Prototype Machining, the Equipment It Is Used Widely

How much do you know process of prototype machining? How much do you know which machining equipments can produce the right prototypes. 

CNC milling

1.      Manual milling and CNC milling

Manual milling is the process of removing a material from a workpiece by using a rotary tool.. But nowadays, a more advanced milling machine called CNC milling is gradually replacing manual milling machines, it brings a variety of benefits for both the machining providers and the clients that outsource the production of their components.Comparing to manual milling, CNC milling has benefits of more precision, higher production, less labor and better uniformity.

CNC milling machines can be controlled not only by computer but also via manual override. Computer programming allows the machine to make the precise cuts accordingly but the manual function allows an operator to slow down or speed up or tweak the process at any time.

2.      Multi-axis CNC milling

As technology develops, multi-axis CNC milling machines were invented,  this brings more convenience to prototype and production. There are 3,4,5 axes CNC milling machines.

5-axis machining offers unlimited possibilities for part size and shape that you can handle efficiently. The term “5-axis” refers to the number of directions which the cutting tool can move in. On a 5-axis machining center, the cutting tool can move across the X, Y and Z linear axes as well as rotates on the A and B axes to approach the workpiece from each direction. This means that you can machine five faces of a part in a single setup. Of cause, with such wonderful function, CNC prototyping cost of process in 5-axis machines will be more expensive than those in 3 or 4 axis machines.

Turning

Turning is a cutting tool (usually a non-rotating tool) that describes the machining of a spiral tool path by more or less linear motion while the workpiece remains rotating.

During the turning process, a variety of operations can be performed to the workpiece to yield the desired part shape. These operations may be classified as external or internal. External operations modify the outer diameter of the workpiece, like turning, facing,  grooving, cut-off and thread cutting. Internal operations modify the inner diameter, such as drilling, boring, reaming and tapping. These operations are commonly used in lots of machined parts.

Sinker EDM

Electrical discharge machining (EDM), also known as spark eroding, spark machining, burning or die sinking, is a commonly used manufacturing method to obtain a custom shape.

The material is removed from the workpiece by a series of rapid cycle current discharges between the electrodes separated by a dielectric liquid and controlled by voltage.

EDM is the most widely used in mold making, tools, molds and other industries, but it is becoming a common method of manufacturing prototypes and producing parts, especially in the aerospace, automotive, electronics and other industries with relatively low production volumes.

Electrostatic discharge machining requires electrodes, insulating fluids, and power supplies. The power supply connects the electrode to the workpiece. The spark generated by the connection creates a channel. Unlike wire EDM, sinking EDM does not completely cut the material. This allows our operators to generate complex shapes. At the same time, it does not create stress in the material. This makes it an excellent means of producing injection molds and stamping dies. But comparing to CNC milling and turning, the process speed of sinker EDM is slower. Besides, surface will be rougher.

Wire EDM

Wire EDM, as its name suggests, uses wire discharge current to feed conductive metal parts. Both the wire and the workpiece are located below the dielectric layer. This wire is thin and tight. It acts as a cathode in this process and usually penetrates the material completely, and the operator can adjust this to cut only the part, but a complete cut is more common. The result is a very precise cut.

Advantages of CNC prototype machining

With combination of above equipment, custom machining brings a lot of benefits to manufacturers. These benefits include:

1.      Save manufacturing costs

By using CNC service, you can take advantage of all the raw materials involved in the manufacturing process. Due to the precise operation of CNC machines, waste is greatly reduced. This helps CNC machine operators minimize any losses they may suffer and increase profitability over time.

2.      Increase production speed

CNC machining is a very efficient machining method. Because of this, the production process of CNC machine tools reduces the number of steps required to produce a specific part. As a result, you can produce multiple parts or projects in less time than other manufacturing processes.

3.      Increasing the safety

The entire CNC prototype machine is automated. Therefore, the machine operator does not even participate in the production process. This creates a safe environment because the machine can do all the work without anyone present. Some production involves potentially hazardous materials such as metals or steel. CNC machining is so precise that it poses virtually no safety risk.

4.      Improve production efficiency

CNC machine tools are considered to be the most effective system for designing parts. This is because most CNC machines are equipped with built-in quality assurance protection. Therefore, when a problem occurs during production, the machine detects it and closes it to prevent further problems or fix the problem internally.

5.      Reduce production costs

A properly functioning CNC machine should work flawlessly for a long time without the need to repair parts or repair the machine in any other way. Since there is a good production process from the beginning, and because there are few defects, there is a few maintenance work, so the production cost is very low. The budget of any company may be significantly reduced by the manufacturing sector. But with CNC machines, this process can save a lot of money.

This design was transformed into a physical prototype, which was time-saving and attracted many customers because of its aesthetics due to the use of modern rapid prototyping technology. A lot of software are available for designing purposes now a days which are easy to use and have better interface as compared to old software.