Introduction

Why is the aerospace industry different from other industries we have covered on our blog? Is it the cost, or is it what’s at stake? The aerospace industry cannot afford the consequences of part failure. This is because human lives are at stake. Every part should work in harmony with the other, which puts immense pressure on the design and manufacturing process. We have found CNC machining an ideal manufacturing process for the aerospace industry since it delivers the required precision and tight tolerances while prioritizing quality and time. However, there are several challenges associated with CNC machining, especially for manufacturing aerospace parts. Let’s discuss them in detail!

1.Finding suitable manufacturers

Aerospace engineers and manufacturers often find it challenging to source manufacturers, especially reliable ones. Finding the right manufacturing partner helps meet the special requirements in the aerospace industry. The manufacturing company and supplier should have AS9100 certification based on ISO 9001 since quality and safety are everything to the aerospace industry.

The challenge is to find manufacturers with such certification as AS9100 is expensive and takes the manufacturer quite some time to earn it. We suggest you go for a digital manufacturing company as they have a wide pool of certified manufacturing partners that can supply the necessary material.

2.Achieving required material properties

Aerospace components manufacturing comes with highly specific material properties. Although the metals are usually heat-treated to trigger the desired amount of hardness and strength, the heat-treating process poses many challenges. Once heat treated, the metal becomes harder and stronger – perfect combination to achieve tighter tolerances

 However, CNC machining such hardened material is expensive, time-consuming, and wears out the tools quickly. The metal can be heat treated after machining as well. But that comes with a whole new set of issues. Heat treating after machining can affect the part’s dimensions and push it out of spec.

3.Dealing with CNC limitations

Aircraft are made of millions of small and large components assembled to perfection. The size of the parts can be an issue while machining. Since typical CNC machining beds are only a few feet long, they might not support larger structural aerospace components.

In other words, you will have to work hard to find CNC machine suppliers that can work on bigger components. You can also redesign the large part to make things manageable. However, that will increase the aircraft’s overall weight due to the additional fasteners and holding materials.

4.Deformation due to residual stresses

Components like aircraft engines or compressor housing are made out of a large block of material. Such components have large internal cavities and can take a lot of time and effort to manufacture. Not just that, the process ends with a lot of scrap material and residual stresses in the component leading to deformation.

Engineers and manufacturers often rely on the Internal and External Removed Material Ratio to determine how much material they will need to remove. You can even cast such components instead of machining them.

Casting helps overcome material wastage and warping. However, you will have to rely on CNC machining to finish the component while meeting the set tight tolerances.

5.Achieving complex geometries

Some aerospace components require complex geometries since they need to fit into tight spaces, reduce weight, and maximize overall strength. Such complex geometries are hard to achieve using CNC machining.

Although such complex geometries in the aerospace industry are often unavoidable, one should check if the geometries are necessary or not.

We suggest you promote design for manufacturability among your team of designers and engineers. DFM considers the feasibility, time, and design costs while addressing the component’s complexities.

6.Efficient sourcing of suitable materials

CNC machining isn’t possible if you don’t have the material ready. Finding or sourcing suitable materials for the components can be a nightmare. You will often find yourself searching for superalloys and specialized plastics like titanium, nickel alloys, Ultem, and more.

Such materials are required constantly, which makes sourcing them a long-lasting challenge. Again, a digital manufacturing ecosystem will help you search for reliable suppliers. This allows the engineers and designers to focus on their tasks instead of worrying about logistics. 

7.Dealing with advanced engineering plastics

Most aircraft use advanced engineering plastics that are quite challenging to machine. Such plastics are high temperature resistant and possess high tensile strength. Advanced engineering plastics function more like a metal than a polymer and can quickly dull the cutting blades.

Consequently, the CNC machines will lose their accuracy and precision due to improper cutting speeds. It is crucial for you to have highly skilled engineers and machinists in your team. You will need to optimize the cutting speeds and machine the AEPs under ideal conditions.

8.Lack of demand/production

Lastly, demand for aerospace parts and components is constantly fluctuating. The demand for some components could go from non-existent to overwhelmingly large in a matter of hours. Since aerospace components are not mass-produced, you often find yourself in a high mix, low quantity production scenario.

It involves reviewing and setting up manufacturing processes to produce each component. This can be time-consuming and often quite expensive since the manufacturing partners have to work on complex geometries. Such projects are not efficient and cost-effective. 

Keep reading!

Running into the challenges mentioned above is guaranteed, especially when you work as an engineer or manufacturer in the aerospace industry. Although such challenges are prevalent in other industries, the inability to overcome them can lead to scary consequences in the aerospace sector. We suggest you make the most of the lessons provided in the post and put them to use when you run into similar CNC machining issues. Did you find this post helpful? Let us know in the comments. Also, don’t forget to check out other informative posts on the blog!

Related Articles:

• Aerospace Fasteners: Understanding Types and Materials
• What is CNC machining? An Overview of the CNC Machining

CNC machining is known as computerized numerical control machining. Its purpose is to shape, cut, and create different parts and prototypes.

CNC machining is a computerized or automated machines phenomenon. Because this machine is controlling by computer.

Although CNC machining is most important in the manufacturing process. Basically, computer software is controlling this programming. CNC machine is also a shaping machine. Because it also performs three-dimensional, four-dimensional cutting tasks for giving specific shapes to products.

CNC machining gives a hundred percent accuracy when it works best. This accuracy insurance consistent product quality. While using CNC machining technology, production speed is increasing. Because it works automatically.CNC machining works by computer control. But it gives more production and ensures safety while performing its tasks.

In CNC machining computer software and written code control the programming. In the whole manufacturing process while performing its difficult tasks.

CNC machining can be defined as the subtractive manufacturing method of technology. In which cutting tools are present for shaping.In this process of CNC machining removal of waste material from a block of material.

