Manufacturing is at the heart of a country, and at the heart of manufacturing is machining technology. Machining technology is the process of changing raw materials into finished products or parts. It plays a key role in many industries. This ranges from small parts in daily life to aerospace parts. Science and technology continue to develop. So, machining capacity will improve. Next, we will define machining. We will cover types of machining technology and processes, materials, and applications. This will give you a deep understanding of machining.
Table of Contents
What Is Machining?
Machining is the process of creating a component that meets the design requirements by removing material, adding material, or changing the shape and properties of material. It includes a variety of processes such as turning, milling, drilling, and grinding. Common machining involves removing material, but there are also machining processes that add material. For example, 3D printers are used to add material. Machining is not only applied to metallic materials, but is also widely used for non-metallic materials such as plastics, wood, and ceramics. Since it can process a wide range of materials, it is widely used in various fields.
Types of Machining Operation Technology
There are two main methods of machining: subtractive manufacturing and additive manufacturing. This is what a maker does to either take away or add material to a part.
Subtractive
Additive manufacturing methods are commonly used for prototyping and production. It involves cutting away unwanted material from a larger block of material to create the desired shape. This method is also referred to as subtractive production. It builds parts by removing material. For example, the CNC machining services we offer are subtractive manufacturing.
Additive
Additive manufacturing, also known as 3D printing, is a relatively new method of manufacturing. It allows you to produce three-dimensional objects based on a computer model. It enables mechanics to create things that are both lightweight and strong.
Common Equipment for Machining
As the scope of machining is large, the equipment required is also large. Here, we will briefly discuss the common machining equipment used to obtain parts by removing materials.
Lathe
The lathe is one of the most common machining equipment. It is mainly used for machining rotating body parts like shafts, disks, and bushings. You fix the workpiece on the lathe. Then, you rotate it and remove the material using a tool. At present, according to the different structures and functions, lathes can be divided into ordinary lathes, CNC lathes, and so on.
Compared with ordinary lathes, CNC lathes have many advantages. For example, it can greatly improve productivity when processing large quantities of parts. It can also process some parts with complex shapes and high precision. Therefore, with the continuous development of science and technology, the application of CNC lathes is more and more extensive. For example, in automobile manufacturing, the crankshaft of the engine is precision machined by CNC lathe.
Milling Machine
A milling machine is also one of the most common equipment for machining. Compared with lathes, the tools used in milling machines are generally rotating, while the tools used in lathes are generally not rotating. Milling machines can machine a wide range of surfaces such as flat surfaces, grooves, gears, helical surfaces, and so on. Common milling machines include vertical milling machines, horizontal milling machines, and gantry milling machines.
At present, with the continuous upgrading of machine tools and equipment. The common milling machine has many disadvantages compared with CNC milling machines. Ordinary milling machines have higher requirements for operators. And for some more complex parts processing efficiency is low. Therefore, the use of ordinary milling machines is gradually less and less common, while the use of CNC milling machines is more and more common. In mold manufacturing, complex cavities are usually processed by a CNC milling machine. If you are interested in some of the special processes and challenges of CNC machining, especially how to deal with sharp internal corners, you can refer to our comprehensive guide.
Drilling Machine
The drilling machine is mainly used for drilling but also can be reaming, reaming, and other operations. The size of the holes drilled by ordinary drilling machines is usually from 0.2 millimeters to about 40 millimeters. If larger hole diameters are required, specialized drilling equipment is needed.
Since holes of various sizes are present in most machined parts, drill presses are used more frequently in the machining process. When choosing a drill, consider the material being drilled. Also, consider the precision needed for the hole diameter.
Grinding Machine
Grinding machines are mainly used to grind the surface of the workpiece to obtain a higher surface finish and precision. So, if the parts need the grinding machine, this means the process needs high precision and finish.
Machining with a grinder usually follows milling or turning, so grinder machining is generally the last process in machining. Machining with a grinder guarantees the final accuracy required for the part. The machining accuracy of the grinding machine can generally reach more than IT6, and the surface roughness Ra value can reach below 0.8μm. Therefore, the grinding machine belongs to a kind of finishing equipment.
