With the continuous development of technology, consumers have different personalized needs, customization requirements continue to improve, consumers need to customize professional spare parts according to their own needs and preferences, if this can be achieved, will greatly increase the customer's goodwill, enterprises can also continue to increase their own visibility. Therefore, CNC custom machining services also play an important role in manufacturing.

The application of CNC custom machining services in the field of automotive automation has also achieved remarkable results. Take our company as an example, we provide one-stop customized CNC production services, with advanced equipment and technical team, has provided high-quality parts processing services for many well-known automobile manufacturers, and won the favor of partners.

In short, the application of CNC custom machining services in the field of automotive automation is gradually changing the pattern of traditional manufacturing. For custom CNC production services, please choose us and we will provide you with the best quality service and the most competitive price. Let us jointly promote the innovation and development of the automobile manufacturing industry!

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.

DETROIT-Executives from four auto parts companies said Tuesday that they don't expect widespread fallout from a shortage of a key ingredient in plastic resin following a factory explosion.Officials with Delphi Automotive, Illinois Tool Works, AK Steel and Parker Hannifin said during conference calls to discuss their companies' earnings that a shortage of PA-12 shouldn't disrupt their operations.Automakers and parts companies have been scrambling to find substitutes since a factory in Germany that makes much of the world's supply of the ingredient suspended production after it exploded in March.The resin is used in hundreds of parts. It's most critical in fuel and brake lines because it can carry gasoline and other fluids without deteriorating.Companies that make fuel lines, brake lines and connectors have been worried they will run out of PA-12 and they may have to stop shipments to automakers and larger parts suppliers. One key fuel line maker, TI Automotive, warned last week that the auto production interruptions are likely in the next few weeks. TI and a trade group of suppliers held an industrywide meeting last week to look at the remaining supply of PA-12 and encourage faster testing of alternatives.But Rodney O'Neal, CEO of Delphi, one of the largest parts suppliers, said he sees little impact on Delphi or auto production."I don't see this as a crisis in terms of tremendous downtime at all for anyone around the world," O'Neal said. He said the auto industry is addressing the problem quickly and with flexibility.Delphi, a Troy, Mich., supplier of audio systems, fuel pumps, wiring connectors and other items, uses PA-12 in a small number of parts and has lined up substitutes, O'Neal said."We believe there's enough inventory in the channel right now to handle this," John Brooklier, vice president of investor relations for Illinois Tool Works, told investors on a separate call Tuesday. He said the Glenview, Ill., maker of metal and plastic parts such as door handles uses little PA-12 but is watching the impact on auto companies.At AK Steel, CEO James Wainscott said customers are telling the company that any shortage is likely to be a challenge mostly for European automakers in the U.S.The West Chester, Ohio, company, he said, was concerned about the problem until the last day or so."There may be some trickle-lower effect here, but we don't look for that to be a great concern," Wainscott told investors.Automakers say the issue hasn't interrupted production thus far. The shortage was caused by a March 31 explosion at Evonik Industries' plant. The factory supplied at least a quarter of the world's PA-12, and about 70 percent of a chemical that's used by other companies to make resin. Evonik has said the plant will be out of operation for at least three months.At Parker Hannifin, a maker of valves, filters, pumps and hoses, CEO Donald Washkewicz said his company isn't in the fuel line business but does use PA-12, also known as nylon-12, in air brake tubing and other parts. The Cleveland-based company, he said, has been using alternate materials."We're able to keep our customers out of trouble," Washkewicz said.But Washkewicz said the shortage could drive up the cost of raw materials used to make plastic parts.Few plastics can do what PA-12 does. The chemical doesn't absorb as much moisture as other plastics and will stand up to carrying gasoline, brake fluid and other hydrocarbon liquids. Sadhan Jana, a professor of polymer engineering at the University of Akron in Ohio, said he knows of no other plastic as as durable as PA-12.Any substitute would have to go through rigorous testing to make sure it would work for a specific automotive part, Jana says. Those tests could take months.Automakers and suppliers are close to agreeing on a fast-track process for testing replacements.The Automotive Industry Action Group, a nonprofit trade group, said Monday that General Motors Co., Ford Motor Co., Chrysler Group, Honda Motor Co., Hyundai-Kia, Volkswagen AG and their suppliers, are expected to finalize new testing standards next week. The agreement would reduce the interim approval process for new materials to three weeks from the current eight weeks or longer.AIAG said the group feels confident it can shorten the testing time because alternative resins are already well known and previous testing has accurately predicted real-world performance.

