Precision machining is a manufacturing method that produces parts using computer-controlled machine tools. It is a high-speed machining method used to create items with tight tolerances, high complexity, or both. Precision machining can be performed by a trained precision machinist or by high-speed robots.
It is a subtractive manufacturing method in which a cutting tool is used to remove material from a block. Precision machining is typically utilized to create a variety of pieces that fit and function together.
Precision machining success is dependent on a combination of two factors:
First, superior precision machining necessitates the use of a high-end cutting tool capable of precisely removing material to fit the intended product specifications.
Second, the procedure necessitates the use of a Computer Numerical Control (CNC) machine. CNC machining procedures, which often incorporate high-speed robots, autonomously control the cutting tool, guiding it where to cut/mill on the workpiece.
What are the Precision Machining Process Steps?
Most precision machining firms follow a set of stages for various sorts of items.
- Create a graphical model
To construct any part, a graphical model is necessary. This is done with the use of Computer-Aided Design (CAD) software. The designer can use the CAD software to build 2D and 3D models of any item for manufacture.
Hand-drawn drawings are commonly used to comprehend the fundamental principles of a part. The Computer-Aided Design (CAD) designer then resorts to these sketches to produce an accurate graphical model. There are several popular software applications for Computer-Aided Design, both free and commercial. For any sophisticated design development, manufacturers might also outsource the design process.
- CAD to CAM conversion
Computer-Aided Design generates a computerized graphical representation of the part. This depiction is simple to grasp for designers, operators, and manufacturers. However, the CNC machines used to make the component do not immediately grasp this digital format.
The machine understands coordinates and may move the cutting tool or change the workpiece based on them. As a result, CNC machines demand that the part design be in a format that includes the essential production instructions. The readable format for CNC machining is created using Computer Aided Manufacturing (CAM) software. The CAM software translates the CAD model into a format that CNC machines can recognize.
Computer Aided Manufacturing (CAM) software employs two sorts of codes: G and M. The G code governs the cutting tool’s coordinates. The M code regulates the machine’s auxiliary operations, such as turning on or off the coolant flow.
- Machine Configuration
When the drawings in CAM format are complete, it is time to set up the machine. This usually necessitates machine tool calibration and the installation of the workpiece on the machine. Machine tools might differ depending on the workpiece material and final item design. Precision machining tools are offered for a variety of applications. It is critical to tighten all clamps appropriately and confirm that machine parameters such as coolant levels are acceptable during this process.
- Carry out the Machining
When the setup is finished, the machine software is ready to run. The majority of CNC machines include a display for monitoring the program and adjusting different settings. When the program is run, the CNC machine will commence precision machining.
- Finishing
The precise machine may be used to remove the item once it has been created. The part may be sent for secondary procedures such as grinding or polishing depending on the needs. However, in most circumstances, a precision-machined completed product does not require any extra processing.
What are the various precision machining methods and equipment available?
Because of the vast range of applications for precision machining, there are several machinery and equipment available. Because various parts need different forms of cutting, a variety of cutting instruments have been produced.
CNC Milling Equipment
CNC milling is a subtractive manufacturing method that removes material from an object using rotary cutters. Different cutting effects may be achieved by varying the direction, angle, pressure, and cutting tool speed. CNC milling machines are available in a variety of configurations, including bed, box, C-frame, floor, gantry, horizontal boring, knee, planer type, turret, and ram milling machines.
CNC Machining
The workpiece spins around a central axis in CNC turning, while a linearly moving cutting tool removes material from the workpiece. Unlike CNC mills, the cutting tool is normally non-rotary. Single-point cutting tools are most typically utilized in this operation.
Grinders with High Precision
After machining parts/components, precision grinders are one of the final production operations. Abrasive grinders (or grinding wheels) are used in precision grinding to provide a precisely flat surface with a very smooth finish on machined items. Furthermore, precision grinding can aid in the production of close-tolerance finishes on completed products by eliminating small amounts of superfluous material.
Drill Presses with CNC
The workpiece is kept fixed in CNC drill presses while a spinning drill bit goes around and makes holes in the workpiece. The perforations might be for part assembly or for aesthetic reasons. By adjusting the size of the drill bit, CNC drill presses can produce a variety of hole sizes. The machine tool calibration may be used to modify the hole depth.
CNC multi-axis machining
CNC multi-axis machining is a complete machining system. The cutting tool has the ability to move in four or more directions. Multi-axis CNC machining allows for the production of complicated components utilizing a variety of cutting tools and methods such as milling, waterjet cutting, and laser cutting.
Machining by Electrical Discharge
Electrical discharges (sparks) are used to form metal in Electrical Discharge Machining (EDM). This procedure is also known as spark machining, die sinking, wire erosion, wire burning, or spark eroding. Because metals carry electricity, electrical discharge machining can only be used on metals. It employs two electrodes: one for the tool and one for the workpiece. The two electrodes are brought near to one other by this machining procedure, but they do not establish physical touch.
An electrical arc forms between the electrodes, boosting the temperature of the tool electrode and melting the metal. Due to the difficulties of cutting the hardest metals using milling machines, EDM applications typically incorporate them. EDM is frequently used to make holes, slots, and tapers in gears.
Swiss Manufacturing
Traditional lathes are improved by Swiss machining. It employs specialised Swiss-made CNC lathes for low-cost, high-precision machining of components. The headstock in a typical lathe is stationary and merely turns the workpiece. In Swiss cutting, however, the headstock allows for linear movement, allowing for more accurate and sophisticated cutting possibilities.
Aside from the moving headstock, a sliding guide bush travels along the workpiece’s longitudinal axis. The guiding bush supports the workpiece during high-precision machining.
CNC Laser Cutting Machines
A high-frequency laser beam is used in CNC laser machining to slice or etch materials. Unlike EDM machining, laser machining may be used to machine both metals and nonmetals.
CNC Mill Turning Centers
CNC mill turning centers, also known as CNC mill-turn machines, are machines that combine milling and turning processes. Milling and turning have always been done on separate CNC machines. However, combining them into a single machine can considerably simplify the production process. CNC mill-turn centers are offered in vertical and horizontal designs. Because of the impact of gravity on the arrangement, the vertical layout is regarded as more stable.
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