What Are the Different Types of Machining Processes?
There are many different machining tasks and processes, each with a specific purpose. Here is a brief introduction to these different machining technology types:
Turning
In turning, a cutting tool rotates around a central axis while cutting the workpiece. This method is used to shape workpieces symmetrically on both sides. Turning processes can be used to machine the following parts:
- Engine components
- Machine components
- Shafts
- Threads
- Tapers
Milling
In milling, a rotating cutting surface is moved relative to the object to form flat surfaces of different shapes. Depending on the application, the cutting shape can be a simple straight cut or an angled or sloping area. This can be done with bed milling, column milling, gantry milling, and other milling tools. Milling tools can be used for the following purposes:
- Gears
- Slotting and grooves
- Aerospace components
- Agricultural equipment
- Automotive parts
- Energy sector
Drilling
Drilling tools are among the simplest machine tools. They work by moving over the workpiece and using the drilling tool to make holes in it. These holes are used for fixing screws, secondary assembly, or decoration. Drilling can be used for the following purposes:
- Screw holes
- Fuel injector bodies
- Heat exchanger tubes
- Fluid assembly ends
- Aircraft landing gear
Boring
Boring tools drill holes in a workpiece that are larger than the holes already drilled. For this purpose, single-point cutting tools or a set of such tools are used. Boring is similar to turning in some respects. The main difference is that boring tools machine internal diameters, whereas turning tools machine external diameters. Common uses of boring are as follows:
- Engine cylinders in the automotive industry
- Cranes and end loaders
- Mining
- Firearms
Reaming
Reaming is a process that slightly widens the diameter of a hole and increases the internal surface finish. It is used when a precise hole diameter or surface finish is required that cannot be achieved with a drill. Usually, a precision hole is first drilled using a reamer. The hole is then widened to the precise width and finished using a reaming tool. Reamers are used for the following purposes:
- Screw cutting
- Turret lathe
- Removing burrs
Grinding
Grinding removes small amounts of unwanted material from a workpiece, smoothes it, and ensures very precise measurements. A grinding wheel with a rough surface is used as the grinding tool. There are many different types of grinding tools, some of which are hand tools and some of which are computer-controlled. Many people use angle grinders, die grinder,s and bench grinders to grind things. Grinding is used for the following:
- Brake cylinders and pistons
- Hydraulic steering pistons
- Gear shafts
- Surgical drills
- Aerospace components
- Furniture industry
Planing
With a planer, you can create a flat surface on a workpiece. This is called planing. The cutting action of a planer is caused by the relative movement between a single-point cutting tool and the surface. They are suitable not only for straight planing, but also for spiral planing. Planing can be used for the following purposes:
- Generate flat surface for any requirements
- Creating multiple slots at the same time
Sawing
One of the first methods of machining is sawing. A sharp blade with teeth is used, but wire or chains can also be used. Sawing is most commonly used in woodworking, but can also be used in metalworking or stone cutting. Here are some applications of sawing:
- Wood cutting
- House making
- Furniture making
- Tile cutting
Combustion Processing Techniques
Combustion processing does not use sharp cutting tools but instead uses high temperatures to remove material. The material melts when the combustion tool transfers heat to the material that needs to be removed. The way the material melts depends on the type of combustion technique. Combustion processing usually takes place in three ways:
- Laser Cutting: This is a process that uses a highly concentrated beam of light to remove material. It can be used to cut objects into any desired shape. This method is suitable for processing both metal and non-metal objects. It is one of the most precise ways to cut objects.
- Plasma Cutting: This process uses a stream of ionized gas to melt and remove material. As the process requires the workpiece to be electrically conductive, it is only suitable for conductive metals and alloys.
- Oxy-fuel Cutting: This cutting method is also known as oxygen cutting. It is a very old-cutting method. It melts the material by mixing air and a combustible gas such as acetylene, natural gas, propane, or propylene. This cutting method is not as precise as laser or plasma cutting. However, this technique is very portable.