The whole process of CNC machining is notably reliable and profitable. This whole process of manufacturing and cutting is controlling by the computer. CNC machining has its unique parts to work accurately. This machining is present  in many shapes and ranges.Although it works on the basis of the automatic machining phenomenon.

Every CNC machine has its own specific parts to work accurately.Such as spindle,  and controller.

CNC machines are playing a basic role in shapers, lathe, mills, welding purposes.

This machine plays a wide role in industries.

Its most significant use is, in metal and plastic production. All industries which are using CNC machines. The metal removing industry, fabricating metals industry, automotive industry, electrical discharge machining industry, wood industry, and plastic industry.

Benefits of CNC machining

• Increase production speed
• Safety
• More cost-effective
• Automatic performance
• Eliminates unnecessary waste of production
• Controlled by computer software.
• Reduce errors from the manufacturing process.
• Remove unnecessary waste while the manufacturing process.
• More capabilities and accuracy in working.
• Save labor cost
• Save money and time of labors
• Capable to produce complex designs with accuracy in minimum possible time.
• Does not need highly skilled operators to operate it.
• Easily changeable for improvements and reduce the delay time.

Overview of CNC machining process

Although, CNC machining is computer-controlling machining technology. It is computer_aided design (CAD) and computer-aided manufacturing (CAM) using machines.

In CNC machining different materials are specific in different machines of multiple functions. Moreover, different materials are using in CNC machines for specific functions. Material is dependent on the application of CNC machines. Commonly, these materials are aluminum, steel, brass, wood, plastic, foam, copper, titanium, and fiberglass.

The code which is using in the CNC machine is responsible to control the functionality of the machine. The code controls everything from the moment to the cutting head, speed, RPMs, and the part movement of the spindle.

CNC machine has specific parts. These are the main parts of the CNC machine.

Input devices

In CNC machines devices play a significant role to control the programming of machines. These input devices Keep monitoring the magnetic tape reader, and computer  RS 232_C communication.

The machine control unit (MCU)

It is a basic part of the CNC machine because it controls the complete action of the CNC machine. MCU perform various functions such as;

• Reads codes of instructions, that are given to the machine.
• Process of decodeof the given codes.
• MCUreceives signals that are feedback for the position and speed of the drive axis.
• MCU plays a basic role in controlling complete functionality such as coolant or tool change of spindle on/of.

Machine tool

In a CNC machine, there is a slide table and spindle to control the position and speed,

while working the machine. The slide table is controlling the x-axis and y-axis. The spinner is controlling the z-axis direction while working on the CNC machine.

Driving system

This system of a CNC machine has specific parts to work accurately. Such as Amplifier circuit, drive motors, and Ball leads screw.

Amplifier circuits receive signals from MCU and control the signals to work accurately of drive motors. Through which screw keep the right position of the machine table.

Feedback system

The feedback system of the CNC machine is consists of transducers. Which act as sensors in the machine working. This system is maybe a measuring system. In which position and speed transducers are present. Which monitors the speed and position of cutting tools in the working of the machine. These transducers send signals to the MCU. Both signals of Reference signals and feedback signals are handling differently. To generate the control signals for correcting the speed errors and position in the CNC machining process.

Display unit

Tere is a display unit in CNC machines. Which is a monitor. This monitor plays a specific role to display the programs of working and other useful data of the CNC machine.

The most important process, a CNC machine starts is “designing the part.”

Which is controlling through CAD software. The model gives the necessary dimensions and properties of the final part. This final part is the target of the CNC machine.

Although, CNC machine relies on programmings. Additionally, behind these programmings, there are specific languages for machining. A language is G_code. G_code is responsible for the varying behavior of CNC machines. This G_code controls feed rate speed and coordination of CNC machines. The most interesting thing is G_ code and other languages are installed into computer software only once. After that, there is no need for human operators while the CNC machines working.

The designers produce a model for final products to attach with CAD or computer-aided design software. In this process, basic technical specifications such as geometry and dimensions for producing the final product while the working of CNC machine.

Before the working of the CNC machine, the operator completes machine setup necessities. Such as affixing the workpiece into the machine. He also checks and monitors all basic components of the Machine. The setting of machinery spindles, and other work holding devices by attaching the required tooling.

NC- code is a special simple computer language. CNC machines can easily understand this language and execute it. These codes of NC code, G_code, and ISO code of computer language can control feed speeds, feed rate, coolant, and spindle in the high_tech machinery of CNC machines.

Along with these codes language, CNC machines can read blueprints and sketch manufacturing files for their final product production.

CNC machines can produce specific products, that are specific in functionality.

Some important productions are ;

Sheet metal cutting

This product of CNC machine can cut every type of metal, according to requirement. This product Can cut cabinet and server Rack. Sheet metal also has the capability of laser cutting and welding servers. This product of CNC machining works accurately. With high-speed efficiency and high reliability in the process of metal sheet cutting purposes. It insure the quality of work for a lifetime accuracy with professional design software.

This product of CNC machine is available in every size. Commonly it is of aluminum. The product can cut every type of metal sheet with 100% accuracy of functionality.

CNC machining products of CNC milling, CNC turning, CNC bending, CNC Gentry machining

CNC milling products are available in high quality and provide perfect service. It is a process to remove material from the surface of the workpiece.

This product of CNC machine works efficiently. The tools of the CNC  machine are controlling the desk work of CNC milling products. It also works to protect workpieces by removing material from the surface of the product. This product is available in almost every size. Which are maybe copper, steel, stainless steel, titanium, nickel, aluminum, aluminum alloy, and magnesium alloy. These products are useful for plane parts and surface parts.

CNC turning piece is also a product of  CNC machines. It is a process in which the rotatory motion of a workpiece occurs. Then a curve or linear motion of the tool changes the shape and size of the blank. The machine turns it into a part that matches the requirement of that drawing of the product.

Turning products are significant for machining rotatory surfaces.

