precise machining for tools making

  What is the definition of Precision Machining?

Precision machining, also known as CNC machining, removes material from a part while holding close tolerances. A computer numerical control or CNC generally controls a precision machine.

Precision machining makes part contributing to the space shuttle pencil. Precision machining is employed by almost all material products such as plastic and wood, operated by highly skilled machinists. The tools are manipulated in a specific manner to achieve optimum results.

The cutting speed is the primary motion, and the workpiece can be moved as a secondary motion known as “feed.” These motions and the sharpness of the cutting tools allow the precision machine to run.

CAD (computer-aided design) and CAM (computer-aided manufacturing) software programs like AutoCAD and TurboCAD can produce the complex, 3D diagrams needed to manufacture or manipulate an individualized tool, machine or object with high precision.

It is important to pay attention to the details of these blueprints to ensure a product will remain in its original form. While most precision machining companies work with some form of CAD/CAM programs, they often work with hand-drawn sketches in their early stages of a design.

Materials such as steel, bronze, graphite, glass and plastics are machined using precision machining tools. The size of the project and the material to be machined will influence the tooling used.

The manufacturing industry may use high-speed machines, the aerospace industry may use high-velocity machining, and the woodwork tool-making industry might use photo-chemical etching and milling processes.

The manufacturing of a run can number in the thousands or just a single one. Precision machining often involves using CNC devices, which are computer numerically controlled, which allows for the product to be produced to exact dimensions.

injection molding

  • WHAT IS LATHING?

    A tool rotates the workpiece around the spinning axis to execute multiple operations, such as cutting, sanding, shifting, conducting, deforming, facing, spinning, using the materials attached to this workpiece to create the object symmetrically around this axis.

    The potter’s wheel is the most common style. Lathes are used to form pottery.

    Mainly fitted metalworking threads, most durable materials, flat surfaces and screw threads or helices may also be used to make.

    Ornamental lathes can generate incredibly complex three-dimensional solids.

    The workpiece is normally kept in one or two centers, with at least one may usually be rotated horizontally for various lengths of the piece.

    The work on the axes of rotation with a chuck or collector or on a façade is also included.

    Examples of things that may be manufactured include screws, candlestick-holder, arms, cue sticks, mats, cups, baseball bats, musical instruments, crank-shaft and camshaft instruments, in particular for woodwind instruments.

  • WHAT IS MILLING?

    Milling is the machining process of using rotary cutters to remove material from a workpiece by advancing (or feeding) the cutter into the workpiece in a certain direction.

    The cutter may also be held at an angle relative to the axis of the tool.

    Milling covers various operations and machines on scales from small individual parts to large, heavy-duty gang milling operations.

    It is one of the most commonly used processes for machining custom parts to precise tolerances.

    Milling can be done with a wide range of machine tools. The original class of machine tools for milling was the milling machine (often called a mill).

    After the advent of computer numerical control (CNC), milling machines evolved into machining centers: milling machines augmented by automatic tool changers, tool magazines or carousels, CNC capability, coolant systems, and enclosures.

    Milling centers are generally classified as vertical machining centers (VMCs) or horizontal machining centers (HMCs).

    The integration of milling into turning environments, and vice versa, begun with live tooling for lathes and the occasional use of mills for turning operations.

    This led to a new class of machine tools, multitasking machines (MTMs), which are purpose-built to facilitate milling and turning within the same work envelope.

  • WHAT IS CNC?

    Computer numerical control (CNC) is the automation of machine tools through computers executing pre-programmed machine control commands.

    This contrasts to machines that are manually controlled by hand wheels or levers or mechanically automated by cams alone.

    In modern CNC systems, the design of a mechanical part and its manufacturing program is highly automated.

    The part’s mechanical dimensions are defined using computer-aided design (CAD) software and then translated into manufacturing directives by computer-aided manufacturing (CAM) software.

    The resulting directives are transformed (by “post processor” software) into the specific commands necessary for a particular machine to produce the component and then are loaded into the CNC machine.

    Since any particular component might require the use of several different tools – drills, saws, etc. – modern machines often combine multiple tools into a single “cell.”

    Several different machines are used in other installations with an external controller and human or robotic operators that move the component from machine to machine.

    In either case, the series of steps needed to produce any part is highly automated and produces a part that closely matches the original CAD.

    As the controller hardware evolved, the mills themselves also evolved.

    One change has been to enclose the entire mechanism in a large box as a safety measure, often with additional safety interlocks to ensure the operator is far enough from the working piece for safe operation.

