CNC Prototype

The Advantage of CNC Prototype Machining In Rapid Manufacturing Industry

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Nowadays, rapid prototyping technology has become more and more popular. For example, 3D printing is loved by many people. However, due to the limitations of materials, surface treatment requirements, and large-size workpieces, CNC prototype may be the best choice in many cases. For the production and processing of new products, this also benefits from the continuous innovation, development and upgrade of CNC technology, which makes it indispensable in the rapid manufacturing industry. Below we describe some advantages of CNC machining:

1) Material Selection

CNC machining is basically unlimited in the choice of materials. In addition to common plastic and metal materials, wood and ceramics are now more and more used. You can increase the corresponding margin on one side according to the size of the workpiece, and you can cut the original It does not waste a lot of materials when used for the board. However, 3D printing cannot print wood ceramic materials, which contain some special metals, such as magnesium alloys, zinc alloys, etc., so you can see that it has many limitations in the selection of materials.

2) Surface Treatment

Basically, the surface of the workpiece processed by CNC is smooth. After deburring, the corresponding surface treatment can be carried out according to customer requirements, such as :anodized, painted, electroplating, etc. The most important thing is to obtain a high quality finished. This has a great relationship with the performance of the selected material block,which can save a lot of time and production costs.

3) Precision Requirements

CNC machining is very good for the accuracy control of the workpiece. Many tools can be installed on the tool magazine at one time, and the cutting can be selected according to the program path. The programmer can select a specific tool and optimize the program according to the accuracy requirements on the customer’s drawing file. , To meet the accuracy requirements, and the positioning of the workpiece when using the fixture is also very important.

CNC Prototype

4) Rapidity

For some simple workpieces, such as those without a cambered structure, it may be completed within an hour. After receiving the customer’s CAD drawings, you can immediately prepare materials, program, machine, and run, which is why many products Developers and designers like to choose CNC machining as the production process, especially in the rapid prototyping industry, this function creates high value for the enterprise.

5) Flexibility

For CNC prototype, you can choose to make one, several, or hundreds, but only one program is enough. If you need to change the material later or modify the CAD drawing file, you only need to update the program and adjust the fixture. For example, some holes need to be enlarged, and the grooves are deepened. These changes are more convenient and will not take a lot of time.This will increase the economic efficiency virtually.

6) Quality

The advantages of quality are mainly reflected in two aspects: on the one hand external: according to the above The description, surface treatment and dimensional accuracy can meet customer requirements very well, one the other hand: The mechanical properties of the material, functional testing can meet engineering needs, and at the same time, the tapping requirements for some very hard plastic or metal parts In the CNC machining process, it can be more perfectly reflected.

How Can We Help You ?

We are experts at CNC prototype machining and low volume manufacturing ,if you have some projects which are related with machining services .We can help you within the shortest possible lead times. Please don’t hesitate to contact us for a quote ,send us your CAD files and PDF drawings .

Aluminum CNC Machining

Why Aluminum CNC Prototype Machining Is Often Applied ?

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For CNC machining jobs, aluminum is among the most popular substance choices because of the desirable physical attributes. It’s strong, making it well suited for mechanical components, and its particular outer layer is more resistant to corrosion from the elements. These benefits are made aluminum components common across all industries, even though they are especially favored in the automotive, aerospace, health care and consumer electronic equipment spheres.

Aluminum also provides certain advantages that simplify and enhance the practice of CNC machining. Unlike a number of different metals using similar material possessions, aluminum provides excellent machinability: lots of its ranges can be efficiently penetrated by cutting edge tools, chipping readily while being comparatively easy to form. Due to this, aluminum could be machined almost three times faster than steel or iron.

This report describes some of the essential advantages of aluminum CNC machining , reasons why it’s among our most widely asked prototyping and manufacturing processes — but additionally suggests machining options to aluminum. Other metals and plastics can offer similar benefits to aluminum, along with the unique benefits of their own.

Aluminum CNC Machining

The advantages of Aluminum CNC Machining

Strength-to-weight ratio

Aluminum has desired physical attributes which make it perfect for both mechanical and facet components. Some of the main are the metal’s high durability and its own lightweight, each of making the substance beneficial for crucial parts like the ones required from the aerospace and automotive sectors. Aircraft fittings and electrical shafts are just two examples of components which will be successfully machined together with aluminum.

Corrosion resistance

Different aluminum levels vary greatly in their resistance to rust — the amount to which they could defy oxidization and chemical harm. Luckily, a number of the very well-known grades for CNC machining would be the most resistant. 6061, by way of instance, offers excellent corrosion resistance, as with additional metals on the lower end of their strength spectrum.

Machinability

One of the chief reasons why engineers choose aluminum to get his or her parts is because, quite simply, the material is easy to machine.　Even though this would seem to be of a benefit for your machinist fabricating the component, in addition, it has important benefits for your company ordering the component, in addition to the end-user which will eventually use it.

Electric conductivity

CNC machined aluminum parts can be useful for electrical components due to their electric conductivity. Alloys may have reduced conductivities, but aluminum substances are significantly more reflective than, by way of example, stainless steel.