CNC turning is useful for metal brackets, motorcycle parts, machinery parts, aircraft components, and robot parts.

CNC bending products are also useful for bending purposes. These products are available in different sizes. Bending products works accurately with high efficiency and life long quality.

Metal enclosure boxes

It is a product of CNC machining. Metal enclosure boxes are useful for electronics protection. These boxes are available in a variety of durable materials. Commonly these boxes are present in aluminum and steel materials.

Metal enclosure boxes are helpful for both indoor and outdoor environments. These boxes give production to your electronic pieces of equipment. This product of CNC machine is available in a variety of sizes, styles, and ranges.

Environmental protection has always been a cause of concern, ever since the industrial revolution. Whether due to excess energy consumption or toxic waste products, factories have become one of the biggest environmental polluters.

Factories perform various operations, but the one we want to discuss today is Steel Machining. Steel is a popular metal due to its relatively low cost, high strength, and excellent alloy selection.

This article breaks down the various environmental impacts of steel machining and discusses possible solutions to this problem.

What is Steel Machining?

Machining is a subcategory of subtractive manufacturing, which removes material from the workpiece until desired final shape and size is achieved. Steel is one of the most popular metals for machining; It has good corrosion resistance, high strength, durability, decent thermal resistance, and it can be reasonably cheap. Additionally, you can modify all of these properties by using alloys.

For example, Carbon Steel 1045 is used for machining high-strength parts. And Stainless Steel 303 is used for machining parts with lower strength but higher corrosion resistance.

What are the Environmental Impacts of Steel Machining?

The most significant environmental impact of steel machining is energy cost, and it’s mostly related to poor machining practices. For easy understanding, we will break down the environmental impact of steel machining into Two Sections.

1. Machining Environmental Impacts

Let’s start with the material cost; machining involves using a large steel blank and slowly cutting it down to shape. Larger steel blanks are easier to machine, allowing operator mistakes to be easily fixed.

But, using excess material is has both a direct and indirect environmental impact.

Direct Environmental Impact

The direct environmental impact comes in excess machining times and excess material use. The former results in increased energy consumption and later increased material waste.

Indirect Environmental Impact

Machining companies don’t refine their steel; instead, they order the raw steel billets from a steel factory. Steel billets are refined from iron ore at the factory and then shipped to machining companies. Refinement and shipping both have an attached energy cost. If companies are inefficiently using this material, they will have to order more steel billets, which will cost even more energy.

2. Waste Management Environmental Impacts

The second type of environmental impact associated with steel machining is waste management. Steel machining results in waste chips being formed; they are thin, sharp, long, and covered in coolant, requiring protective gloves to handle them.

These waste chips are generally referred to as swarf, and this swarf can be as much as half the volume of the steel blank. Steel is a non-renewable resource; there is a limited amount of steel on this planet. Of course, the more material we waste, the worse it is for the environment.

How can we Reduce the Environmental Impacts of Steel Machining?

So far, we have only discussed the negative impact of steel machining on the environment. But now, we will shift to something positive and discuss the solutions for environmental protection.

Honestly, there are simple steps that can drastically reduce the environmental impact of steel machining. 

1. Better Machining Practices

This one is difficult to explain because there isn’t just one type of machining. So we will discuss the improvements to general machining practices a manufacturer can take. 

1. By selecting the right-sized steel blank. Oversized blanks are easier to machine but waste more material.
2. By selecting a suitable steel alloy. Some alloys require less energy to machine than others.
3. By ordering custom-sized billets. Billets come in various cross-sections; order the most suitable size for your production.

2. Using Efficient CNC Machining

CNC (Computer Numerical Controlled) machining controls the cutting tool feed using a computer system. In short, CNC automates the machining process.

As a manufacturer, you can significantly improve the energy efficiency of steel machining by using CNC machines, which are more accurate precise and result in minimal product defects. CNC machining results in significantly lower machine times, thus saving time and energy.

Also, since CNC machining is exact, you don’t need to use oversized steel blanks. 

3. Recycling Steel Swarf

Finally, the most meaningful method of reducing the environmental impact of steel machining is “Recycling”. Depending on the part, the material loss can range from 10 percent to 90 percent. Recycling this material is an absolute necessity for protecting the environment.

Recycling steel is a simple process if a bit time-consuming. Following are the basic steps of steel recycling.

• The steel swarf is cleaned for any dirt or coolant.
• The cleaned steel swarf is further chopped into fine steel particles.
• These steel particles are then headed to a high-temperature furnace for melting.
• All remaining impurities will float to the surface after melting.
• The pure molten steel can be poured into molds to make steel billets.

Environmental Impact of Steel Recycling

Steel is a high-strength metal, thus requiring lots of heat to melt and recycle. Even though recycling is supposed to be better for the environment, it uses an enormous amount of energy.

You may be thinking that steel recycling is a very environmentally unfriendly process. BUT only if you look at steel recycling in a bubble. Taking a step back and looking at the iron mining industry reveals the bigger picture.

The energy cost of mining iron ores and refining them into steel is significantly higher. Studies show recycled steel costs between 50-75% less energy than iron ore refinement. 

Overall, by considering the above steps to reduce the hazardous effect of steel machining, the process can become sustainable and suitable for environmental protection. 

Conclusion

Now that you have gone through this entire article, we hope you understand steel machining better. Steel is a vital manufacturing material, and machining steel consumes a lot of energy. Poor machining practices and lack of recycling have a heavy impact on the environment.

But this also means by simply adopting CNC machining and recycling waste steel chips; we can negate most of the harmful environmental impact. Environmental protection and steel machining can co-exist; it just requires initiative from companies to shift to environmentally friendly practices.

If you are looking for steel machining services and want environmentally efficient manufacturing. Please contact with QBH Technology. 

We offer CNC machining, laser cutting, and high-quality welding services. Additionally, we accept custom orders of server racks and cabinets and general electronic enclosures.

