CNC mill processing is a key necessity in today's manufacturing industry. High-quality CNC machined parts are used to create high-quality products all over the world. These components must comply with the design specifications specified by the customer and follow the industry standards in order to function accurately and effectively.
Parts that do not meet the required specifications and designs can cause unexpected problems, leading to huge downtime and costs. For example, an inaccurate aerospace component may cause equipment to malfunction during flight, endangering the lives of many people. Similarly, defective brake discs or calipers can cause car accidents, or the costly recall of thousands of cars.
Manufacturers fully understand the importance of timely production of high-quality parts. Failure to do so may result in loss of customers and new orders in the future.
So, what is needed to produce high-quality parts in CNC machining?
First, you need to have a clear assessment of the project you want to participate in. Ask yourself these questions:
What are the different sizes and levels of complexity of the parts?
What materials need to be processed?
What level of accuracy do you need when manufacturing these parts?
What cutting tools do you need?
Do you need expensive fixtures to clamp the machined parts?
Performing this review allows you to choose the most effective and cost-effective method to achieve the desired result.
#2 Consider the best machine type
Does your workshop have the appropriate equipment and machinery to complete this work? If not, you will need to consider the project that best suits you when evaluating the various CNC machine types available on the market.
High-quality CNC machines may cost more. However, they can achieve extremely high accuracy and tight tolerances. The CNC machine is made of good overall mechanics, high-quality ball screw and linear roller guide rail or solid box guide rail. After hardening, grinding, and then manual scraping to perfection, it can provide long-term accuracy and stability.
Be sure to evaluate whether the market needs the same type of machine as you are looking for-this will remind you of what is practical and useful for your processing needs. Finally, consider the delivery time of the brand and type of CNC machine tool so that you are not forced to buy a second or even third option.
#3 Use CNC control to automate
Since computer systems are used to control CNC machines, many production operations can be automated to increase output and reduce non-productive time. The same or mixed parts can be machined with a higher and more stable level of accuracy. Repeat orders can also be set up in a shorter time, while rush orders can be more easily inserted into your production plan.
#4 Use machine software to optimize
Reputable CNC machine manufacturers usually provide specially designed software in their machines to control various parameters and provide error alarms and reports. This type of software enables your knowledgeable machinist to evaluate the machining process, take proactive or corrective actions to ensure that part quality is not affected, and optimize production efficiency by maximizing your machine's capabilities.
#5 make sure to use the right materials
The type of material to be processed will affect the performance level and cycle time. Factors such as durability, bearing load, and overall machine structure all affect the achievable accuracy.
The material properties and tool behavior under the required processing conditions will also affect machine tool factors. These include the maximum spindle speed and feed rate, the most effective motor power and spindle motor torque.
#6 Use the correct feed and speed
Use the correct feed and speed during part processing, because these factors will affect the surface quality of the part and the service life of the selected tool.
If you set the speed too slow, you may experience reduced efficiency and tool damage. If you set the speed too fast, you may encounter accuracy and contour issues, as well as faster tool wear-this will result in higher production costs. Consider the "golden middle" because doing so will ensure good part quality, longer tool life, and stable and economical production runs.
#7 Choose the right cutting tool and cutter
First use the correct cutting tools and recommended cutting settings to obtain the required surface quality and accuracy. After that, you can fine-tune the cutting parameters to achieve the desired output and production cost.
Avoid using blunt tools, wrong (size) tools, or tools that are not suitable for the material being processed-doing so may cause rough edges, cut marks, raised marks and even burn marks on the finished product.
It is also necessary to avoid using the same tool for roughing and finishing in mass production, as this will result in a decrease in finishing quality and may lead to higher wear and cost.
#8 Use proper parts to clamp
How to clamp the material or individual parts to be machined depends on the number of operations to be completed and whether you need to machine on multiple surfaces.
If multiple operations are to be performed (such as milling, drilling, tapping), it is best to clamp the part in a way that allows various operations to be performed in one setup.
This can be achieved through costly "smart" and effective fixture design, or by using an additional axis in your machine (such as a 4th axis or a CNC turntable).