CNC machined aluminum components can be practical for electrical parts because of their electric conductivity. Alloys might have reduced conductivities, but aluminum substances are more reflective than, by way of instance, stainless steel.

Recyclability

Another benefit of aluminum is its own high recyclability, making it preferable for companies trying to reduce their ecological impact or for people who only need to decrease material wastage and recover some of their expenditure. Recyclable materials are especially essential in CNC machining, in which there’s a comparatively large quantity of waste material in the kind of chips from the cutting tool.

Anodization possible

Machined aluminum components are particularly well known in the consumer electronics business, not only for strength and weight requirements, but due to significant aesthetic factors. In addition to being open to paints and tints, aluminum could be medicated with anodization, a coating completing process that thickens the protective and oxidized outer coating of this part.

The anodization process, which normally occurs after machining is finished, involves passing an electrical current through the component within an electrolytic acid tub and ends in a bit of aluminum which is more immune to physical corrosion and impact.

CNC Prototyping in Aluminum May Pose Some Significant Benefits

Enrolling from simpler materials can start up new software in a wider number of businesses. Being among the most common substances in aluminum CNC machining is a perfect material for design, and bringing the capacity in house is surely worth considering. Based upon the businesses your performance functions, and the components they want, it might even be a requirement.

Diving to it, there is a shocking quantity of information to find out about aluminum. To be able to acquire an easy, full image of exactly what CNC aluminum prototype might mean to you personally, follow along with our instructions and ideas to get aluminum prototyping.

Metal Prototyping

CNC machining is a somewhat inexpensive way of producing metal prototyping. A CNC machine employs computer directions to direct a metal cutting instrument, which just eliminates sections of material by a metal block.

Machining is a useful monitoring tool because electronic CAD designs are readily altered between prototypes, leading to an efficient workflow. It’s also easy to make copies or disperse the design to other celebrations. CNC machined prototypes are rather cheap because they needs no tooling and so don’t have any minimum order amount. But, there’s some material wastage as a result of subtractive nature of this procedure.

Rapid CNC Machining

The Importance Of Rapid CNC Machining In Industry

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In the development of numerical controls, it is the needs of the end users that ultimately define the trends. The extreme pressure to which they are subjected to maximize productivity and flexibility in all their operations reverts to the corresponding demands on machine and control manufacturers. In a study conducted last year in Germany, a wide range of industry areas were examined and assessed, including that of CNC machine. The findings revealed that the study group considered reliability the most important factor in assessing the quality of CNC machined parts, followed by service issues such as prompt supply of spare parts and fast service response times. The results of the study speak for themselves: investors and end users attach great importance to the reliability of their machines, which is the basis for maximum productivity in manufacturing processes.

These results are broadly consistent with those of surveys conducted by controls manufacturer GE Fanuc, for which availability is a top priority. The world market leader in CNC machining products ensures that the reliability of its control systems is not affected by poor design of new developments. Nothing hurts productivity more

Rapid CNC Machining

What is a CNC machine?

Also known as a CNC machining center, in short, they are automated machine tools, controlled by a computer. They are tools capable of performing multiple operations on a part, using rotating tools with multiple cutting edges and with minimal worker intervention during the machining process.

CNC machines are used in modern industry, not only to reduce production costs but also to save time and improve work precision, as manufacturing centers are very useful for complex prototype machining. There are two types of machines, vertical and horizontal, classification given based on the position of the spindle motor. There are also machines of different sizes to make parts, such as 3, 4 and 5 axis. The larger the number of shafts, companies can produce comparatively faster and more complex parts. In addition to improving productivity and a better finished job, CNC machines offer a wide range of benefits; Here we bring you a list of the 6 biggest advantages of  machines.

The main advantages of CNC machines

  1. Improved accuracy
  2. Security
  3. High process precision
  4. Waste reduction
  5. Reduction of worker involvement
  6. Execution of complex processes

Technological advancements are not only apparent at the higher end of the CNC control range. The basic range, intended for simpler machine tools, also has considerable improvements. The compact structure of these CNCs is the one that most favors the normally compact design of these machines. GE Fanuc’s 0i-C Series is integrated into the LCD screen, reducing the overall depth to approximately 7 cm.

The CNC can communicate with a PC through a card inserted in the PCMCIA slot. In addition, memory cards in the PCMCIA slot allow for fast upload and download of CNC programs, parameters, and setup data for tool compensation. The data of the alarms and operation histories can be viewed in the CNC and easily transferred through this type of memory cards. Efficiency and overall size are not, however, the only factors that determine the suitability of a control unit. The ease of use and maintenance of the installation are increasingly important aspects for both machine manufacturers and end users.

How does CNC work?

The CNC must facilitate the machine tool manufacturer to adapt the installation to its needs and, finally, to the needs of the end user. This mainly concerns the user interface. While the standard interface is usually sufficient for turning and milling work on a single machine, a special user guidance system is required for grinding and erosion operations. In these cases, machine tool builders often develop their own interface to offer end users greater technology-based ease of use. Control manufacturers, for their part, must provide their customers with the tools necessary to enable them to meet the user’s system specifications. PC technology offers the best options for this.