Contact Us Now!

In manufacturing, precision is critical, and achieving high precision by hand has never been easy. Nowadays, we have computers to help us achieve that high precision without compromising on time. Manufacturing where a computer system guides the cutting tool is called CNC Machining.

CNC machines have been an industry standard since the 1960s. But what are CNC machines? And how do they work?

This is a beginner-friendly guide designed to help you learn the basics of CNC Machining.

What is CNC Machining?

CNC machining is a subtractive manufacturing process. A computer-controlled tool removes material from the workpiece until the desired shape is achieved.

CNC stands for Computer Numerical Control, a method of automating the movement of machine tools by using computer software. A CNC machine has an embedded microcontroller, which is responsible for the motion of the machine tool. A computer then sends instructions to the microcontroller, including cutting speed, cutting depth, and the cutting path.

The computer can be a separate device, such as a laptop, which connects to the CNC machine via a cable. Or it could be an inbuilt computer attached to the outer body of the CNC machine.

Types of CNC Machines

CNC machining is just a general term for computer-controlled machining. Therefore, any cutting machine that is controlled by a computer system is a CNC machine. Following are the most common types of CNC machines.

• CNC Lathe Machines

• CNC Milling Machines

• CNC Laser Cutting Machines

• CNC Electrical Discharge Machines (EDM)

• CNC Plasma Cutting Machines

The key differences between the machines, as mentioned above, are their cutting tools. Some tools require the workpiece to be rotating for best results. While other tools give the best result with a stationary workpiece and a moving tool. Depending upon the machine type, a tool can be rotating about a fixed axis or moving in the cartesian coordinates (X, Y, and Z-axes)

Here is a simple chart to help you remember the workpiece and tool rotation/motion. 

CNC machines can have either a horizontal or vertical orientation, and the direction of the tool feed determines this orientation. Suppose a tool is fed to the workpiece from the side (horizontally). In that case, the machine is horizontally oriented and vice versa.

How does a CNC machine work?

So now that you’re familiar with CNC machining and the types of CNC machines let’s discuss the technical operations of CNC machining.

CNC Machining Steps

Following are the basic steps involved in CNC machining

Step 1: Create a Design using CAD Software

CAD (Computer-Aided Design) allows you to create a 2D or 3D design according to the technical specifications.

Step 2: Convert the CAD file into CNC compatible Code

CAD files are standard across several types of software, but CNC machines operate on instructions and not design. So, you have to convert the CAD model into G-codes or M-codes.

G-codes or Geometry codes dictate the motion of the machine tool; they determine the starting point, the tool, and the stopping point.

M-codes or Machinists codes dictate the secondary operations of the machine; they control coolant rates, tool change, and other miscellaneous operations.

Step 3: Preparing the CNC Machine

Before machining, you need to perform two tasks.

1. Check and test the CNC machine for errors.
2. Ensure the workpiece is fixed correctly on the machine and the right tool is attached.

Step 4: Executing the Code

Finally, you can start the machining operation by entering the g/m-codes. If a computer is attached to the CNC machine, you can manually input the codes. Otherwise, you can send the code file to the CNC machine from a separate computer via a data cable.

CNC Machining Operations

Since there are several types of CNC machines, thus there are several types of CNC machining operations. The sheer number of operations can be daunting for newcomers. But don’t worry for we have a simple solution to help you with this problem.

There are two basic CNC operations that you need to familiarize yourself with, Milling and Turning. These operations are the foundation for all CNC machining. If you have a firm grasp of these, you will quickly adapt to any CNC machine and operation.

CNC Milling Process

Milling is the process of material removal from a workpiece using a rotating tool. A milling tool can move in X, Y, and Z-axes; this is particularly useful for precision work and prototyping. These three degrees of freedom are responsible for the versatility of CNC Milling Machines.

CNC Mills can be used for various functions depending on the application. But the two most commonly performed operations are, Face Milling & Peripheral Milling.

Face Milling Process

If the milling surface is perpendicular to the axis of rotation of the cutting tool, it is called Face Milling. This method of removing material is slower, as the tip of the cutter only does the milling. Therefore, Face Milling is commonly used for cutting,

Flat Surfaces

Shallow Surfaces

Flat-Bottom Cavities

Peripheral Milling Process

If the milling surface is parallel to the axis of rotation of the cutting tool, it is called Peripheral Milling. This method is primarily useful when removing large amounts of material because the entire side of the cutter is being used, rather than just the tip. Therefore, Peripheral Milling is commonly is used for,

• Cutting Deep Cavities

• & Shaping Large Workpieces

CNC Turning Process

Turning is a machining process in which the tool is fed to a rotating workpiece. If this definition reminds you of CNC Lathes, you’re exactly right. Turing is typically done on Lathe machines. However, the definition for Turing is broad enough that it is applicable for other machines.

A rotating workpiece can have quite a few advantages; the most common turning operations are,

• Boring – Cutting a long cavity into the workpiece

• Facing – Cutting the outer surface of the workpiece, flat.

• Grooving – Cutting grooves into the workpiece.

• Thread Cutting – Cutting screw threads into the workpiece.

Best Materials for CNC Machining

CNC machines are compatible with almost every material you can think of right now. As long as the material is rigid but still weaker than your cutting tool, you can easily CNC machine it. As you may have guessed, materials compatibility is more dependent on the cutting tool than the process.

 While we are on the topic of cutting tools, some cutting tools are only compatible with some materials. Consider CNC EDM machines; here, the cutting tool is electric sparks. And these sparks can only exist if the workpiece is electrically conductive. So, all most non-metals are automatically ineligible for this specific machining process.

This isn’t a limitation for CNC machining. CNC EDM and Plasma cutting is rarely used. And even then, it supports most metals.

The second important criterion for material compatibility is application. CNC Milling and Turing can be performed on wood, plastics, metals, and even some composites. So the next step is to pick the material according to your desired application.