    Most new CNC systems built today are 100% electronically controlled.

    CNC-like systems are now used for any process described as a series of movements and operations.

    These include laser cutting, welding, friction stir welding, ultrasonic welding, flame and plasma cutting, bending, spinning, hole-punching, pinning, gluing, fabric cutting, sewing, tape and fiber placement, routing, picking and placing, and sawing.

  • WHAT IS CNC MACHINING?

    CNC machining is a manufacturing process in which pre-programmed computer software dictates the movement of factory tools and machinery.

    The process can be used to control a range of complex machinery, from grinders and lathes to mills and routers.

    With CNC machining, three-dimensional cutting tasks can be accomplished in a single set of prompts.

    When a CNC system is activated, the desired cuts are programmed into the software and dictated to corresponding tools and machinery, which carry out the dimensional tasks as specified, much like a robot.

    In CNC programming, the code generator within the numerical system will often assume flawless mechanisms, despite the possibility of errors, which is greater whenever a machine is directed to cut in more than one direction simultaneously.

    The placement of a tool in a numerical control system is outlined by a series of inputs known as the part program.

    With a numerical control machine, programs are inputted via punch cards. By contrast, the programs for CNC machines are fed to computers through small keyboards.

    CNC programming is retained in a computer’s memory. The code itself is written and edited by programmers.

    Therefore, CNC systems offer far more expansive computational capacity.

    Best of all, CNC systems are by no means static since newer prompts can be added to pre-existing programs through revised code.

  • WHAT IS CNC PROGRAMMING?

    In CNC, machines are operated via numerical control, wherein a software program is designated to control an object.

    The language behind CNC machining is alternately referred to as G-code, and it’s written to control the various behaviors of a corresponding machine, such as the speed, feed rate and coordination.

    Basically, CNC machining makes it possible to pre-program the speed and position of machine tool functions and run them via software in repetitive, predictable cycles, all with little involvement from human operators.

    Due to these capabilities, the process has been adopted across all corners of the manufacturing sector and is especially vital in metal and plastic production areas.

    A 2D or 3D CAD drawing is conceived for starters, which is then translated to computer code for the CNC system to execute.

    After the program is inputted, the operator gives it a trial run to ensure no mistakes are present in the coding.

    In today’s CNC protocols, the production of parts via pre-programmed software is mostly automated.

    The dimensions for a given part are set into place with computer-aided design (CAD) software and then converted into an actual finished product with computer-aided manufacturing (CAM) software.

    Any given workpiece could necessitate a variety of machine tools, such as drills and cutters.

    To accommodate these needs, many of today’s machines combine several different functions into one cell.

    Alternately, an installation might consist of several machines and a set of robotic hands that transfer parts from one application to another, but with everything controlled by the same program.

    Regardless of the setup, the CNC process allows for consistency in parts production that would be difficult, if not impossible, to replicate manually.

  • WHAT IS TURNING MACHINING?

    Turning machining involves a workpiece (typically metal but could also be wood, plastic or stone) rotated next to a rotating cutting tool.

    Turning machining is generally performed on lathe machines.

    Different types of turning to the machine include straight turning, threads, taper turning, and external grooving.

    In straight turning, the workpiece is rotated while a single cutting tool moves parallel to it.

    In tapered turning, a tapered turning attachment is used.

    For external grooving turning machining, grooves are cut to specific depths.

    The grooves are not removed completely as they are in the parting turning method.

    Lathe machines are used to shape materials by rotating the workpiece into a cutting tool.

    There are three types of lathe machines: engine lathe, turret lathe and special purpose lathes.

    Lathe machines can range in size from small and portable to big, floor-mounted machines.

  • WHAT ARE CNC LATHE MACHINES?

    A computer controls a CNC Lathe Machine. It is an automated method of generating various shapes, features and dimensions while holding close tolerances.

    Lathe machines date back to ancient Egypt.

    Over the years, lathe machines have transitioned from being made of wood to metal. Computers usually operate today’s lathe machines.

    In lathe machines, pieces are cut in a circular direction with indexable tools.

    With CNC technology, the cuts employed by lathes are carried out with precision and high velocity.

    CNC lathes are used to produce complex designs that wouldn’t be possible on manually run machine versions. Overall, the control functions of CNC-run mills and lathes are similar.

    As with the former, lathes can be directed by G-code or unique proprietary code. However, most CNC lathes consist of two axes — X and Z.