The solution from the world market leader in CNC, GE Fanuc, called ‘Open CNC’, incorporates an additional PC (Windows 2000 / XP) or an integrated system (without hard disk) and Windows CE. For the design of the interface, GE Fanuc tools can be used, or others available on the market. The maximum security in the data transfer through this interface is guaranteed by means of the physical connection through fiber optic cables and by using a software protocol for the identification and correction of faults. In terms of reliability, the advantage that this solution presents over the single processor solution is that the machining preserves its programmed cycle times regardless of the PC workload.

5 Axis CNC Machining

The Benefit Of 5-axis CNC Machining Revolution

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When we think of part machining, we tend to immediately think of the traditional 3-axis machining (radial, axial and tangential) for both machine tools conventional as for machine tools. While it is true that machine tools have facilitated mass production, much more the CNC prototyping than being controlled by computer reduce the times and increase the precision of production, when dealing with the production of complex parts the 3 aforementioned axes previously they become insufficient.

Thus, the so-called “machining centers” arise which allow work in 4 or more degrees of freedom. This is achieved by starting from the 3 original axes (radial, axial and tangential) and make angular movements with respect to them. Of these machining centers, the most common due to their versatility without reaching extreme complexity, are those that perform 5-axis machining. By using these machines it is possible to machine complex parts, lateral and angular surfaces, as well as undercuts that require interpolation in 5 axes simultaneously.

Some other advantages that this type of machines provide are the following:

  • Possibility of working 5 different faces of the piece simultaneously, eliminating the need for changes of fasteners and repositioning, while increasing precision and repeatability
  • Possibility of tools reaching sections of the part that are impossible to reach for conventional machines.
  • Combination of different types of tools simultaneously, such as milling, turning and drilling tools, along with process tools more
  • Specialized as water jet or laser cutting.
  • Ability to work with a variety of materials on the same machine.
  • Saving physical space in the plant.
  • Reduction of unwanted vibrations due to increased dynamic robustness.
  • It should be noted that these machines achieve their work thanks to great technological advances in terms of the software used for its programming, many of these being compatible with the most famous CAD / CAM systems on the market, which allows a
  • Optimized workflow from the design area to the end product.

Among the various chip removal machining technologies that exist, 5-axis machining is one of the most complex. The 5-axis machining centers have the ability to carry out translations through the X, Y, Z axes; and rotations through two other axes A and B that can be carried out by the table or by the machine head, thus making the tool more accessible to the part to be machined.

5 Axis CNC Machining

There are two work cycles within multi-axis machining:

  • Cycle 3 + 2: the fourth and fifth axis remain fixed, they only move in the step of a process to another, while the X, Y, Z axes move simultaneously.
  • Simultaneous 5-axis cycle: the 5 axes move at the same time, thus reducing the machining times and a better finish of the piece.

To carry out the multi-axis CNC machining process, it is necessary to have a CAM programming software. Using this software, a program is created in which the different parameters to be taken into account during the manufacture of the part are configured, such as the definition of the tool paths, speeds and machining advances. Once the program is finished, a code is generated and transmitted to the machine, which will automatically carry out all the previously predefined movements.

Among the main applications of this type of machining are the CNC prototype of parts in the automotive industry, the manufacture of aeronautical components or the machining of molds and high-precision parts. The purpose of using this type of technology is to achieve a better quality finish and increase productivity, that is, to optimize the low volume manufacturing process. For everything detailed above, it has a 5-axis machining center that also has another advantage: high-speed precision machining, with which optical and high-precision finishes are obtained in the manufacture of prototypes.

Regarding of Promising future:

Thanks to the so-called “internet of things” or “Iota” for its acronym in English, it is expected that technological development in the field of 5-axis machining is accelerated. The possibility of connectivity between prototyping and smartphones has already been tested successfully, opening up a large number of possibilities for monitoring production activities and automation of the same. There is also talk of integrations of functionalities such as fingerprint and iris readers, operation interrupt commands and program restart through voice, nanotechnology and Pico technology, among others, which although they sound like science are very close to becoming a reality today . Without a doubt, 5-axis CNC machining is vital in the productive process of rapid prototyping companies today and will continue to be increasingly important by integrating all those functionalities that technological advances may provide.

CNC Milling Services

What Are Difference between Titanium Machining and Aluminum Machining?

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To carry out a machining process, it is necessary to know the physical characteristics of the material to be machined, which are important when selecting tools, cutting angles, speeds, among other parameters. Only in this way can we maximize production efficiency. Obviously aluminum is much harder than titanium. Some important aspects of both aluminum machining and titanium machining are described below.

Aluminum CNC Machining

Relatively little energy is required to aluminum machining, since to achieve cutting of the material thanks to its mechanical characteristics, it uses a third of the energy compared to the energy used in the machining of steel. CNC aluminum machining can be achieved with high speeds and removal rates without generating excessive stresses between the material and the cutting tool. High machining speed means higher productivity and better surface finishes.

  • The process tips

To aluminum machining it is required that the tool have certain special characteristics, it is desirable that the cutting tools used for this type of materials allow the efficient evacuation of the material to avoid dulling that can ruin the part and the cutting tool, as well as the rake angles should be greater than those used to machine steels. Thanks to the high thermal conductivity of aluminum, the cooling process of the cutting tool does not require too much cooling liquid flow, just enough to evacuate loose material.In the market there are a variety of cutting tools with different properties and costs. For the machining processes of aluminum machining, like steel, it is desirable that the tools are very efficient and durable over time.