Depending upon the application, you may need to CNC machine Titanium or Aluminum. Both are very different materials with a vast difference in cost, so you must select the suitable material for your use case.

Applications for CNC Machining

CNC machine is often used to manufacture components, which are part of a bigger assembly. The material for these components depends on the application and environment of the assembled unit. Electric insulation, heat resistance, and corrosion are the two most common concerns for any component. 

Following is a simple chart comparing CNC machinable materials and their applications.

This brief guide cannot mention all the possible CNC machine applications. For example, if you want custom-sized electric insulated gears, you can use nylon with a CNC mill. And if you wish to engrave metal sheets, you can use either CNC EDM or Laser cutting machines.

Approach material selection based on your unique use case. Machining takes time and experience to master, and with enough time, you will become an expert in the field.

Advantages and Disadvantages of CNC Machining

Generally speaking, CNC machining has no particular disadvantages. But CNC machines are better suited to some applications than others. Following is a brief overview of the pros and cons of CNC machining.

Advantages

The advantages of CNC machining are application dependent. If we list all the combined benefits of CNC machining, it will take over this entire guide. So, here are the most common advantages of CNC machining.

• Great for Rapid Prototyping.
• High accuracy: can only be achieved by a computer.
• High precision; can produce hundreds of parts with the exact same dimensions.
• Safer than Manual machining equipment.
• Faster Production runs, and lower lead time.
• Cost-efficient.

Disadvantages

CNC machining only has two minor drawbacks,

• Operator training is compulsory for the safe operation of a CNC machine.

• Machining Complex parts require the use of two or more CNC machines.

Conclusion

CNC machining is an incredibly versatile process; it can accommodate almost every situation. We hope that this guide has helped you get a core understanding of CNC Machines and the process of CNC Machining.

If you need CNC Machining services, QBH Technology offers CNC Milling, Turning, and Laser Cutting services. We also have excellent post-processing options, everything from welding to powder coating.

Send us your drawing files or sample photos with Material, Quantity, Tolerance, and Finishing specification, and we will get you a quote ASAP.

Contact Us Now!

CNC prototype machining is a combination of CNC machining and Prototyping. It is a computerized process used to make prototypes in a very short time. It is used to create a single kind of prototype as per customers’ specifications and requirements, but a variety of prototypes can make with this process’s help. In the case of validating the machining operations, making the prototypes is very useful. Here in this article, there is detailed information on CNC Prototype machining.

Process of CNC Prototype Machining

The complete step-by-step process of CNC Prototype Machining is discussed below.

1- Create Multiple Designs

The first step in manufacturing CNC prototype machining includes creating multiple different designs of similar components. It is done by the collaboration of various engineers and product designers. The main factors that vary in design are:

• Positioning features
•  Dimensions
•  Materials

The preparation of the unique ideas is compulsory for testing and manufacturing assembly design. The preparation of this distinct ideation ensures optimal production and the current prototyping.

2- 3D File Generations

The generation of the 3D files is compulsory for the properly manifestation of the designer’s ideas. Thus drawing the prototypes is necessary. Drawing the prototypes is not easy, but they can be successfully removed using CAD software. CAD is an advanced application that helps create the designs considering the needed objects’ features and dimensions.

The CAD software only draws the prototypes because the applications that enable the CNC machine programming are based on CAD files. So, the generation of 3D files is essential because it helps the specialists prepare the computer-based machining centers. It also allows engineers to consider the technical characteristics and the designers to manifest their ideas fully.

3- Production Sequence Identification

The CNC prototyping involves multiple manufacturing processes, including drilling, milling, turning, routing, cutting, and several other procedures. It is vital to choose the implemented methods to enable sample production.

It also ensures that the production line consisting of CNC machining possesses proper machining operation sets for particular components. Implementing all the procedures by a single reliable equipment unit is also possible. In all cases, the respective specialists select the sequence of production.

4- CNC Programming

This step of CNC programming involves integrating the designs and the production sequence into CNC machine control panel software. The integration is done with the help of the G-coding those programs the tool travel time, cutting depth, and feed rate.

The CAD files are automatically transferred to the C-codes-based with the help of complex software solutions. Using this procedure, the workpieces and the cutting tools are feed move and turned by the machining centers. To eliminate all the potential errors, it is compulsory to understand all the processes at this stage.

The manufacturer rarely employs a specialist having command on the perfecting CNC machining programming. So it is usually done by a third party that offers rapid prototyping.

5- CNC Rapid Prototyping

CNC rapid prototyping produces multiple samples per 3D file coded. The signals are received by the numeric control panel of a CNC machine. The movement of the spindles is dictated by the signs along a center’s axes. It results in the achievement of the desired products as the material is cut off a workpiece.

The elimination of the potential errors may take time, so that it may prevent the delivery of the repetitive outcomes by the CNC machines. The designed ideations and the machining processes should optimize at the end of the prototyping stage.

6- Testing

Testing is the last stage in CNC prototyping machining. The primary purpose of rapid prototyping is to make sure that the components of the designs must meet all needed requirements. Fulfilling this requires testing the innovative samples for overall performance, durability, defects, and functionality.

The experts conduct multiple tests that generate ideas to satisfy the customers’ requirements and prove the ideation viability. In the end, it is further analyzed, and the best prototype is selected.

Uses/Applications of CNC Prototype Machining

CNC prototype machining is mainly used due to the requirement of functional prototypes in industries. The CNC prototype machining is used primarily in the following sectors.

1: Automotive Industry

The CNC prototype machining is used to test the prototypes of the parts of the innovations of the automobile companies. The prototype testing is necessary to know whether it functions properly or adjusts well into automobiles. It can be responsible for the development of automotive prototypes to definite specifications.