Plastic parts are produced through a process known as custom plastic extraction. This is a manufacturing process where raw plastic materials are melted down and formed into the desired plastic parts. Before you choose a manufacturer for your custom parts, you must consider things like capabilities and production capacitates because they can vary greatly from one manufacturer to the other. Here are some of the factors you should consider.
Strategic Plan You should consider whether or not you are looking for a long term relationship. You need to locate a good cultural and strategic fit. Do your due diligence and take your time in uncovering a manufacturers professional reputation in that industry. During your research, don't just look at the positive reviews to determine how good they are, look for the red flags and see how bad things can get.

The Process Type Different manufacturers use different manufacturing processes that include extrusion, co-extrusion, tri-extrusion as well as crosshead extrusion coatings.

The Plastic Materials The plastic extrusion materials are used in different applications and each of them has their unique properties. One of the most important aspects of hiring a manufacturer is considering the extrusion materials they use for the custom parts. You have to be sure that the parts will be manufactured successfully and will perform as properly as is expected. In case you are not sure about the kind of plastic extrusion materials that would be best for your parts, an engineer can assist you in that area. There are also numerous grade types for the extrudable materials so you should choose a company that can produce the grade you need.

Capabilities If you have a significant production volume requirement, it is essential to know the production capabilities of the manufacturer. The manufacturer should also be able to provide you with extensive capabilities in terms of the design, tooling and fabrication. With these plastic extrusion capabilities, a manufacturer is able to produce high quality custom parts that meet the requirements of their customers. The finishes should be considered as well as they could be matt, glossy or textured. That means your custom plastic parts manufacturer should know about the latest finishes in the market.

Tooling Custom plastic extrusion needs tooling, which is a lot cheaper compared to injection molding. A quality extrusion manufactures ought to offer you state of the art tooling capabilities. They should have an experienced team that designs, engineers and tests all tooling. This will improve productivity, efficiency, safety and reduce costs.

Customer Service When working with any manufacturer, the process will become easier if they have working customer services that communicate effectively. A great manufacturing company is determined by the quality of customer services they offer. If for instance you have any last minute requests or want to change your order, you need to know that someone will be there to attend to you and support you. This will be more important if you are looking for a long term relationship. For it to be successful custom plastic parts manufacturer there needs to be helpful and pleasant customer service.

Conclusion You must consider these things when you are looking for the right manufacturer. As long as you evaluate their previous work and ensure they can provide you with all your requirements at a reasonable price, you will find a good company to work with.

CNC machining process common problem points and improvement methods

Starting from the actual production, this paper summarizes the common problems and improvement ways of CNC machining process, and how to choose the three important factors of speed, feed rate and cutting depth in different application fields

The workpiece is over-cut
The reason:


Knife, tool strength is not enough too long or too small, resulting in knife.
Improper operation by the operator.
Uneven cutting allowance (such as: 0.5 on the side of the surface, 0.15 on the bottom)
Improper cutting parameters (such as: tolerance is too large, SF setting too fast, etc.)

Improvements:


The principle of using a knife: can be big or small, can be short or not long.
Add the clearing procedure, and the margin is as even as possible (the margin on the side and the bottom is the same).
Reasonable adjustment of cutting parameters, large margin corner round.
With the SF function of the machine, the operator fine-tunes the speed to achieve the best cutting effect.

The central question
The reason:


Operator manual operation is not accurate.
There are burrs around the mold.
The center bar has magnetic field.
The four sides of the mold are not vertical.

Improvements:


Manual operation should be carefully checked repeatedly, and the points should be at the same point and height as far as possible.
Remove burrs with a whetstone or file around the mold, wipe clean with a rag, and finally confirm with your hand.
Demagnetize the dividing rod before dividing the mold (ceramic dividing rod or other).
Check whether the four sides of the mold are vertical (if the verticality error is large, it is necessary to review the plan with the fitter).

The knife problem
The reason:


Operator manual operation is not accurate.
Tool clamping error.
The blade on the knife is wrong (the knife itself has a certain error).
There is an error between R knife and flat knife and flying knife.

Improvements:


Manual operation should be carefully checked repeatedly, and the knife should be at the same point as possible.
Blow clean with air gun or wipe clean with rag when clamping the tool.
One blade can be used when the blade on the flying knife is to measure the rod and light the bottom surface.
A separate knife program can avoid the error between R knife flat knife flying knife.

The crash - programming
The reason:


The safety height is not enough or not set (the knife or chuck hits the workpiece when the fast feed G00).
The tool on the program list and the actual program tool are written wrong.
The tool length (blade length) and the actual machining depth on the program list are wrong.
The depth Z-axis fetch number and the actual Z-axis fetch number on the program are written incorrectly.
The coordinates are set incorrectly during programming.