  • The option of cutting tool

Thanks to technological advances, it is possible to find tools with hard coatings such as DLC (diamond like carbon – carbon like diamond), which provide hardness and tribological properties to the tool, up to complex coating processes such as PVD (vapor deposition) treatments. , with which titanium nitride coatings capable of protecting the tool with superficial layers with titanium are achieved. Some materials for cutting tools for aluminum machining are:

  • High speed steels are special high performance steels with high hardness up to 500 ºC and high resistance to wear thanks to alloying elements such as tungsten, molybdenum, vanadium and chromium, capable of forming carbides. Cobalt is added to increase hardness. HSS tools are suitable for machining low-silicon aluminum alloys. Supports the use of large rake angles for better cutting conditions.
  • Carbide is a mixture of tungsten carbide and cobalt (CW + Co). This coating provides a longer tool life. They are used in the machining of aluminum with high silicon content and for machining at high cutting speeds.

Titanium CNC Machining

Titanium machining is always a challenge. This is mainly due to the fact that it is an abrasive and cut resistant metal. If we add to this its poor thermal conductivity, machining strategies become a critical aspect when approaching each part to be machined.

CNC Milling Services

  • The process tips

When CNC titanium machining part, you must carefully monitor the amount of material to remove, as well as the advances. A large pass at a high advance will cause great stresses in the machine and an increase in the temperature of the piece. In addition, as a result of the efforts and because it is a ductile material, it is also very possible that deformations appear in the final piece. We must not lose sight of the fact that this ductility can generate vibrations during the machining of the part. Ultimately it is about weighing toughness and cut resistance. The tools used for titanium machining parts are characterized by an important edge. This is to overcome the ductility of the material. Likewise, since it is an abrasive material that accumulates a lot of heat, the tools used to machine titanium have coatings that give them greater durability.

  • The challenge you may meet

Of all the operations in titanium machining, the most complex is threading. External threading can be done using special tools or by using the vortex. On internal threads, especially small diameter threads, chip removal is critical. It must be avoided that it sticks to the edge of the tool, due to the risk of breaking the tap inside the hole to be threaded. The machining of titanium parts is usually demanded in industries such as aerospace, mainly for its weight and resistance.

Above all, you can see that aluminum machining is much easier than titanium machining ,thus ,there is a big difference on cost . In the end, it is necessary to decide which material to use according to the mechanical properties of the product and the design requirements.

aluminum fan blade machined

The Benefits of Prototyping And Low Volume Manufacturing In The Aerospace

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The aerospace and defense sector was perhaps the first industry to incorporate additive manufacturing into its production process, dating back to 1988 when some leading companies in the sector began to experiment with this new technology. Over the years, additive manufacturing has become more important in the aerospace industry and currently accounts for more than 10% of total industry revenue.

Additive prototype manufacturing (or CNC prototyping) in the aerospace sector is used for both simple elements of the interior of the plane and for complex parts of the engine  Additive manufacturing in the aerospace sector is used for both simple elements of the interior of the aircraft and for complex parts of the engine

aluminum fan blade machined

Aerospace industry

The different current applications of CNC machined prototype in the aerospace sector cover both the manufacture of simple objects, such as armrests, to complex parts and different engine components. Applications such as printing of wings and aircraft parts under microgravity conditions are foreseeable in the near future.

Some of the advantages that CNC prototyping brings to this sector are:

  • Reduced time to market: Companies can with CNC prototyping rapidly build prototypes with the required fit, shape and functionality, speeding up design cycles and thereby reducing time to market.
  • Complex Design Tools – The ability to 3D print freeform designs aids in the construction of tools or accessories that are difficult or impossible to produce with traditional machining techniques.

CNC prototyping can create cooling channels that adapt to the required curvature.

  • Low-cost tooling: Not only does CNC prototyping allow companies to quickly design and test new products, it also helps reduce the cost of manufacturing tooling and accessories.
  • Complex part design: CNC prototype enables the design of products with geometries that are difficult to create through traditional prototype manufacturing. Parts can be designed without looking at how they accommodate manufacturing capabilities (which is the case with traditional methods), but instead are designed to offer maximum efficiency. For example, CNC prototyping is already used in aviation to create turbine blades with complex geometric shapes that optimize airflow, which is difficult and time-consuming in traditional prototype manufacturing.
  • Simplification of parts: Additive manufacturing or CNC prototyping, allows the manufacture of multiple parts as a single component, thus reducing the assembly effort.

Embedded electronics (embedded): CNC prototype offers the possibility of adding embedded electronics in the part’s own prototype manufacturing, offering a great opportunity for product innovation. In the unmanned aerial vehicle (UAV) industry, this application of CNC prototyping is gaining strong momentum.

