Forgings where, why, how?
According to Forging:
"The North American forging industry continues to grow in technical prowess. OEMs are realizing that nothing beats forgings for strength and reliability. Advances in forging technology have expanded the range of shapes, sizes, and properties available in forged products to meet an increasing variety of design and performance requirements. Forgings are regularly specified where strength, reliability, economy, and resistance to shock and fatigue are vital considerations. Forged materials offer the desired degree of high or low temperature performance, ductility, hardness, and machinability.
Automotive and Truck
"In automotive and truck applications, forged components are commonly found at points of shock and stress. Cars and trucks may contain more than 250 forgings, most of which are produced from carbon or alloy steel. Forged engine and powertrain components include connecting rods, crankshafts, transmission shafts and gears, differential gears, drive shafts, clutch hubs, and universal joint yokes and crosses. Forged camshafts, pinions, gears, and rocker arms offer ease of selective hardening as well as strength. Wheel spindles, kingpins, axle beams and shafts, torsion bars, ball studs, idler arms, pitman arms, steering arms, and linkages for passenger cars, buses, and trucks typify applications requiring extra strength and toughness.
Aerospace
"High strength-to-weight ratio and structural reliability improve performance, range, and payload capabilities of aircraft. That's why ferrous and nonferrous forgings are used in helicopters, piston-engine planes, commercial jets, and supersonic military aircraft. Many aircraft are "designed around" forgings, and contain more than 450 structural forgings as well as hundreds of forged engine parts. Forged parts include bulkheads, wing roots and spars, hinges, engine mounts, brackets, beams, shafts, bellcranks, landing-gear cylinders and struts, wheels, brake carriers and discs, and arresting hooks. In jet turbine engines, iron-based, nickel-base, and cobalt-base superalloys are forged into buckets, blades, couplings, discs, manifolds, rings, chambers, wheels, and shafts--all requiring uniformly high-yield tensile and creep rupture strengths, plus good ductility at temperatures ranging between 1,000 and 2,000°F. Forgings of stainless steels, maraging steels, titanium, and aluminum find similar applications at lower temperatures. Forged missile components of titanium, columbium, super alloys, and refractory materials provide unduplicated mechanical and physical properties under severe service conditions. Aluminum structural beams for boosters, titanium motor cases, and nuclear-engine reactor shields and inflatable satellite launch canisters of magnesium are used in the space shuttle program.
Off-Highway and Agricultural
"Strength, toughness, machinability, and economy account for the use of ferrous forgings in off-highway and heavy construction equipment, and in mining machinery. In addition to engine and transmission parts, forgings are used for gears, sprockets, levers, shafts, spindles, ball joints, wheel hubs, rollers, yokes, axle beams, bearing holders, and links. Farm implements, in addition to engine and transmission components, utilize key forgings ranging from gears, shafts, levers, and spindles to tie-rod ends, spike harrow teeth, and cultivator shanks.
Ordnance
"Forged components are found in virtually every implement of defense, from rifle triggers to nuclear submarine drive shafts. Heavy tanks contain more than 550 separate forgings; armored personnel carriers employ more than 250. The majority of 155-mm, 75-mm, and 3-in. shells as well as mortar projectiles contain at least two forged components.
Valves and Fittings
"For valves and fittings, the mechanical properties of forgings and their freedom from porosity are especially suited to high-pressure applications. Corrosion and heat-resistant materials are used for flanges, valve bodies and stems, tees, elbows, reducers, saddles, and other fittings. Oilfield applications include rock cutter bits, drilling hardware, and high-pressure valves and fittings.
Industrial Hardware and Tools
"Stationary and shipboard internal combustion engines include forged crankshafts, connecting rods, rod caps, camshafts, rocker arms, valves, gears, shafts, levers, and linkages. Outboard motors, motorcycles, and power saws offer examples of the intensive use of forgings in smaller engines. Industrial equipment industries use forgings in materials handling systems, conveyors, chain-hoist assemblies, and lift trucks.
"'Forged' is the mark of quality in hand tools and hardware. Pliers, hammers, sledges, wrenches, and garden implements, as well as wire-rope clips and sockets, hooks, turnbuckles, and eye bolts are common examples. Strength, resistance to impact and fatigue, and excellent appearance are reasons why forgings have been the standard of quality since the earliest of times. The same is true of surgical instruments. Special hardware for electrical transmission and distribution lines is subject to high stresses and corrosion. For strength and dependability, forgings are used for parts such as pedestal caps, suspension clamps, sockets, and brackets.
