In today’s highly competitive world, it is imperative to stay ahead of your competitors. Rather than using different suppliers for the various manufacturing stages, going for a company that can do all will make a lot of difference. Many contract manufacturers now combine multiple processes, technologies, and services into a single solution. This helps to improve manufacturing efficiency and enhance product quality.
This article will explain the importance of integrated CNC machining solutions, how the various aspects of manufacturing improve productivity, and why you should use a one-stop solution for your CNC machining needs.
Integrated CNC Machining Solutions
CNC machining is not just one process. It encompasses many operations and technologies. Unlike traditional methods, CNC machining integrates different stages of the manufacturing process to improve efficiency and productivity. One can combine machines, robots, and automation systems to streamline the production process and optimize workflow. This approach reduces errors and enhances effective collaboration and communication among important stakeholders.
Furthermore, integrated CNC machining solutions ensure continuity, and quality and prevent avoidable delays in manufacturing. With it, you can easily track and monitor progress and make quick changes if needed. It offers competitive advantages and makes sure your products get to market in time. This is because you save costs associated with outsourcing and transportation and deliver a product that exceeds customers’ expectations.
How is the Whole-solution Approach Different?
The whole solution approach in CNC offers multiple services under one roof from designing and prototyping to full production and even delivery. The main aim is to guarantee continuity and save time. Let’s look at each component in this integrated approach.
Quotation
After deciding on what to manufacture and the third-party manufacturer you want to use, the next step is to request a quote. The company provides a written document that contains a breakdown of the cost you would incur under specified conditions. It is important to include necessary files and notes such as tolerance or surface finish requirements. Many companies provide quotes in less than an hour so you can easily compare prices and delivery time before making a decision.
DFM Analysis
DFM analysis describes the process of reviewing the CAD design, and tolerance requirements to check if it is feasible for manufacturing. The design engineers identify potential issues and optimize the intended design. In some instances, the design change may be minimal such as adding fillers to sharp corners to improve material flow and reduce stress concentration.
It is also possible to change the entire design probably because it may be too complex or may not be compatible with available CNC solutions. You should note that DFM analysis deals with more than just design optimization. It also entails optimizing the process, materials, working environments, and standards.
Selection of Material
‘Components made from metal material using a CNC machine’
Using the right material determines the success of a CNC machining operation. The engineers conduct thorough research before choosing the best. The ongoing advancements in CNC machining are the reason there are expanded material options. The most common CNC materials include
- Metals (aluminum, stainless steel, carbon steel and its alloys, carbon and its alloys, titanium, and magnesium).
- Plastics (acrylic, polypropylene, acetal, nylon, ABS, polycarbonate, and polyvinyl chloride).
- Foam (styrofoam and polyurethane foam).
- Wood (MDF and solid woods).
- Composites (carbon fiber and fiberglass).
There is no standard way to go about selecting the right CNC machining material. However, there are ways to match materials with your CNC machining projects. The engineers have to consider the operating environment and part weight. The required tolerance level, dimensional stability, and intended part applications are also determining factors. Additionally, they check for how easy it is to machine the material, physical appearance, availability, and client’s budget.
Manufacturing Operation
‘A 5-axis CNC milling machine operation’
There are a lot of things a CNC machine can do. Many define it as the movement of tools and machinery using preprogrammed software. However, this definition doesn’t do justice to its capabilities. One can use a CNC machine to mill, turn, drill, grind, laser cut, and even control a plasma cutting system. The particular CNC operation the engineers use will depend on your production goals and project requirements.
The various techniques are accurate and make parts exactly to specifications. They are repeatable and you can use them to manufacture components that closely resemble each other within and across different batches. Additionally, they are fast and produce high-quality components that meet industries’ tight tolerance. CNC machines can work on different sizes and shapes of parts across manufacturing industries.
Note that CNC is constantly evolving and the use of multi-axis machining is now the mainstay. 5-axis CNC machining is a sophisticated system that moves the cutting tool along five different axes to gradually remove excess material and produce the final part. Because of this, 5-axis CNC can create more complex shapes and intricate designs in a single setup which increases productivity.