Applications of prototyping in the aerospace sector

Some of the direct applications of  prototype manufacturing in the aerospace industry:

  • Modeling and prototyping.
  • Low volume manufacturing of complex aerospace parts.
  • Spare parts machining.
  • Machined tooling parts.
  • Printing of very specific or specialized pieces (for example for space exploration).
  • Machining of structures with low weight and high resistance materials.Such as: Titanium

Importance

Currently there is an alternative that the machining industry has found to offer greater reliability in the various products it offers, it is called the manufacture of industrial prototypes. It refers to the ability to test or test a component before it is finally manufactured, assuming a substantial advantage in terms of time and cost savings. In this way, with industrial prototypes, possible weaknesses of the component can be detected before it is put into service. Likewise, the quality of the material is verified and if it can meet the requirements and demands of the service. CNC prototyping is an area of ​​the machining industry that can perfectly provide a solid foundation for product safety.

Technological innovation has made it possible to offer a wide variety of methods using CAD / CAM technology. Assisted prototype manufacturing, for example, stands out for its versatility in guaranteeing a product with all the details that the one who wants to manufacture needs. The responsibilities of the industrial prototype designer lie in knowing the functionality of a number of tools and procedures such as laser sintering. Likewise, the manufacture of industrial CNC prototyping can be done manually or using high-precision machining machine tools. In the same way, the designer must analyze in detail all the aspects through the materials that are delivered by the designers, these may very well be 3D resources, plans or sketches already previously evaluated.

CNC rapid prototyping

Everything You Need To Know About Metal Rapid Prototyping

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The machining of parts is carried out with the help of computers capable of controlling the machinery. And with the emergence of CNC rapid prototyping machining, it was possible to automate this process thanks to the ease of control by a computer program with minimal human intervention.

Its use expands to assembly operations, inspection, work on metal sheets, among others. It can be applied to any field, CNC or numerical control machining is used more than anything in metal or aluminum machining processes such as drilling or milling. Thanks to its automation capabilities, manufacturing proceeds at an accelerated rate and produces more accurate results.

How did CNC machining come about?

CNC machining emerged in 1940 thanks to the work carried out by the American engineer John T. Parsons, who used punched cards as a position coordinate system to control a machine center. Eight years later, this system was presented to the US Air Force to be sponsored in the laboratories of the Massachusetts Institute of Technology (MIT).

By 1952, MIT created the first prototype of a CNC rapid prototyping machining and, shortly after, it was introduced into machine tool factories for the production of metal parts, while they continued their research to provide the programmer with the means necessary to communicate part machining instructions to machinery in an easier way.

Types of machines that work with CNC rapid prototyping

Among the most common CNC machines are milling machines, grinding machines, and lathes. Milling machines are automatic cutting machines capable of working even with metals. Lathes are automated tools that rotate on their axis to shape the material. Grinders, for their part, use abrasive discs to perform abrasive machining on metal or plastic. These machines are easy to program and are used in CNC machining projects that do not need as much precision.

Numerical control machining technology contains information related to the position where the machine parts are to be placed. Currently, most of these tools are connected to a computer network where they receive all the instructions.

Advantage

CNC metal prototype machining encompasses the processes of CNC turning, CNC milling, wire cutting and EDM, being ideal to satisfy the vast majority of needs in terms of product development, always starting from the geometry defined by a 3D file. Here are some of benefits:

  • Highly accurate
  • Obtaining tight tolerances
  • Suitable for most materials
  • Optimal surface finish.
  • Low investment in setup costs
  • Scalable volumes from 1 unit
  • Production agility

CNC metal prototype machining applications

Thanks to the automation of CNC metal prototype machining, its use was extended to different industrial sectors such as wind power, aeronautics and even rail, where CNC milling machines perform the molding of landing gears and fuselage components. Many industries turn to the CNC metal prototype machining center to combine different operations on the same machine. Of course, it is necessary for it to meet the needs of roughing, semi-finishing and part finishing operations using multiple heads with automatic change.

CNC rapid prototyping

Tempocast and Tempoform technology

Through these two processes, we can manufacture parts in Aluminum, Magnesium, and Zink or Zamak. This technology starts from a plastic prototype manufactured by 3D printing metal or resin CNC machining. With these cores we manufacture as many negatives as we need depending on the number of metal pieces to cast.

The negatives are made with a material called “plaster” that is deposited in a liquid state. After a drying process, it is prepared for the casting of the liquid metal and once it has been cast and hardened, the imprint is destroyed for remolding. This is the reason for manufacturing as many traces as parts to cast.

Tempocast technology allows us to obtain surface finishes and dimensional tolerances similar to aluminum injection. There is the possibility of making pieces from 50 to 1000 copies. The thickness of the piece has to be 1mm minimum. Piece dimensions from 10 x 10 x 10 mm to a maximum of 1500 x 1500 x 1000 mm.

The Tempoform process is identical to the previous one, but as an initial prototype, a faster and cheaper 3D printing metal is used to produce as many models as we need footprints. This technology is aimed at series from 1 to 50 pieces and with surface finish requirements similar to sand casting or sintering. The maximum dimensions of these pieces are 340 x 340 x 600 mm.

Apple Watch in Titanium Case

Titanium Case For Apple Watch Series 5

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Around 15 years ago ,Titanium has not been used widely yet ,because titanium machining is very difficult ,and the material is very expensive ,most of manufacturers had not the ability to work with Titanium. What’s more ,they lacked of titanium milling skills and experiences . At that time , it only applied for the aerospace and military installation upscale industry .Less common people can touch it .