  • WHAT IS A MILLING MACHINE?

    CNC mills can run on programs comprised of number- and letter-based prompts, which guide pieces across various distances.

    The programming employed for a mill machine could be based on either G-code or some unique language developed by a manufacturing team.

    Basic mills consist of a three-axis system (X, Y and Z), though most newer mills can accommodate three additional axes.

    A milling machine is used to cut and shape solid materials.

    A milling machine can be vertical or horizontal, based on the orientation of the spindle.

    Both the workpiece and milling cutter move, controlled manually, mechanically or through a digital computer numerical control (CNC Milling Machine).

    Milling machines generally use cutting fluid to wash away excess material and cool and lubricate the metal. The waste material removed is called chips.

    The workpiece and cutting piece can be controlled down to .001 inches. Both simple and complex cuts are made with milling machines, from keyway cutting to diesinking.

  • WHAT IS A CNC MILLING MACHINE?

    A computer controls a CNC Milling Machine. It is generally used with a vertical or horizontal milling machine and can move the spindle along the Z-axis.

    The first CNC machines then called numerically controlled (NC) machines, were built in the 1940s and 1950s and followed points on punched tape to direct the motors to move.

    TODAY, a CNC machine works with computer-aided design (CAD) and computer-aided manufacturing (CAM) programs and is highly automated.

  • WHAT ARE PLASMA CUTTERS?

    Involves cutting a material using a plasma torch. Commonly used to cut steel and other metals but can be used on a variety of materials.

    In this process, gas (such as compressed air) is blown at high speed out of a nozzle; simultaneously, an electrical arc is formed through that gas from the nozzle to the surface being cut, turning some of that gas into plasma.

    The plasma is sufficiently hot to melt the material being cut and moves sufficiently fast to blow molten metal away from the cut.

  • WHAT IS ELECTRIC DISCHARGE MACHINING?

    (EDM), also known as spark machining, spark eroding, burning, die sinking, or wire erosion, is a manufacturing process in which the desired shape is obtained using electrical discharges (sparks).

    Material is removed from the workpiece by a series of rapidly recurring current discharges between two electrodes, separated by a dielectric fluid and subject to an electric voltage.

    One of the electrodes is called the tool electrode, or simply the “tool” or “electrode,” while the other is called the workpiece electrode, or “workpiece.”

  • WHAT ARE MULTI-SPINDLE MACHINES?

    Type of screw machine used in mass production. Considered to be highly efficient by increasing productivity through automation.

    Can efficiently cut materials into small pieces while simultaneously utilizing a diversified set of tooling. Multi-spindle machines have multiple spindles on a drum that rotates on a horizontal or vertical axis.

    The drum contains a drill head consisting of several spindles mounted on ball bearings and driven by gears.

    There are two types of attachments for these drill heads, fixed or adjustable, depending on whether the center distance of the drilling spindle needs to be varied.

  • WHAT IS WIRE EDM?

    Also known as wire cutting EDM, wire burning EDM, or traveling wire EDM, this process uses spark erosion to machine or remove material from any electrically conductive material using a traveling wire electrode.

    The wire electrode usually consists of brass or zinc-coated brass material.

    Wire EDM allows for near 90-degree corners and applies very little pressure on the material.

    Since the wire is eroded in this process, a wire EDM machine feeds fresh wire from a spool while chopping up the used wire and leaving it in a bin for recycling.

  • WHAT IS SINKER EDM?

    Also called cavity type EDM or volume EDM, sinker EDM consists of an electrode and workpiece submerged in oil or another dielectric fluid.

    The electrode and workpiece are connected to a suitable power supply, which generates an electrical potential between the two parts.

    As the electrode approaches the workpiece, dielectric breakdown occurs in the fluid, forming a plasma channel and small spark jumps.

    Production dies, and molds are often made with sinker EDM.

    Some materials, such as soft ferrite materials and epoxy-rich bonded magnetic materials, are not compatible with sinker EDM as they are not electrically conductive.

  • WHAT IS A WATER JET CUTTER?

    Also known as a waterjet, it can be sliced into metal or other materials (such as granite) by using a jet of water at high velocity and pressure or a mixture of water and an abrasive substance such as sand.

    It is often used during the fabrication or manufacture of parts for machinery and other devices.

    Waterjet is the preferred method when the materials being cut are sensitive to the high temperatures generated by other methods.

    It has found applications in many industries, from mining to aerospace, where it is used for operations such as cutting, shaping, carving, and reaming.

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