CNC Machining
CNC machining is not a machining method in itself. It is a technology that can be used in combination with other methods. In addition, it stands for “computer numerical control” and allows machines to operate on their own. It is expensive to set up and requires skilled operators. However, it can save time and money on projects. It is used in all modern industries due to the high productivity required.
Precision Machining
A more advanced form of CNC machining is precision machining. Precision machining enables products to be manufactured with extremely high precision. It uses the various machining techniques we mentioned earlier and has the highest quality standards in the field of cutting tools, tools, and other areas. Generally, precision machining is required in fields where micron or nanometer-level precision is required. Such as medicine, electronics, aerospace, military,y and other similar fields.
Process Flow of Machining
In cutting and processing, many parts need more than one piece of equipment. So, the processing of a part is divided into multiple steps.
Process Design
According to the customer parts drawings, process engineers prepare the process flow. First select the appropriate processing methods, equipment, and tools, and then develop the processing sequence and process parameters. Provide machining basis for machining operators. A step-by-step description of the CNC turning process can be found in the CNC Turning Process.
Blank Preparation
According to the requirements of the process documents, select the appropriate blank material. For example, steel, aluminum, copper bar, and cast iron. According to the number of machined parts choose the amount of material to be prepared. Normally, we prepare extra blank material, 1-2 pieces more than the final delivery quantity. This prevents the scrapping of parts during processing. It stops us from ending up with too few parts for the customer.
Rough Machining
Rough machining refers to the process of removing most of the excess material from the raw material or blank in machining to form a process close to the final shape and size. The dimensional accuracy and surface finish of the parts obtained after this process are not high. It is characterized by a large tool-eating capacity and large feed.
Semi-finishing
In order to further improve the accuracy and surface quality of parts, semi-finishing machining is to prepare for finishing. For some parts that require high precision or are prone to deformation, it is often used to remove the material for processing using semi-finishing before finishing. Doing so has two benefits. It prevents the deformation of the workpiece from rough machining. It also releases some of the processing stress to ensure accuracy. In addition, it can also leave a uniform machining allowance for finishing. It can also reduce the impact of some errors that may occur in rough machining on finishing.
Finishing
Finishing is the last stage in machining. It is the processing of the workpiece using high-precision processing machinery and technology after roughing and semi-finishing. The purpose of machining is to obtain higher dimensional accuracy, surface finish, and geometric accuracy. Commonly used finishing methods include grinding, lapping, polishing, fine milling, and fine turning.
Parts Inspection
After the parts machining is completed, the finished parts are inspected for size, shape, positional accuracy, and surface quality. The inspection’s purpose is to find out if the machined parts do not meet the requirements. It is to ensure that all parts are well-made and to stop bad parts from getting to customers. Therefore, it is essential to carry out this step of parts inspection.
What Are the Main Materials That Can Be Processed by Machining?
There is a wide variety of materials that can be machined, covering a wide range from metallic to non-metallic materials. Different materials have different characteristics and application scenarios. Choosing the right machining material and process is critical to ensure product quality and performance.
Steel Materials
Iron and steel materials have good material properties. Therefore, they have a wide range of applications in the manufacturing industry. For example, carbon steel with good strength and toughness, a relatively low cost, is widely used in machinery manufacturing. Alloy steel with good wear resistance and corrosion resistance is commonly used in the manufacture of high-strength, highly wear-resistant parts, such as gears, shafts, molds, and so on.
Aluminum Alloy
Aluminum alloy has low density and good electrical and thermal conductivity. It also has good corrosion resistance. It is commonly used in aerospace, automotive, electronics and other fields. For example, the skin of an airplane, the wheel hub of an automobile, the shell of an electronic product, and so on.
Copper Alloy
Brass with good cutting performance and corrosion resistance, is commonly used in the manufacture of pipe fittings, instrumentation parts and so on. As bronze has high strength and good wear resistance, it is commonly used in manufacturing bearings, worm wheels, etc.