However , today with the capability of manufacturing is improved and in progress rapidly. Due to Titanium has gained widespread applications in aerospace industries. They are light weight, possess high strength, have excellent fatigue performance and offer high resistance to a bad condition environment. Titanium has become more and more welcomed premium metal material, it has came into common people’s life . So you can see and touch it in our daily life.

The Premium Material For Watch Case

The list of titanium benefits and favorite properties is lengthy. This makes it incredibly useful for all kinds of industries, including the electronic products .Such as : Some of the most common uses for titanium are the case of consumer electronics product. Last year Apple announced that they launched the Apple Watch Series 5 with titanium case , it is as strong as stainless steel but much less dense, obviously the new premium material in the titanium watch case is lighter than stainless steel cases they made in the past years. Although the original material is expensive, it is really different .Titanium makes the most sense to compare with those aluminum ,stainless steel material choices for the Apple Watch .

Apple Watch in Titanium Case

 

 

 

 

 

 

 

 

 

 

Source : from the Apple Watch

What Is the Difference With Titanium?

1) Exceptionally strong, lightweight

2) Better prevention of scratch

3) Special characteristics to help it wear better over time.

4) More fashionable.

The Cost Factor

When a new product is launched into the market, in addition to paying attention to appearance and function, consumers also have a particularly important factor, which is price. Obviously, the cost will be increased too much for the whole watch product to use Titanium material as the watch case .People will have to consider it when they are going to buy it .Maybe many people are not affordable for this type of luxury. Apple Watch needs to consider improving the production process or vast production scale to bring the costs down, so that more and more people can accept reasonable prices range.

How Can We Help You ?

We are experts at machining Titanium prototype parts and low volume production ,if you have some projects which are related with Titanium components .We can provide custom Titanium CNC Machining services within the shortest possible lead times. Please don’t hesitate to contact us for a quote ,send us your CAD files and PDF drawings if have threads ,tolerances ,surface roughness,parallelism..etc requirements. You will see how we can be your strategic partner on your key projects .

CNC machined parts inspection

How to Offer the Best CNC Machining Services for Customers?

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You are able to find out a lot of machining shops through by searching on the Google. Bing. Yahoo. They are from many nations and serving all kinds of industries accordingly .Almost these manufacturers could provide CNC prototyping services and a series of volume production. However, as a professional and excellent machined supplier, how to offer the best CNC machining services for your customers?

Response Fast to Customers Questions and Quote

 The sales should reply quickly after received the RFQs from the customers, for some of uncertain issues, sales should discuss with the engineering team to get a confirmation before answering, especially on the design issues. In fact, most of the machining customers are designers, they like to communicate with the manufacturer to discuss their ideas and designs in order to optimize the design better. Even you can also provide some suggestions or solutions to help customers save cost.

 Choosing the Correct Materials According to Customers Requirements

After received the order from customers, the first step is prepared for original material ordering .You have to provide the correct materials, if customers require Aluminum 7075, then, you cannot provide Aluminum 6061 instead. And also, for some of material colors difference, you need to pay attention too, for example, there are both white and black POM. You have to confirm with customer which one they prefer .

Checking the CAD Models before Making CNC Programming

In China , engineering people like to work with PROE or UG software ,but most of western designers and engineers like to use SolidWorks as their working software ,when converting 3D files ,maybe some issues will be happening ,such as : perhaps some of caves will be incorrect or broken. Thus, programming maker should repair it before starting programming job.

Checking the Programming before Inputting the Machines

After the programming done, it should be checked by the leader or another coworker before inputting the machines to make sure it correctly. If you have not checked it ,once the machine running , the work piece will be incorrect if some of programming made a mistake .So this step is very important for the whole CNC machining process .

Quality Control

Parts need to be Inspected and Checked after Machined

 In fact , the machinist should pay attention to the work piece during machining step , and observe if it is running according to the programming of setting up ahead .Especially for some of stiff metal cutting. Such as, it probably produce huge noise and smoke during titanium machining process. These factors the machinist should know. After machined parts done, you need to check and inspect them before starting deburring, polishing, anodizing or other finishing. Such as: if customers request threading? Or some tight holes? The clearance of sharp corners?  It will cost too much if you did not inspect after machined, and directly make the process of finishing, when you looking back to make an inspection on the parts. The operators should check the drilling tools with Caliper before drilling holes to keep the tools what they use are 100% correct, rather than feeling with their experiences.

Make the Final Inspection before Parts Packing

You need to check and inspect the quantities, dimensions, tolerances, threads, and some finishing again before packing the parts .QC should be responsible for the whole quality control process. And make a full inspection on each part. For some of customers who are demanding the report of quality inspection. QC will be prepared for it. In the meantime, if customer has emphasized the fitting relationship between some of parts, then, the manual workers must try to fit them.

CNC machined parts inspection

Keep the CNC Programming Well for Future Production

In machining industry, usually customers will make one CNC prototype or a few pieces as test and checking. Once the prototype approved, then, the next step is production running .So the manufacturer has to keep the programming,if the customer modified their design ,programming makers can also adjust and remake it accordingly on the former programming, thus ,it can save lots of time .