Why are forgings prevalent?
"Since the dawn of mankind, metalworking has assured strength, toughness, reliability, and the highest quality in a variety of products. Today, these advantages of forged components assume greater importance as operating temperatures, loads, and stresses increase.
"Forged components make possible designs that accommodate the highest loads and stresses. Recent advances in forging technology have greatly increased the range of properties available in forgings.
"Economically, forged products are attractive because of their inherent superior reliability, improved tolerance capabilities, and the higher efficiency with which forgings can be machined and further processed by automated methods.
"The degree of structural reliability achieved in a forging is unexcelled by any other metalworking process. There are no internal gas pockets or voids that could cause unexpected failure under stress or impact. Often, the forging process assists in improving chemical segregation of the forging stock by moving centerline material to various locations throughout the forging.
"To the designer, the structural integrity of forgings means safety factors based on material that will respond predictably to its environment without costly special processing to correct for internal defects.
"To the production employee, the structural reliability of forgings means reduced inspection requirements, uniform response to heat treatment, and consistent machinability, all contributing to faster production rates and lower costs.
"Forgings are superior to metal parts produced by other methods in their compatibility with other manufacturing processes.
"The characteristically uniform refinement of crystalline structure in forged components assures superior response to all forms of heat treatment, maximum possible development of desired properties, and unequaled uniformity.
Because forged components of weldable materials have a near absence of structural defects, material at welding surfaces offers the best possible opportunity for strong, efficient welds by any welding technique.
"Again, the near absence of internal discontinuities or surface inclusions in forgings provides a dependable machining base for metal-cutting processes such as turning, milling, drilling, boring, broaching, and shear spinning; and shaping processes such as electrochemical machining, chemical milling, electrical-discharge machining, and plasma jet techniques.
"Forged parts are readily fabricated by assembling processes such as welding, bolting, or riveting. More importantly, single-piece forgings can often be designed to eliminate the need for assemblies.
"In many applications, forgings are ready for use without surface conditioning or machining. Forged surfaces are suited to plating, polishing, painting, or treatment with decorative or protective coatings
How Forgings are Produced
"Forging--metal shaping by plastic deformation--spans a myriad of equipment and techniques. Knowing the various forging operations and the characteristic metal flow each produces is key to understanding forging design.
Hammer and Press Forging
"Generally, forged components are shaped either by a hammer or press. Forging on the hammer is carried out in a succession of die impressions using repeated blows. The quality of the forging, and the economy and productivity of the hammer process depend upon the tooling and the skill of the operator. The advent of programmable hammers has resulted on less operator dependency and improved process consistency. In a press, the stock is usually hit only once in each die impression, and the design of each impression becomes more important while operator skill is less critical.
The Process
"Open Die Forging Open die forging with hammers and presses is a modern-day extension of the pre-industrial metalsmith working with a hammer at his anvil.
"In open die forging, the workpiece is not completely confined as it is being shaped by the dies. The open die process is commonly associated with large parts such as shafts, sleeves and disks, but part weights can range from 5 to 500,000 lb.
"Most open die forgings are produced on flat dies. Round swaging dies and V dies also are used in pairs or with a flat die. Operations performed on open die presses include:
"Drawing out or reducing the cross-section of an ingot or billet to lengthen it.
"Upsetting or reducing the length of an ingot or billet to a larger diameter.
"Upsetting, drawing out, and piercing--processes sometimes combined with forging over a mandrel for forging rough-contoured rings.
"As the forging workpiece is hammered or pressed, it is repeatedly manipulated between the dies until it reaches final forged dimensions. Because the process is inexact and requires considerable skill of the forging master, substantial workpiece stock allowances are retained to accommodate forging irregularities. The forged part is rough machined and then finish machined to final dimensions. The increasing use of press and hammer controls is making open die forging, and all forging processes for that matter, more automated.
"In open die forging, metals are worked above their recrystallization temperatures. Because the process requires repeated changes in workpiece positioning, the workpiece cools during open die forging below its hot-working or recrystallization temperature. It then must be reheated before forging can continue. For example, a steel shaft 2 ft in diameter and 24 ft long may require four to six heats before final forged dimensions are reached.
"In open die forging of steel, a rule of thumb says that 50 lb of falling weight is required for each square inch of stock cross-section.