2: Military and Defense Industry

CNC prototype machining has significant uses in this industry. It is used to make the prototypes of the complicated gadgets required to work the war vehicles and the ammunition properly. Some industry devices include communication, transportation, plane, etc.

3: Medical Industry

In medical industries, the companies need to analyze the prototypes of the new equipment to test whether or not these equipment perform relevant functions. The requirement of the medical industry is so high, and CNC prototype machining is one of the best methods for this requirement. The CNC prototype is used to manufacture the equipment. Some medical equipment includes safe enclosures, research equipment, implants, orthotic devices, MRI machines, etc.

4: Aerospace Industry

There is no chance of any mistake in aerospace because a small error can lose the part’s functionality. Therefore the prototype is the main requirement in these industries. The prototypes help check the functionality of these parts, and CNC prototype machining aids in making various components in this industry. Some components include bushing, airfoils, landing gear parts, manifolds, etc.

Advantages of CNC Prototype Machining

Following are the benefits of CNC prototype machining.

1: Bulk production of the same size

CNC prototype machining is responsible for creating the functional prototypes. The prototypes developed by the CNC prototype machining look and perform like the original ones.

2: No need for fixed tooling

Many prototype processes may need additional tools for corrections resulting in additional cost. On the other hand, the CNC prototype machining performs the work with the already available tools in the turntable.

3: Fast process

CNC prototype machining is a fast process used to make prototypes. The best 3D models can be prepared using this process in a very short time. As a result, the final product can be manufactured faster than the other methods.

4: Works with multiple materials

CNC prototype machining can use various types of materials for making similar prototypes. Other prototyping methods, such as 3D printing, cannot use multiple materials. They can only use a limited variety of materials for making prototypes.

5: Accurate method

CNC prototype machining is an accurate method for making the parts that need high tolerance. The parts made by this process may have accuracy up to 50 Microns tolerance. It can also help improve the surface finish of various parts with the help of advanced finishing methods. Thus it results in making the parts with high tolerance.

6: Easily modified

Many designs may have flaws that need to be corrected in most cases. These flaws can be recorrected, and designs are modified easily with the CNC prototype machining. It only requires the recorrection of the CAD design and reprogramming of the machine.

7: Quality and Consistency

The CNC prototype machining makes the best machining part with high quality and consistency. The parts made in each batch are similar with no significant deviation. In rare cases, some batches may have minimal dimensional variation. It is especially beneficial for assembly that needs tight tolerance between mating parts.

Disadvantages of CNC Prototype machining

The disadvantages of the CNC prototype machining are discussed below.

1: Production of waste material

In CNC prototype machining, many of the workpieces are removed to form the final product. These workpieces may convert to plastics or chipped metal, so they are no longer used. In this case, their disposal is necessary that results in excessive waste material. The production of a lot of waste material makes the environment polluted and enhances the cost of the overall process.

2: High cost

One of the main disadvantages of the CNC prototype machining method is the high cost of the manufacturing process. It is much more expensive as compared to the other methods. The startup of the method makes it more costly than other methods. Moreover, the raw material on which the CNC prototype machining works is more expensive than the material used in other simple printing methods.

3: Geometrical restrictions

The complex parts can be easily shaped or cut using CNC prototype machining. But, in rare cases, it may face problems in designing some features. For example, the cutting tools may not get in the piece in the parts having complex internal geometries. So, the other prototyping methods are considered more beneficial in such cases. A good company can decrease these drawbacks by implementing state-of-the-art machinery and skills. So it is necessary to contact a reliable service provider.

Conclusion

CNC prototype machining method is a fast and reliable process to make a prototype. If you need a top-notch CNC prototype machining service, we are offering the best and cheapest CNC machining service for you. Contact QBH Technology to get a free quote and further information. Here you can find all products to meet your needs and solutions for your problems.

The Importance of Sheet Metal Gauge for Sheet Metal Fabrications

Sheet metal fabrication is creating different objects by using metal sheets. It may look simple process, but in reality, it is a very complicated and detailed process. The metal sheets are flexible metal sheeting. It means that you can cut, design, and give them desired shapes. Sheet metals are used mainly in:

• Building materials
• Computers
• Architectural materials
• Dumpsters
• Structural materials
• The automotive industry

A wide range of sheet metal thicknesses and the metal sheets’ sizes can use in industries. The thickness of the sheet metal varies from object to object. The thin metal sheets can term leaf or foil, while the thick metal sheets term plate. By gauge, you can measure the thickness of the sheet metal. If the gauge number is smaller, the sheet metal is thicker.

Similarly, the more significant gauge number shows thin sheet metal. Usually, the gauge numbers used range from 30 to 7. The range of the gauge number varies with the type of material used. The sheet metal gauge is considered very important for metal sheet fabrication. Let’s find the importance of the sheet metal gauge for sheet metal fabrication.

Importance of Sheet Metal Gauge 

As we know, there is a great importance of sheet metal gauge in sheet metal fabrication. This importance is because choosing the wrong sheet metal gauge can lead to an undesired final object because of varying thickness. It can be proving damaging for your reputation, and your customers can dissatisfy.

Hence to design the object with the desired thickness, it is compulsory to choose the required sheet metal gauge. For a successful business project, selecting the right and suitable design and desired thickness for your metal parts is critical.

Sheet metal gauges have much importance in various sectors. Some prominent factors of the importance of the sheet metal gauge are as follow:

1- Economic

Economically it is crucial to choose the accurate sheet metal gauge with a thin or thick metal sheet. Each object can design with a definite sheet metal thickness. Some objects can design with thick sheet metal, while others can design with thin sheet metals. If a thing that requires a thin metal sheet to design can create with a thick metal sheet, then the object’s design and shape are destroyed. The thing needs to design again, which requires more cost.