 

CNC milling

CNC Milling–What You Need To Know

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When we talk about CNC machines, one of the types that we must attend to know everything about them are milling machines. Like the other machines that are manipulated by Computerized Numerical Control, CNC milling services machines are an update of conventional milling machines carried out by modernizing wave of recent times.

In basic terms, there is not much differentiation between CNC milling machines and conventional milling machines, so much so that there are special kits capable of converting a common milling machine into a CNC machine. Both formats have the same moving parts, such as the table, cutting head, spindle, and lateral and transverse displacement carriages.

However, CNC service machines do not have levers to operate these parts; instead, they have a screen inserted into a control panel, as well as a metal case to house the electronic and mechanical components of the device. These components include the CNC, which is primarily responsible for the movements of the milling machine.

CNC milling

CNC milling machine components

As we said before, a CNC mill shares some parts with its more basic and conventional counterparts. In the following list we will expose the components of a basic model of CNC  machine , highlighting those exclusive parts of them:

  1. -Column
  2. –Work piece
  3. -Strawberry
  4. -Milling table
  5. -Cutter head with spindle motor included
  6. -CNC control panel
  7. -Hoses for coolant liquid

On the other hand, CNC milling machines have two main axes for movement and two complementary axes for the cutting head.

Function of the Computerized Number Center

The main function of the CNC in a milling machine is to control the movements of the table, the transverse or lateral carriages and / or the spindle along the main axes by means of numerical data. Controlling the movements requires an almost perfect synchronization of all the components that allow the execution of the CNC process, such as the following:

  • Axes of displacement, main and complementary.
  • Transmission systems
  • Clamping systems for parts
  • Tool changers.

CAD and CAM programs

The use of CAD (Computer Aided Design) and CAM (Computer Aided Manufacturing) programs is practically mandatory on all CNC milling machines. The intervention of each one facilitates the manufacturing process in an unequaled way. We will detail below the function of each one, also including the control software:

  • CAD: It is responsible for the design of the piece.
  • CAM: It takes care of the calculation of the displacements of the axes for the machining of the part, in addition to adding the speeds of the turns and the various cutting tools.
  • Control software: Each CNC milling includes its own. It receives the commands from the CAM program and executes the orders to move the moving parts of the milling machine according to these commands.

CNC milling services machines are adapted to milling profiles, cavities, surface contours and other operations. The milling table generally requires manual control of two or three axes of travel for the table in this type of work. However, depending on the complexity of the job and the type of machine, the process can be completely automatic.

Differences between a CNC milling machine and a conventional milling machine

An advancement of the CNC machining services over the conventional milling machine is the ability offered by the computer that controls them to carry out movements that cannot be performed manually, such as circles, diagonal lines and complex three-dimensional figures. It should be taken into account that a CNC machine allows the programming of the milling operations through numerical codes, to execute them by themselves without the need for an operator to handle them.

The computer of a machine controls the position and speed of the motors that drive the axes of the machine; as well as the movement of the table, the carriage and the spindle. An advantage that enables uniform production, through improved precision, as well as the quality of the final part.

Medical Device Prototyping

Why Custom Machining Medical Parts?

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CNC medical componentsRecently, cutting tool concepts have been introduced that increase efficiency and optimize productivity in small part machining for the medical industry. As sliding head machines evolve for small CNC machined parts, so do cutting tools to deliver the performance required for maximum machine utilization. In UYEE industry, many tool areas have reached new levels of performance, of which rotary head threading and high-pressure coolant turning are two excellent examples.

The growth in the production of large volumes of long and thin screws in high performance metals, such as bone screws, evolves in parallel with the competitive pressure of their manufacture. This is the typical case for providers in the UYEE industry, where bone screws, for example, are machined in increasing volumes and for whom rotary head threading is an established method. The inherent stability of the process makes it the method of choice for high volume machining and demanding metals.

Choosing the Right Cutting Tools

The main benefit is a longer tool life, which means less Medical device prototyping machine downtime during the production process. In addition, the robustness of the cutting edge line can be optimized to achieve sharper and more reliable edges. Taking advantage of advances in other areas of machining, and developing specific index able cutters and inserts for rotating head threading of small CNC machined parts, offers great advantages in the manufacturing economy of CNC medical components.

The developments in inserts have provided the necessary means to achieve a new concept of cutting edges, which takes more advantage of the benefits of threading with rotary head. Coated carbide inserts, for example, offer longer and more predictable service lives, as well as the ability to achieve higher cutting speeds. This has resulted in higher productions and more CNC machined parts within required tolerance and finish levels. New insert grades, such as those with PVD / TiAlN coating, feature a genuine thin coating layer with excellent adhesion to the insert substrate. The grade has proven to be especially advantageous for the sharp cutting edges required for rotary head threading of materials such as those used in bone screws.

The Skills of Milling Medical Components

Operational safety and tool handling are additional essential features for higher performance in rotary head threading. The precision of the tool determines the quality of the insert seat, the rectification of the insert and the ease and reliability of the correct location of the insert at all times. Newly developed insert clamping for rotary head threading mills has improved cutting edge positioning accuracy, machining safety, and ease and time of tool change. Also, to ensure the high precision and surface finish required during the process, a smooth tangential cutting action is required.