"Compression between flat dies, or upsetting, is an open die forging process whereby an oblong workpiece is placed on end on a lower die and its height reduced by the downward movement of the top die. Friction between end faces of the workpiece and dies prevents the free lateral spread of the metal, resulting in a typical barrel shape. Contact with the cool die surface chills the end faces of the metal, increasing its resistance to deformation and enhancing barreling.
"Upsetting between parallel flat dies is limited to deformation symmetrical around a vertical axis. If preferential elongation is desired, compression between narrow dies (Fig. 1) is ideal. Frictional forces in the ax ial direction of the bar are smaller than in the perpendicular direction, and material flow is mostly axial.
"A narrower die elongates better, but a too-narrow die will cut metal instead of elongate. The direction of material flow can also be influenced by using dies with specially shaped surfaces.
"Compression between narrow dies is discontinuous since many strokes must be executed while the workpiece is moved in an axial direction. This task can be made continuous by roll forging (Fig. 2). Note the resemblance between Fig. 1 and Fig. 2. The width of the die is now represented by the length of the arc of contact. The elongation achieved depends on the length of this contact arc.
"Larger rolls cause greater lateral spread and less elongation because of the greater frictional difference in the arc of contact, whereas smaller rolls elongate more. Lateral spread can be reduced and elongation promoted by using specially shaped rolls (Fig. 3).
"The properties of roll-forged components are very satisfactory. In most cases, there is no flash and the fiber structure is very favorable and continuous in all sections. The rolls perform a certain amount of descaling, making the surface of the product smooth and free of scale pockets.
Impression Die Forging
"In the most basic example of impression die forging, which accounts for the majority of forging production, two dies are brought together and the workpiece undergoes plastic deformation until its enlarged sides touch the die side walls. Then, some material begins to flow outside the die impression, forming flash. The flash cools rapidly and presents increased resistance to deformation, effectively becoming a part of the tool. This builds pressure inside the bulk of the workpiece, aiding material flow into unfilled impressions.
"Impression die forgings may be produced on a horizontal forging machine (upsetter) in a process referred to as upsetting. In upsetting, stock is held between a fixed and moving die while a horizontal ram provides the pressure to forge the stock (Fig. 5). After each ramstroke, the multiple-impression dies can open to permit transfer of stock from one cavity to another.
"A form of impression die forging, closed die forging does not depend on flash formation to achieve complete filling of the die. Material is deformed in a cavity that allows little or no escape of excess material, thus placing greater demands on die design.
"For impression die forging, forging dies become more important, and operator skill level is less critical in press forging operations. The press forging sequence is usually block and finish, sometimes with a preform, pierce, or trim operation. The piece is usually hit only once in each die cavity.
Ring Rolling
"Ring rolling has evolved from an art into a strictly controlled engineering process. Seamless rolled rings are produced on a variety of equipment. All give the same product--a seamless section with circumferential grain orientation. These rings generally have tangential strength and ductility, and often are less expensive to manufacture than similar closed die forgings. In sum, the ring rolling process offers homogeneous circumferential grain flow, ease of manufacture, and versatility in material, size, mass, and geometry.
"In the ring rolling process, a preform is heated to forging temperature and placed over the idler (internal) roll of the rolling machine. Pressure is applied to the wall by the main (external) roll as the ring rotates. The cross-sectional area is reduced as the inner and outer diameters are expanded. Equipment can be fully automated from billet heating through post-forge handling. Advanced ring rolling equipment can roll contours in both the inner and outer diameter of the ring, allowing for excellent weight reductions, material savings, and reduced machining cost.
"There is an infinite variety of sizes into which rings can be rolled, ranging from rollerbearing sleeves to rings of 25 ft in diameter with face heights of more than 80 in. Various profiles may be rolled by suitably shaping the drive and idling rolls.
"Extrusion In extrusion (Fig. 6), the workpiece is placed in a container and compressed until pressure inside the metal reaches flowstress levels. The workpiece completely fills the container and additional pressure causes it to travel through an orifice and form the extruded product.
"Extrusion can be forward (direct) or backward (reverse), depending on the direction of motion between ram and extruded product. Extruded product can be solid or hollow. Tube extrusion is typical of forward extrusion of hollow shapes, and backward extrusion is used for mass production of containers.
"Piercing is closely related to reverse extrusion but distinguished by greater movement of the punch relative to movement of the workpiece material.