If your materials or parts need to be machined on all five sides, you need to consider using a multi-axis machining center. These can be 3+2 or better 4+1 axis configurations. If you plan to machine molds or very complex shapes and contours, you should use the full 5-axis functionality.
#9 Ensure effective chip clearance
Chips generated during the production process need to be effectively removed from the machine, otherwise they will seriously hinder your processing process. They should not accumulate in the cutting area and must be removed with effective coolant or air pressure.
When chips cannot be effectively removed from the cutting area immediately, they may be dragged around the tool and repeatedly contact the cutting area and the tool. This leads to higher wear, which may cause damage to the surface of the material area, and in the worst case, damage to the cutting tool due to increased load. Avoid chip residues on the entire workpiece, and ensure that the surface quality of the machined parts is not affected.
After ensuring that there is enough coolant or air to blow away the chips from the ongoing cutting area, you can use the conveyor belt inside the machine to effectively handle the chips. There are a variety of conveyor designs to choose from:
The standard hinged conveyor is an all-round conveyor for various materials.
For cast steel materials, scraper conveyors are recommended.
Roller conveyors are mainly used for aluminum materials to ensure that fines are filtered out of your cooling system.
#10 Manage your manufacturing environment
Beware of the effects of external sources of debris and contamination-these can have a very negative impact during processing and can cause costly damage to your machine.
These examples include:
Grinding or worse dust from a nearby foundry
Shock waves generated by presses or punching machines
Power fluctuations caused by unstable power networks
Welding operation near CNC machine
In addition, the unstable and constantly changing temperature in the workshop will affect the accuracy of the machine, and the unclean (moist) and unfiltered air provided to the machine by the air compressor and air duct will affect the function and effectiveness of the machine. sex.
#11 Hire skilled CNC operators
The expertise and experience of CNC machinists play a vital role in producing quality products. A skilled CNC machinist with good manufacturing knowledge and mechanical ability will execute, set up your machine and handle your operations carefully and significantly reduce errors.
#12 In-process inspection
Perform quality checks while the parts are still running to immediately spot any problems and adjust your CNC machine to achieve the required tolerances. You can use high-precision workpiece probes for "online measurement"-these probes allow you to check specific dimensions immediately, or after the operation is completed and before the part leaves the fixture or machine. Then, you can adjust the data as needed and work again.
Online inspection of your tools can also prevent worn tools from being reused-these are dangerous because they may break during processing. Tool inspection can not only help you confirm whether your drill or tap is normal-the real-time tool monitoring system will notify your operator when your tool must be replaced. The tool laser measuring system can even measure tool wear based on length and radius.
#13 Implement quality control measures
The quality system is an integral part of manufacturing. Implement an effective quality control system throughout the operation process-from the beginning of the project to the final product.
Your strict work procedures should ensure compliance with the final product's material inspections, process inspections, dimensions, tolerances and specifications. These will avoid non-compliant products and meet the high quality required by customers, thereby increasing your reputation and productivity levels, while reducing costs. Ideally, manufacturers should also pass ISO certification.
#14 Regular preventive maintenance
Adopting a regular maintenance agreement will help keep your CNC machine tools in good condition. It is recommended to calibrate frequently to prevent your machine from running beyond specifications or generating potentially destructive vibrations.
This type of maintenance inspection can also help you avoid technical problems at the wrong time. Schedule such preventive maintenance inspections at least once a year-preferably twice a year.
Make sure that the expensive machine tools that make money for you get the care and attention they deserve. Don't try to save a few dollars by using cheap lubricating oil. Trying to take shortcuts and buy cheaper substandard oil may result in invalid warranty and expensive repair costs in the near future.
in conclusion
The production of high-quality parts usually depends on a complex combination of CNC machines, software, tools and processes, and skilled machinists. By well managing these different parameters, you will be able to deliver high-quality and consistent machined parts with the correct level of accuracy required by your customers.
In order to continuously produce high-quality CNC machined parts, you need to invest in higher-quality CNC machines. Doing so helps you meet the ongoing demand for higher productivity, constantly changing parts, increased complexity, and the need for consistent product quality.