Titanium Alloy
Titanium alloy has excellent properties such as high strength, low density, high-temperature resistance, and corrosion resistance. It has important applications in aerospace and medical fields, such as aircraft engine parts and artificial joints. Machining is also usually used, but it has poor machining properties.
Other Materials
In addition to the above four categories of materials that use machining, there are also types of engineering plastics, composites, ceramics, and rubber.
For example, nylon in engineering plastics has good abrasion and corrosion resistance and can be used to manufacture gears, nuts, and so on.
Carbon fiber-reinforced composites have high strength, high modulus, and low density, and are widely used in aerospace and sporting goods. For example, airplane wings, bicycle frames, and so on.
Alumina ceramics have high hardness, high-temperature resistance, and good insulation, commonly used in the manufacture of cutting tools, wear-resistant parts, and so on. The more common rubber, on the other hand, can be used to manufacture seals, shock-absorbing parts, and so on.
These materials can be milled on CNC machines, which are capable of machining a wide range of materials efficiently and accurately, and the materials suitable for milling on CNC machines cover a wide range of metallic and non-metallic options.
Main Application Areas of Machining
Machining has a wide range of applications, covering almost all areas of manufacturing. Whether the industry is automotive, aerospace, electronic equipment or medical devices, it relies on machining technology to manufacture a variety of parts and products.
Automotive Industry
Machining plays a crucial role in the automobile manufacturing industry. In the process of automobile manufacturing, machining technology is widely used in the manufacture of key components such as engines, chassis, and transmissions. For example, the roundness and cylindricity of cylinders are ensured by the boring process to improve the compression ratio and power output of the engine.
Aerospace
In the field of aerospace, machining technology also plays an important role. Since aerospace components require particularly high precision and quality, machining technology is widely used in this industry. For example, engine parts and structural components of airplanes and spacecraft need to be machined with high precision. High-precision CNC machining services are vital in aerospace, and learning more about CNC machining technology for aerospace ensures precise manufacturing and quality assurance of these critical components.
Electronic Equipment
In the field of electronic equipment manufacturing, many parts of electronic equipment, such as integrated circuit substrates, connectors, heat sinks, etc., need to be manufactured by machining. These parts must be very precise. Their surfaces must be smooth. This is vital for the electronics’ performance and reliability. Machining equipment commonly used in the manufacture of electronic devices includes wire cutters and laser processing machines. These machines are capable of high precision and high-efficiency machining.
Medical Devices
Since medical devices also require high precision and quality, machining techniques are needed to ensure their functionality and safety of use. For example, surgical instruments, dental tools, artificial joints, etc. need to be manufactured through precise machining.CNC machining is particularly useful in medical devices, where its benefits ensure that these devices are functional and safe to use.
Motorcycle Parts
CNC machining technology also plays an important role in the manufacturing of motorcycle parts. Through precision CNC machining, high-quality custom motorcycle parts can be manufactured to meet the individual needs of different customers. Whether it’s engine components, frames, or other critical parts, custom CNC machining ensures that each part meets the highest standards. Using CNC technology for custom motorcycle parts machining can significantly improve the performance and aesthetics of your motorcycle.
Conclusion
This paper provides a comprehensive account of machining. Firstly, its definition was introduced. It then describes the four common types of equipment used in machining. Then it introduces the process flow and machining materials. Finally, the main application areas of machining are discussed. To summarize, machining is a key part of the manufacturing industry, it is important to understand the related knowledge for manufacturing. Yonglihao Machinery has more than ten years of machining experience in the field of machining. If you have project needs in machining, you can contact us. We can provide you with a free quote and also provide you with professional consultation on machining. We look forward to hearing from you.
FAQ
Which parts can be machined?
Almost all parts in the industry that require a specific shape, size, and precision can be machined. For example, parts such as shafts, disks, and boxes.
How accurate is machining?
Machining can be very accurate. But, the accuracy depends on many factors. These include the machining process, equipment, tools, materials, and the operator’s skill.