"Secondary Processes Besides the primary forging processes, secondary operations often are employed. Drawing through a die is a convenient way to eliminate forged draft (Fig. 7a). The mode of deformation is tangential compression. The diameter of the drawing ring can be slightly smaller than the outer diameter of the preforged shell to control or reduce wall thickness and increase the height of the shell in a drawing or ironing operation (Fig. 7b).
"Bending can be performed on the finished forging or at any stage during its production.
"Because forging stock may assume complex shapes, it is rare that only a single die impression is needed. Preforming the forging stock--by bending or rolling it, or by working it in a preliminary die--may be more desirable. Gains in productivity, die life, and forging quality often outweigh the fact that preforming adds an operation and attendant costs. Forging in one final die impression may be practical for extremely small part runs.
"Since bending of larger parts requires a machine of long stroke, special mechanical or hydraulic presses are often necessary. Simple shapes can be bent in one operation, but more complex contours take successive steps. If complex shapes are to be formed in a single operation, the tool must contain moving elements.
"Special Techniques After deformation, forged parts may undergo further metalworking. Flash is removed, punched holes may be needed, and improved surface finish or closer dimensional accuracy may be desired.
"Trimming-- Flash is trimmed before the forging is ready for shipping. Occasionally, especially with crack-sensitive alloys, this may be done by grinding, milling, sawing, or flame cutting.
"Coining--Coining and ironing are essentially sizing operations with pressure applied to critical surfaces to improve tolerances, smoothen surfaces, or eliminate draft.
"Coining is usually done on surfaces parallel to the parting line, while ironing is typified by the forcing of a cup-shaped component through a ring to size on outer diameter. Little metal flow is involved in either operation and flash is not formed.
"Swaging--This operation is related to the open die forging process whereby the stock is drawn out between flat, narrow dies. But instead of the stock, the hammer is rotated to produce multiple blows, sometimes as high as 2,000 per minute. It is a useful method of primary working, although in industrial production its role is normally that of finishing. Swaging can be stopped at any point in the length of stock and is often used for pointing tube and bar ends and for producing stepped columns and shafts of declining diameter.
"Hot Extrusion-- Extrusion is most suitable for forming parts of drastically changing cross section and is, therefore, a direct competitor to continuous upsetting and the horizontal forging machine. In Fig. 8, a bar section of car efully controlled volume is heated, descaled, and placed into the die. Under pressure of the closely fitting punch (Fig. 8a), the material first fills the cavity, then part of it is extruded into a long stem. At the end of the stroke (Fig. 8b), a valve body is obtained that needs only grinding of the seating surfaces.
"There are a number of variants of the extrusion process, many of them patented. The slug may be hollow (machined), pierced in a separate operation or in the extrusion process itself. In all instances, the quality of heating, the efficiency of scale removal or prevention, and the effectiveness of lubrications are matters of greatest importance. The variety of shapes produced are numerous. Dimensional accuracy, surface quality, and productivity are high, and a greater degree of deformation can be achieved in a single operation than in any other forging method."
Hybrid Forging: Advances in Open Die and Closed Die Forging
According to Thermal Processing:
"Using the advantages of open die forging combined with the near-net shape capability of closed die forging, the forging process can be tailored to optimize time and cost savings.
"Today’s high-strength material users are increasingly obliged by everyday economic and competitive realities to seek alternatives to their current manufacturing processes. The reality that forgings can be used for more than simple parts — and forged at very large sizes and unique geometries — is slowly being realized. Companies who are looking for a better competitive advantage have started seeking the help of forging facilities with the metallurgical know-how to deliver improved products, processes, and especially costs.
"Forgings target a lower total cost when compared to a casting or fabrication. When considering all the costs that are involved in a product’s life cycle from procurement to lead time to rework and then factoring in the costs of scrap, downtime, and further quality issues, the long-term benefits of forgings far outweigh the short-term cost savings that castings or fabrications might offer.
"Due to computer-aided design, close customer collaboration, and creative forging techniques, advanced forging companies have been able to combine the advantages of open die forging with the near-net shape capability of closed die forging to tailor a forging process that optimizes time and cost savings. These hybrid open die, closed die designs allow for part flexibility and economic advantages for gearing innovation and are ideal for prototypes or low-volume production where the die block cost for impression die does not provide economic justification. The immediate availability of this tooling can also allow for a shortened production lead time, offering flexible order quantities and reduced lead time in situations where needed.
