing the market competitiveness.
In the field of high-end medical device manufacturing, CNC machined plastic parts provide a more reliable guarantee for the treatment of patients with their precise dimensions and perfect surface quality. In automobile manufacturing, the high-quality processing of plastic interior parts improves the quality and comfort of the vehicle, and meets the continuous pursuit of consumers for automobile quality.
Flexibility and customization: The factory can quickly adjust the CNC program according to the specific needs of customers to achieve small batch and diversified production. This flexibility allows the plant to better meet the individual needs of the market and adapt to rapidly changing market trends.
For example, a custom furniture factory can use CNC machining to create unique plastic decorative pieces for customers to meet the pursuit of personalized home. In the field of industrial design, CNC machining can quickly respond to the creativity of designers, translate concepts into actual products, and provide strong support for innovation.
Easy implementation of complex design: Modern product design is increasingly complex and innovative, and CNC machining can easily meet these challenges. The factory can undertake a variety of complex shapes and structures of plastic parts processing orders, to provide customers with more innovative solutions.
In the aerospace sector, complex plastic parts are made possible by CNC machining, contributing to the lightweight and high performance of aircraft. In the emerging field of 3D printing and CNC machining, it is possible to achieve unprecedented complex design, creating a new situation in the manufacturing industry.
Sustainable development: CNC machining plastics contributes to sustainable manufacturing to a certain extent. Through precise processing, the waste of materials can be minimized. Moreover, some recyclable plastic materials can also be reused through CNC processing, contributing to the cause of environmental protection.
Many factories began to pay attention to and adopt environmentally friendly plastic materials, and through CNC processing technology to transform them into high-quality products, both to meet the market demand, while reducing the impact on the environment.
In short, CNC machinable plastics bring unprecedented opportunities and advantages to the manufacturing industry. CNC technology is shaping a more exciting world of plastics processing through the ability to process with high precision and complex shapes, as well as the advantages of increasing efficiency, reducing costs, improving quality and achieving customization in factory production. Whether in consumer electronics, automotive, medical or other fields, CNC machinable plastics will continue to play an important role in driving the manufacturing industry forward and creating more high-quality, high-performance products for us.