The same is the case with creating an object that requires a thick metal sheet with a thin metal sheet. So, the sheet metal gauge is crucial because it will determine your requirements and the exact thickness needed to design the desired object. Otherwise, your budget can disturb harshly if the sheet gauge is not chosen wisely. In this way, the thing with the same thickness can design and makes it cost-effective.

2- Deformation and a Structural Problem

The sheet metal gauge also plays a vital role in reducing the deforming and structural problems in sheet metal fabrication. The objects can design with a very thin metal sheet in most cases. If a little more force can apply to such objects, they may undergo structural changes and deform easily. Such things cannot maintain their shape for a long time and hence lose their functions and cannot use for longer. By sheet metal gauge, you can choose metal with enough thickness to prevent the deformation and the structural changes in the sheet metal fabrication, making the object more reliable.

3- Durability

The object’s durability is also greatly dependent on the sheet metal gauge. The sheet metal gauge determines the exact thickness of sheet metal while designing an object to design perfectly. It helps efficiently work the thing for a longer and thus makes it durable.     

4- Flexibility

The metal sheet gauge is compulsory in choosing the metal sheet for an object that requires flexibility. If you have to design a thing that requires certain different curves or that may need flexibility, then you must choose a thin sheet metal. This selection is due to the reason that you can easily add curves in thin sheet metal. But if you go for thick sheet metal, it can be a more complex process, and you may not get the desired results. Thus choosing a thin sheet metal with a gauge can give the required flexibility to your designed object.

Deciding the Best Sheet Metal Gauge for the Sheet Metal Fabrication

It is also compulsory to decide the best sheet metal gauge for sheet metal fabrication. If you don’t choose the correct sheet metal gauge, it may lead to the failure of your object design.

So for the proper functioning and the efficiency of your object, you must choose the appropriate sheet metal gauge. By following simple ideas/steps, you can decide the best sheet metal gauge for your project sheet metal manufacturing.

1- Cost

Cost is the main factor when deciding a suitable sheet metal gauge for sheet metal fabrication. The sheet metals made of thick material can find at a much higher cost than those containing lighter components. Thus they are more expensive. Before selecting sheet metal, you must consider which purpose you will choose the sheet metal. In this way, the best sheet metal gauge can help you save costs.

2- Scenario

When deciding on a sheet metal gauge, you must have a complete idea of what kind of object you will design. If you have to create a thing that needs rigidity, you must go for the lower gauge sheet materials. If you choose a lower gauge, the object you design will be rigid and thicker. If you have to design a thing that should be flexible and need different curves, then you must go for the high gauge material. Thus, the high gauge material can create flexibility and lack rigidity.

Certain environmental factors may also affect your designed object. If you have to keep your thing in an open environment, select the lower gauge material. The lower gauge material will protect your designed object from harsh environmental conditions such as high temperature, high pressure, or extreme weather. If you have to protect your created object from harsh conditions by keeping the thing indoors, you must select high gauge material.

3- Efficiency

The right choice of the sheet metal gauge greatly affects the efficiency of the designed object. If you do not choose the suitable gauge sheet metal for your thing, your created object will not function properly. An object made with an accurate thickness of sheet metal will operate efficiently. So, for the efficient working of the thing, you must consider a sheet metal with the required thickness.

It would help consider other factors when deciding on a perfect sheet metal gauge. These factors include:

• Hardness
• Ductility
• Maximum temperature
• Tensile strength
• Surface finish
• Malleability
• The cost of the sheet metal fabrications

Without these, you cannot select a suitable sheet metal gauge for your sheet metal fabrication.

FAQs

1- For what purpose a sheet metal gauge can use?

A sheet metal gauge may use to determine the sheet metal’s thickness. It tells us the appropriate thickness of the sheet or whether the sheet metal is thick or thin. To determine the exact thickness of the sheet metal in millimeters or inches, you can also use a gauge conversion chart. By choosing the exact thickness of the metal sheet with the help of a gauge, you can design an efficient object.

2- What are the types of sheet metal materials?

You can use a wide range of materials for sheet metal fabrications. Following are the main types of sheet metal materials.

1. Stainless steel
2. Aluminum
3. Brass
4. Mild steel sheet
5. Galvanized steel
6. Corrugated sheet metal
7. Alloy steel

3- Why a sheet metal gauge can use for measuring the thickness of sheet metal?

The thickness of a metal sheet can also measure without a sheet metal gauge, but you will not get accurate measurements. So to get the exact thickness, the sheet metal gauge is commonly used.

4- What are the advantages and disadvantages of sheet metal materials?

The followings are the advantages of sheet metal materials.

Advantages

• Sheet metals are durable and malleable.
• They can be easily replaced, fixed, or repaired.
• They are easily transportable and sustainable.
• They are considered environmentally friendly and are recycled.

Disadvantages

They are mostly expensive and may take time to manufacture products.

Conclusion

Metal sheets can use throughout the world for manufacturing various objects. The sheet metal gauge is compulsory for sheet metal fabrication as it specifies the thickness of the sheet metal. Without proper consistency, the thing cannot work efficiently and loses its durability.

So, to retain efficient working and durability, specifying the thickness with the help of a sheet metal gauge is essential. The gauge also aids in maintaining the shape of sheet metal, thus protecting it from deformation. The gauge also affects certain factors such as the sheet metals’ cost, scenario, and efficiency. So, one should be careful while deciding the best sheet metal for their construction project.

If you are looking for CNC machining services, ensure you can acquire the top ones. So, you are supposed to look for a CNC machining service provider that can provide these services. Ensure you know the top CNC machining service providers in the market. CNC machining has to be done with a focus on detail. So, accuracy is very important in CNC machining. You should also look for a professional CNC machining service provider to work with. There are many factors that you are supposed to keep in mind when you are picking a CNC machining service provider to rely on. Here is what you should look into when you are picking a CNC machining manufacture in China:

How long have they been in the manufacturing business?