How it works
"Instead of pushing 100 percent of the material’s surface area, hybrid forgers are able to use far less tonnage in a prescribed manner to move material more efficiently. This is due to the tooling and mechanics of the process. For impression die (or closed die), a forging company must manipulate 100 percent of the workpiece at the same time. So it comes down to pounds per square inch, which is why this hybrid process makes it possible to make larger, more complex parts on an open die press. It’s also a more efficient use of tooling and investment dollars; the tool design can be changed quicker and more effectively than closed die impression blocks or casting molds.
Hybrid gear case study
"For example, a typical bull gear is manufactured in three parts: a rim, a hub, and a plate welded together. Fabricating a gear from multiple parts increases the risk for error and requires continual sourcing management. Added processing for welding of the fabrication proves to be costly and time-consuming. Not only is coordinating the manufacturing and shipment of all three components tedious, but someone also has to manage the requirement flow-down and payment schedule from different vendors. From a product standpoint, cracking in the weld layer is common, causing failures in the field that require extensive weld repair and re-inspection.
"Fortunately, this product can be manufactured as a single-piece hybrid forging, improving properties and eliminating non-value-added steps. The strength and structural integrity of the forged material meets demanding application requirements, resulting in less rework, fewer rejections, and increased part life. The elimination of welding shortens part-production process time, and the component is better able to withstand the rigors of field use. The ultimate benefit, however, is that the component can be turned around faster and machine-finished for immediate production response. A single-piece forging is much less prone to error and setback due to the removal of steps, such as managing multiple suppliers and welding.
"Hybrid forging compared to castings and fabrications
When compared to alternative metalworking processes, forging delivers significant economic, manufacturing, and quality advantages such as directional strength, structural strength, and impact strength.
Directional Strength
"By mechanically deforming the heated metal under tightly controlled conditions, forging produces predictable and uniform grain size and flow characteristics. Forging stock is also typically pre-worked to refine the dendritic structure of the ingot and remove porosity. These qualities translate into superior metallurgical and mechanical qualities and deliver increased directional toughness in the final part.
Structural Strength
"Forging also provides a degree of structural integrity that is unmatched by other metalworking processes. Forging eliminates internal voids and gas pockets that can weaken metal parts. By dispersing segregation of alloys or non-metallics, forging provides superior chemical uniformity.
Impact Strength
"Parts can also be forged to meet virtually any stress, load, or impact requirement. Proper orientation of grain flow assures maximum impact strength and fatigue resistance. The high-strength properties of the forging process can be used to reduce sectional thickness and overall weight without compromising final part integrity.
Grain Flow
"Forging also provides means for aligning the grain flow to best obtain desired directional strengths. It is well-known that bridges are prone to cracking and fatigue problems. Therefore, it is helpful to understand how proper orientation of grain flow can ensure maximum fatigue resistance.
"In open die forging, the metal — once subjected to the compressive stress — will flow in any unconstrained direction. The expanding metal will stretch the existing grains and, if the temperature is within the forging temperature region, will recrystallize and form new strain-free grains. This results in even better resistance to fatigue and stress corrosion than a forging that does not contour the component.
"This predictable structural integrity inherent to the forging process reduces part inspection requirements, simplifies heat treating and machining, and ensures optimum part performance under field-load conditions. The high-strength properties of the forging process can be used to reduce sectional thickness and overall weight without compromising final part integrity.
Forged Grain Flow
"Forgings to near-net shape offer contoured grain flow, yielding greater impact and directional strength. Grain flow is oriented to improve ductility and toughness and increase fatigue resistance.
Cast Grain Flow
"Castings typically do not have a grain structure, which is not desirable for critical, load-bearing components.
Machined Grain Flow
"Machined parts have a unidirectional grain flow that has been cut when changing contour, exposing grain ends. This renders the material more liable to fatigue and more sensitive to stress corrosion cracking.
Additional benefits
"Forging can also measurably reduce material costs, as it requires less starting stock to produce many part shapes. Therefore, less machining is needed to finish the part with the added benefits of shorter lead time and reduced wear and tear on equipment. Virtually all open die forgings are custom-made one at a time, providing the option to purchase one, a dozen, or hundreds of parts as needed. In addition, the high costs and long lead times associated with casting molds or closed die tooling and setups are eliminated.