Today, in rotary head threading, end mills should include precision ground specialty inserts and pre forms should be compatible with most types and brands of tailstock spindle. Despite already being a high-volume production process, meeting higher production and new CNC medical components demands requires new tool technology to achieve more advanced ring concepts in rotary head threading.

In one example of rotary head bone screw threading fabrication, with volumes of around half a million per year, in varied small batches, installing the modern index able insert tool resulted in machining savings that greatly increased manufacturing competitiveness . The long service life of the new tool allowed nine times as many components to be Medical device prototyping machined before having to change the cutting edge, when CNC medical components dimensions began to fall outside tolerance requirements. In addition to eliminating machine downtime, the easy maintenance of the cutter saved a lot of time in the tool room.

The Development of Coolant on Machines

Medical Device PrototypingThe coolant supply available in today’s sliding head machines offers new possibilities for optimized small CNC machined parts production. Replacing the conventional flow of coolant in the machining zone with a high pressure coolant system offers many machining advantages. In addition, the introduction of this assisted cutting means does not have to involve complicated and elaborate installations, since there are standard tools for this and the supply of internal coolant is already a very common practice.

In recent years, high pressure coolant machining has been continuously developed, resulting in today’s efficient concept. The great advantage of this system lies in the optimization of performance and chip evacuation when machining demanding materials, from the point of view of chip control, such as low carbon steels or super alloys.

The application of a tool concept to precisely direct the jets of high-pressure coolant to the cutting area is now also available for machining small CNC medical components. The current solution combines precisely directed coolant jets with a simple and safe clamping system.

This opens new doors for the efficient machining of demanding materials, especially in sliding medical device head machines, where groups of small tools are in very tight spaces and whose change and adjustment is slow and complicated. Both machining and tool change are optimized with the new tool holder system, equipped with location, locking system and connections for the coolant, on the machine.

 

Aluminum Handle Prototype

What Is The Most Commonly For Aluminum CNC Machining?

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Aluminum alloy is the most widely used non-ferrous metal material in the industry. It has low density, high strength, good plasticity, excellent electrical conductivity, thermal conductivity, and corrosion resistance. It can be manufactured for various products. It has been used widely in industry, such as our common electronic product housings, frames, and home windows. These are all aluminum alloy materials. According to different properties and application fields, it can be divided into ordinary aluminum alloy, high-strength aluminum alloy, and heat-resistant aluminum alloy. The most commonly used are 6061,5052，6063, 6082,7075 .The most commonly for aluminum CNC machining that there are main four points as below:

The Application Of Rapid Prototyping Industry

Due to the continuous update and change of technology in the rapid prototyping industry, CNC machining is already a very mature manufacturing technology, which is mainly suitable for processing complex curved surfaces, deeper inner cavity shells, multiple procedures, and high precision parts. Compared with traditional processing Way, obviously its production efficiency has been greatly improved, and in some respects it is no longer replaceable. When customers require CNC Aluminum Prototype and low volume production, its higher flexibility and superiority are presented. For example, making aluminum handle, because it is solid and heavier, and the surface requires fine sandblasting and black anodizing . 3D printing is also possible, but the surface will be rough and it will take a long time to polish, so the cost will be much higher. The CNC machined surface will be very smooth, as long as the burr is removed off. And if the customer needs to modify the design after received the prototype, it only needs to modify or adjust the programming accordingly in the subsequent production.

CNC Aluminum prototype machining

Applications In Automotive and Aerospace Fields

The traditional automobile industry usually pursues efficiency and scale. Now people have put forward higher requirements for automobile functions. This also requires automobile parts to meet higher accuracy. The application of CNC manufacturing technology can promote automobile processing enterprises to gradually become small-scale , Personalization and high-efficiency are developing rapidly to improve work quality and work efficiency.

In aerospace equipment, the most commonly used lightweight materials are titanium alloys and aluminum alloys. If the traditional methods are used to cut titanium alloys and aluminum alloys, it is easy to cause heat and deformation of the parts. In this way, the processing accuracy and the overall the quality will have a bad influence and the safety will be greatly reduced. However, through the use of CNC technology combined with professional high-speed machining technology, this problem can be solved well and the production safety and reliability are guaranteed. At the same time, the speed is faster and the quality is better to meet the needs of the equipment.

Aluminum Mold Making

Since aluminum alloy is a relatively soft metal compared to steel, it can be machined faster and cost less, usually saving 30% to 50% of cycle time. It is also much more convenient to repair the mold later. However, the life of aluminum mold is relatively shorter, which is why aluminum mold have not been widely used and promoted, and the application ratio in the injection molding industry is still not high.

Machinery Manufacturing

In work and life, we can see products and components which are made out of aluminum almost everywhere. These parts are basically produced through by molding, CNC machine, sheet metal, and profile extrusion, of which CNC machining occupies a certain proportion. With the development of society, people are more and more inclined to personalized customization. Due to market competition, new product designs are updated and the delivery time is shorter, which promotes the continuous development and higher demand of CNC technology.