Improvements:


Accurate measurement of the height of the workpiece also ensures that the safety height is above the workpiece.
The tool on the program list should be consistent with the actual program tool (try to use the automatic program list or use the picture program list).
Measure the actual depth of machining on the workpiece, write the length of the tool and the length of the blade on the program sheet (generally, the tool clip length is 2-3MM higher than the workpiece, and the blade length avoidance is 0.5-1.0MM).
Take the actual Z-axis number on the workpiece and write it clearly on the program sheet. (This operation is generally written manually to check repeatedly).

Crash machine - Operator
The reason:


Depth Z-axis alignment error ·
The number of touch and operation errors (such as: unilateral access without feed radius, etc.).
Use the wrong knife (such as: D4 knife with D10 knife to process).
The program goes wrong (for example: A7.NC goes A9.NC).
The hand wheel is rotated in the wrong direction during manual operation.
Press the wrong direction (for example, -X +X) during manual fast feed.

Improvements:


Depth Z-axis knife must pay attention to the position of the knife. (bottom, top, analysis, etc.).
Check the number of touch and operation repeatedly after completion.
When installing the tool, it should be installed after repeated check with the program list and the program.
The program should go one by one in order.
In the manual operation, the operator should strengthen the operation proficiency of the machine tool.
In the manual fast movement, you can first raise the Z axis to the workpiece above the move.

Surface accuracy
The reason:


The cutting parameters are unreasonable and the workpiece surface is rough.
The edge of the tool is not sharp.
The tool clamping is too long, and the blade is too long.
Chip removal, air blowing, oil flushing is not good.
Programming cutting mode, (you can try to consider going down milling).
The workpiece has burrs.

Improvements:


Cutting parameters, tolerances, allowance, speed feed Settings should be reasonable.
The tool requires the operator to check and replace it periodically.
When installing the tool, the operator is required to clip as short as possible, and the blade should not be too long.
For the lower cut of flat knife, R knife and round nose knife, the speed feed setting should be reasonable.
The workpiece has burrs: the root of our machine tools, tools, and cutting methods are directly related. Therefore, we need to understand the performance of the machine tool and repair the edge with burrs.

The blade is broken
Reasons and improvements:

1. Feed too fast

-- Slow down to a suitable feed speed

2. Feed too fast at the beginning of cutting

-- Slow down the feed rate at the beginning of cutting

3. Clamp loosely (knife)

-- Clamp

4. Clamping loose (workpiece)

-- Clamp

5. Insufficient rigidity (tool)

-- Use the shortest knife allowed, a little deeper in the grip, and try downmilling

6. The cutting edge of the tool is too sharp

- Change the fragile cutting edge Angle, one edge

7. Insufficient rigidity of machine tools and tool handles

-- Use a rigid machine tool and a tool handle

Wear and Tear
Reasons and improvements:

1. Machine speed is too fast

- Slow down and add enough coolant

2. Harden the material

-- Use advanced tools and tool materials to increase surface treatment

3. Chip adhesion

- Change the feed speed, chip size or clean the chip with cooling oil or air gun

4. Improper feed speed (too low)

-- Increase feed speed and try downmilling

5. The cutting Angle is not suitable

- Change to the appropriate cutting Angle

6. The first back corner of the knife is too small

-- Change to a larger back Angle

Destruction
Reasons and improvements:

1. Feed too fast

-- Slow down the feed rate

2. The cutting amount is too large

-- Use smaller cutting amounts per edge

3. Blade length and full length are too large

- Deep grip, with a short knife, try to mill down

4. Too much wear and tear

-- Regrind at an early stage

Vibration marks
Reasons and improvements:

1. Feed and cutting speed is too fast

- Correct feed and cutting speed

2. Insufficient rigidity (machine tools and tool handles)

- Use better machine tools and tool handles or change the cutting conditions

3. The rear Angle is too large

- Change to a smaller back Angle, machining the edge belt (oil stone grinding once)

4. Clamp loosely

-- Clamp the workpiece

◆ Consider speed, feed

The relationship between the three factors of speed, feed and cutting depth is the most important factor to determine the cutting effect, inappropriate feed and speed often lead to reduced production, poor workpiece quality, tool damage.

Use the low speed range for:


High hardness material
Headstrong big material
Hard to cut material
Heavy cut
Minimal tool wear
Maximum tool life

Use the high speed range for:


Soft material
Good surface quality
Smaller tool diameter
Light cut
Large brittle workpiece
Manual operation
Maximum processing efficiency
Non-metallic material

Use high feeds for:


Heavy, rough cutting
Rigid construction
Machinable material
Roughing tool
Surface cutting
Low tensile strength material
Coarse tooth milling cutter

Use a low feed for:


Light machining, fine cutting
Brittle structure
Difficult material
Small cutter
Deep vertical groove machining
High tensile strength material
Finishing tool

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