"Furthermore, by providing weld-free parts produced with cleaner, forging-quality material and yielding improved structural integrity, forging can virtually eliminate rejections (as opposed to fabrications). Using the forging process, the same part can be produced from many different sizes of starting ingots or billets, allowing for a wider variety of inventoried grades. This flexibility means that forged parts of virtually any material or geometry can be manufactured relatively quickly and economically."
What is the difference between forging and machining?
Have you considered the differences between forging and machining?
According to LinkedIn:
"Forging and machining is mainly metalworking processes, when to forge and when to machine? It is real question for HVAC service technician. Here’s you can review the guide below for a better idea of choosing right process for your cooling system like air conditioner and condenser coils unit.
What is forging?
"In simply terms, forging is the process of forming and shaping metals through the use of hammering, pressing or rolling including the open die and rolled ring forging process.
What is machining?
"As like wikipedia said a piece of raw material is cut into a desired final shape and size by a controlled material-removal process. collectively known as subtractive manufacturing,In processing it can’t change raw material properties itself except shape.
Forging’s benefit
"To keep grain flow intact.
"As we know during machining, grain ends are exposed and metal parts are more susceptible to weakening and cracking. Forging process provide refined grains replacement for previous metal grain structure which has been broken in process. And keep the grain flow intact.
To improve part integrity
"Forging is eliminating material structural voids which can weaken metal parts. It provide a level of uniformity to improve metal parts performance.
For material saving
"Take open-die forging for example, your metal parts is sharped by the dies, which can help you reduce waste and material cost, when you machining a product from bar, the Conor stock is lost, you are still required to pay for excess material.
When to forge, when to machine?
"When air conditioner service technician must select a process for production of a critical metal component like brass fittings (flaring nuts, union, Tee, etc), he will face an enormous possible alternatives including machining.
"In fact, forging is often the optimum process, in terms of both part quality and cost, especially in demanding industrial application like maximum strength, durability, custom sizes and critical performance, forging is likely better suited to your needs."
6 Computer Numerical Control (CNC) Machining Trends for 2021
Looking for 2021 CNC trends? Consider these.
According to iEEE Computer Security:
"The new year is here, and with it, predictions for what 2021 will bring. COVID-19 is, hopefully, on its way out. However, its impact will be felt for a long time. Several of the trends below are a direct result of the pandemic.
"For example, Forrester’s 2021 predictions guide anticipates that COVID-19-driven adaptations will bring emerging tech to the forefront in smart factories. As examples, it discusses how AR and VR were used to reskill machinists on how to build ventilators this past year. More and more systems shifted to the cloud this year. This acceleration of digital transformation will continue for 2021.
"Without further ado, here are the six trends we anticipate for Computer numerical control (CNC) machining in 2021.
Manufacturing as a Service Will Increase
"Manufacturing as a service (MaaS) has moved into the CNC industry over the past few years, but it will continue to grow in 2021. MaaS accomplishes manufacturing by using networked resources. The cost of maintaining and operating the CNC equipment is spread across subscribers who need the service.
"The benefit of MaaS is that companies can be agile, more productive, and save expenses. COVID-19’s impact will spur companies to look for more supply chain networks via MaaS. Companies will want to avoid the supply chain disruption they experienced during the pandemic. Having a more extensive supply chain network will future-proof them for whatever comes next.
5-axis and 6-axis Machine Use Will Continue to Expand
"5-axis machines have become more and more cost-effective for factories to use. Its ability to seamlessly rotate around the X and Y axes is very popular. However, the 6-axis machine emerged in 2019, and added an additional rotation around the Z-axis, improving efficiency and speed. This increase leads to faster cut times and more products made in a shorter time frame. A 6-axis CNC milling machine can decrease cutting time by up to 75%. Zimmerman Milling created an incredible video that demonstrates the difference between a 5-axis and 6-axis CNC mill.
Increased Uptime and Longer Life with IoT DONE
"Hitachi’s recent article argues that IoT use has accelerated due to greater need this year with social distancing and mask-wearing. The ability to monitor remotely, and to use sensors to evaluate where in the lifecycle a machine is, became even more critical during the pandemic.
"As more sensors have been applied to machines throughout the machine shop floor, their application has extended. It’s now possible to apply sensors to drill presses, milling and turning machines, lathes, and more. These sensors, in turn, regularly monitor the various parts of the machine, providing a heavy data stream of information. This information can facilitate predictive maintenance.