Inspection
‘A coordinate measuring machine precisely measuring an aerospace part made using precision CNC machining’
The production team then inspects the final part for visible defects and irregularities. They can use hand metrology tools such as vernier calipers and gauges for simple measurements or areas with limited accessibility. To be more precise, they also use coordinate measuring machines (CMMs) to take complex readings. These machines measure the geometry of a physical object using a contact probe.
There are three main types of CMM they use:
Bridge CMM: It is the most common type. Bridge CMM is versatile and suitable for large parts. It has a horizontal beam and a probe that moves along orthogonal axes- X, Y, and Z. The probe collects data points that are converted to the part’s geometrical dimensions.
Gantry CMM: This type has a movable gantry and a stationary base that supports the workpiece. The scanner moves along to measure the physical dimensions of a part. Gantry CMM is accurate and can measure large and heavy parts.
Cantilever CMM: This type has a single arm with a probe attached to one side of the base. With this, the operator has open access from different ends. This feature makes a cantilever CMM ideal when taking measurements in tight spaces. The inspection team also uses cantilever CMM for measuring small parts.
Surface Finishing
‘Process of spraying metal parts with the paint’
Surface finishing impacts product quality in many ways. It influences customers’ appeal and how well a product interacts with the environment. So many factors can affect the final surface finish of a part. Some of these include the material properties, cutting techniques, condition of the tool, and unnecessary vibrations.
Before sending out the products, the quality control inspectors visually inspect the final surface roughness. They can use lasers and stylus profilometers to get accurate readings. Based on the project requirement and intended application of the final part, there may be a need to improve the ‘as-machined’ surface finish. They do this mechanically, chemically, or by adding an extra layer of coatings.
Mechanical finishing describes the process of using abrasive components to remove impurities and enhance the appearance of a product. Based on the type of abrasive used, the final finish can range from rough and matte to smooth and glossy. The team can also chemically improve the surface finish using picking or passivation techniques. Pickling involves immersing the part in hydrochloric acid solutions to slowly dissolve the oxide layer. Passivation, on the other hand, uses nitric acid to form a protective chromium oxide layer. The last category involves electroplating, painting, or powder coating the part to increase the visual appeal and reduce corrosion.
Assembly
For very large components, it may be necessary to produce in bits before assembling to make a whole. There are different ways to go about this. You can either weld using heat and pressure or use rivets. There are different welding techniques the team can use to assemble a part. The most common ones are
- Shielded metal arc welding (SMAW),
- Metal inert gas (MIG) welding, and
- Tungsten inert gas (TIG) welding.
They all operate in different ways and have unique advantages and applications. Furthermore, riveting involves drilling a hole, inserting a rivet, and squashing the tail. This technique is reliable and does not produce any damage.
Package and Logistics
Manufacturing does not end after the machining and assembly process, it continues with adequate packaging of the final part. The packaging team encloses the final part in coverings to protect it during storage and transportation. For brittle components, it may be necessary to include gel wraps, bubble wrap or form to prevent damage from shock. It is important to also use corner protectors to secure sharp edges. When transporting heavy machinery, the team will use restraints such as chains, clamps, and straps to prevent displacement. This ensures that everything gets delivered in perfect state.
Service and Support
There is an after-sales and customer service team that you can keep in touch with after receiving your products. They teach you about the best maintenance options to ensure continued functionality. Many companies offer a time-conscious warranty under specific conditions. You can reach out to the team by sending a mail or calling in cases of defects or damages.
Conclusion
A one-stop CNC machining shop has all you need from designing to sending out the final part. A reliable shop carries out quality inspections in every manufacturing stage to ensure that parts are of the highest quality and meet the required tolerance level. Manufacturers in the aerospace, automotive, medical, electronics, and military benefit from integrated CNC machining services. Using a trustworthy supplier reduces production time and increases efficiency. Looking for a trustworthy one-stop CNC machine shop? Consider reaching out to Zintilon. Our team is ready to bring your ideas to reality and take you through every step of production.
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