You can keep yourself a lot of grief by picking to work with a service provider that has been in business for an extended period. The standard of their products and services is determined by the period of time they have been in business. In general, a firm is more likely to fulfill your specific needs if they have been in business for longer, as this means that they have big experience in CNC precision machining operations. Picking a firm that has been in business for at least a decade is advised when it comes to the Chinese CNC machining industry.

Great standard control systems

The standard of the output is determined by the standard control measures used by the firm under consideration; suffice to say, the standard is a vital part of picking the best CNC machining partner in China.

Familiarizing yourself with the standard control systems of the firm in question will provide you the best idea of the expected product standard even before production begins. Even though a supplier handling medical-grade items should have the top standard control, in the CNC machining globe, the same controls might raise the cost of a commercial-grade product that does not need the same level of precision.

When it comes to CNC machining, examination of raw materials, in-process standard check, an inspection of the machine product, and outgoing standard control, are considered to be the general standard control structure.

CNC milling machine manufacturers place

China has a big area and well-developed producing industry. It has CNC machine-producing firms in almost all provinces in the country. So, it is very vital to pick the best place. It is advised to pick CNC machine producers in coastal cities, such as Jiangsu, Shanghai, and Guangdong. Manufacturers in these provinces generally have powerful producing capabilities and are near to the port.

Delivery time

Time is very important in every business and cannot be compromised at any cost. Delivering items to consumers on time will determine your efficiency and additional transactions. So, you should ask your producing team about the proficiency of the product end schedule. An honest company will describe you in detail without any issue.

Usually, it is not best to sign a contract with a new Chinese supplier under any pressure. It is excellent, to begin with, easy jobs with extremely flexible schedules. The delivery time of sample and mass production must be examined, as well as the supplier’s promise to meet the delivery time.

Certifications

The primary and foremost metric that should be of the issue is a company’s certifications. Outsource certain parts or full assemblies of your product needs alignment of your product’s needs with the certifications of the machining service provider. For example, if your industry is ms matched to the automotive niche, you should lookout for a machining service provider in China that is mainly certified, and their service is made for the specific industry. A machining service certified for car services should not be weighted under the same metrics when it comes to the medical or aviation industry. So, your company or business should have a professional review credible machining service provider in China by the virtue of their certifications to reject any losses later on.

Check the payment terms

Payment terms of machining suppliers in China to possible customers are generally fifty percent down payment and fifty percent balance before delivery. Find out if the supplier agrees to payment terms of thirty percent down payment and the remaining seventy percent will be paid against bill of landing copy and after an inspector has verified the goods on your behalf in China.

It is highly advised to ask about a standard check before shipping even if you are not going to send an inspector or hire a firm that performs standard checks. Ask for the right address of the factory to which you will need to send the inspector. If you get unclear answers, you can understand that supplier does not produce himself but buys from another factory.

Reject suppliers who ask for a hundred percent payment before starting production, unless it is a little work value less than $1,000. For little orders, there is no point in making 2 bank transfers. If the supplier works with PayPal, it is not an issue to split into 2 payments because the PayPal payment process is quick, and the transfer charge is a percent of the transfer amount.

Production capabilities

Ensure that the firm you are working has the best production and hardware capabilities to complete your order, which contains turning machines and multi-axis machining systems, CNC milling, and a lot more. Aside from the product hardware, ensure that the firm is well-versed with the type of material you need, whether it is metal, plastic or other.

Request for a prototype

The excellent way to ascertain the standard of the output, in the machining industry, before production begins, is to ask for a prototype or sample. While the manufacture of mold makes the die casting process pretty costly, it is not necessary for CNC machining.

You just need to cover the shipping, set up, and material costs to get a prototype produced in three working days- the average period for most CNC machining firms in China.

Check the minimum order quantity

The lowest order quantity must be clarified. In principle, a machining producer does not have a technical issue to produce 1 piece or a few pieces, but the cost is extremely high because it is necessary to set up the CNC machine. The true question is the availability of raw material and the MOQ of raw material suppliers.

Machining suppliers buy raw materials from domestic suppliers who have MOQ depending on the raw material type. For example, to purchase stainless steel 316 in a specific shape and size, you may be asked to place an order for MOQ of five tons. For aluminum extruded profiles, there is generally the lowest order quantity of five hundred kg per order.

To check with the producer practically about the lowest quantity, you must send him the production drawings so he can know what material should be purchased for the production of the parts.

In case the Chinese supplier informs you that he has the lowest order quantity of $4,000, you should examine carefully that this is not a trading firm.

Third-party check before shipment

When you begin working with a new CNC machining supplier in China is advised to do a standard check before shipment. The perfect place is that you arrive with a standard inspector for a quality check at the factory. If this is not possible, you should send a 3rd party to do a standard check before shipping, mainly at the starting of the cooperation.

Do not begin cooperation with a Chinese supplier who does not accept the check of the 3rd party before shipping. This is an alert sign, and he probably has the best reason for that. There is no point in asking for samples even if they are free, pass it and go for the next CNC supplier.

After-sale service

After-sale service is very vital, mainly for the custom machining process. The machine is produced according to the drawings. In order to get the right machine can ask the producer to do one sample part to check the standard. Sometimes, you cannot get the best part at one time, so you may need a second sampling. If the sample is not qualified and it is the cause of the machining producer, at this point, we will perform some changes until you get what you want.

A best machining supplier will keep your money, time, and energy, on the contrast, a bad machining supplier will provide you a lot of headaches. If you are still on the way to looking for the best manufacturer, please read through the above key points, you will get an excellent understanding and find your way to pick a qualified CNC machining producer in China.

Conclusion

Finding an affordable and reliable CNC machining supplier in China is a process that needs time and experience. The online network is packed with Chinese machining suppliers. Some give any price to get the work but the quality is not up to the needs, some are untrustworthy suppliers, and some are ethical and reliable manufactures. Hope this page can help you search and pick reliable CNC machining suppliers in China.