"CNC machines, like any machine, require regular upkeep, as the gears and belts turn. Historically, equipment has been kept on a regular maintenance schedule; however, when an unanticipated break occurs, a factory can shut down for hours, as a specialist often has to be brought in from far away. The IoT sensors can ameliorate some of this downtime.
"For example, the sensors can evaluate vibrations and temperature discrepancies that would indicate the equipment is nearing the end of its use. Downtime can be planned, and factories can increase their CNC machine efficiency by fixing equipment right before it causes more problems. Long term, this will extend the life of the equipment and lower downtime. Predictive maintenance allows real-time analysis of the factory floor.
"This is only one example of how CNC machines and IoT sensors can assist in factories. More will come as 5G makes its way into factories.
Digital Twins using VR
"Digital twins will become more and more common in 2021. As 2020 came to an end, Hexagon’s Manufacturing Intelligence division released enhanced NCSimul Software. NC Simul software virtually builds a digital twin so that the real-life machine can avoid errors and decrease setup times.
"This new enhancement allows machinists to identify and avoid the 5-axis singularity point and thereby optimizes the NC programming. This has never been possible before. Why does it matter if the CNC machine can avoid the 5-axis singularity point? If the tool vibrates, it can behave irregularly as it nears the singularity point, creating chatter marks on the component being manufactured. Creating a smooth surface is especially critical with components such as turbine blades for the aerospace industry.
"The ability to predict the 5-axis singularity point will allow programs to be improved by modifying cutting strategy parameters. The result of this? Manufacturers can more accurately complete jobs the first time. This saves time, money, manpower, and supplies.
More Robots and Cobots on the Machine Shop Floor
"Robots and cobots (collaborative robots) have been used in CNC machining in the past; especially as the labor force declines, robots have mitigated some of the strain felt. Collaborative robots are effective and versatile and specifically designed to work with humans.
"As machine learning accelerates and continues to be incorporated into the programming, cobots will be able to accomplish more. Hopefully, this will decrease accidents in the factory. Humans, however, will still need to assist with running and maintaining the cobots. This leads us to the next prediction for 2021.
Greater Need for Skilled Workers
"There’s already a shortage of skilled workers on CNC machining floors.
"Deloitte’s 2021 Manufacturing Industry Report states, “as robots, cobots, and other forms of automation grow in the production environment, the need for a workforce to manage and interact with these technologies also increases. These “middle-skill” roles require technical expertise and regular upskilling.” 28% of the executives surveyed by Deloitte said that upskilling and building new skills are the largest and hardest challenge they face. Additionally, a recent McKinsey survey of manufacturers found that 90% of those surveyed planned on investing in talent.
"Smart manufacturing has entered a brand new phase. In 2021, manufacturers will expand their tech in ways that empower employees to achieve greater productivity and to improve their decision-making. Subsequently, this year will focus on connected workers.
"And there you have it—6 trends for CNC machining in 2021."
How Are Forgings Produced
New to forging? Consider this.
According to Forging.org:
"Forging--metal shaping by plastic deformation--spans a myriad of equipment and techniques. Knowing the various forging operations and the characteristic metal flow each produces is key to understanding forging design.
Hammer and Press Forging
"Generally, forged components are shaped either by a hammer or press. Forging on the hammer is carried out in a succession of die impressions using repeated blows. The quality of the forging, and the economy and productivity of the hammer process depend upon the tooling and the skill of the operator. The advent of programmable hammers has resulted on less operator dependency and improved process consistency. In a press, the stock is usually hit only once in each die impression, and the design of each impression becomes more important while operator skill is less critical.
The Processes
"Open Die Forging Open die forging with hammers and presses is a modern-day extension of the pre-industrial metalsmith working with a hammer at his anvil.
"In open die forging, the workpiece is not completely confined as it is being shaped by the dies. The open die process is commonly associated with large parts such as shafts, sleeves and disks, but part weights can range from 5 to 500,000 lb.
"Most open die forgings are produced on flat dies. Round swaging dies and V dies also are used in pairs or with a flat die. Operations performed on open die presses include:
"Drawing out or reducing the cross-section of an ingot or billet to lengthen it.
Upsetting or reducing the length of an ingot or billet to a larger diameter.
Upsetting, drawing out, and piercing--processes sometimes combined with forging over a mandrel for forging rough-contoured rings.
"As the forging workpiece is hammered or pressed, it is repeatedly manipulated between the dies until it reaches final forged dimensions. Because the process is inexact and requires considerable skill of the forging master, substantial workpiece stock allowances are retained to accommodate forging irregularities. The forged part is rough machined and then finish machined to final dimensions. The increasing use of press and hammer controls is making open die forging, and all forging processes for that matter, more automated.
"In open die forging, metals are worked above their recrystallization temperatures. Because the process requires repeated changes in workpiece positioning, the workpiece cools during open die forging below its hot-working or recrystallization temperature. It then must be reheated before forging can continue. For example, a steel shaft 2 ft in diameter and 24 ft long may require four to six heats before final forged dimensions are reached.
"In open die forging of steel, a rule of thumb says that 50 lb of falling weight is required for each square inch of stock cross-section.
"Compression between flat dies, or upsetting, is an open die forging process whereby an oblong workpiece is placed on end on a lower die and its height reduced by the downward movement of the top die. Friction between end faces of the workpiece and dies prevents the free lateral spread of the metal, resulting in a typical barrel shape. Contact with the cool die surface chills the end faces of the metal, increasing its resistance to deformation and enhancing barreling.
"Upsetting between parallel flat dies is limited to deformation symmetrical around a vertical axis. If preferential elongation is desired, compression between narrow dies (Fig. 1) is ideal. Frictional forces in the ax ial direction of the bar are smaller than in the perpendicular direction, and material flow is mostly axial.
"A narrower die elongates better, but a too-narrow die will cut metal instead of elongate. The direction of material flow can also be influenced by using dies with specially shaped surfaces.
"Compression between narrow dies is discontinuous since many strokes must be executed while the workpiece is moved in an axial direction. This task can be made continuous by roll forging (Fig. 2). Note the resemblance between Fig. 1 and Fig. 2. The width of the die is now represented by the length of the arc of contact. The elongation achieved depends on the length of this contact arc.
"Larger rolls cause greater lateral spread and less elongation because of the greater frictional difference in the arc of contact, whereas smaller rolls elongate more. Lateral spread can be reduced and elongation promoted by using specially shaped rolls (Fig. 3).
"The properties of roll-forged components are very satisfactory. In most cases, there is no flash and the fiber structure is very favorable and continuous in all sections. The rolls perform a certain amount of descaling, making the surface of the product smooth and free of scale pockets.
Impression Die Forging
"In the most basic example of impression die forging, which accounts for the majority of forging production, two dies are brought together and the workpiece undergoes plastic deformation until its enlarged sides touch the die side walls
(Fig. 4). Then, some material begins to flow outside the die impression, forming flash. The flash cools rapidly and presents increased resistance to deformation, effectively becoming a part of the tool. This builds pressure inside the bulk of the workpiece, aiding material flow into unfilled impressions.
"Impression die forgings may be produced on a horizontal forging machine (upsetter) in a process referred to as upsetting. In upsetting, stock is held between a fixed and moving die while a horizontal ram provides the pressure to forge the stock (Fig. 5). After each ramstroke, the multiple-impression dies can open to permit transfer of stock from one cavity to another.
"A form of impression die forging, closed die forging does not depend on flash formation to achieve complete filling of the die. Material is deformed in a cavity that allows little or no escape of excess material, thus placing greater demands on die design.
"For impression die forging, forging dies become more important, and operator skill level is less critical in press forging operations. The press forging sequence is usually block and finish, sometimes with a preform, pierce, or trim operation. The piece is usually hit only once in each die cavity.
Ring Rolling
"Ring rolling has evolved from an art into a strictly controlled engineering process. Seamless rolled rings are produced on a variety of equipment. All give the same product--a seamless section with circumferential grain orientation. These rings generally have tangential strength and ductility, and often are less expensive to manufacture than similar closed die forgings. In sum, the ring rolling process offers homogeneous circumferential grain flow, ease of manufacture, and versatility in material, size, mass, and geometry.
"In the ring rolling process, a preform is heated to forging temperature and placed over the idler (internal) roll of the rolling machine. Pressure is applied to the wall by the main (external) roll as the ring rotates. The cross-sectional area is reduced as the inner and outer diameters are expanded. Equipment can be fully automated from billet heating through post-forge handling. Advanced ring rolling equipment can roll contours in both the inner and outer diameter of the ring, allowing for excellent weight reductions, material savings, and reduced machining cost.
"There is an infinite variety of sizes into which rings can be rolled, ranging from rollerbearing sleeves to rings of 25 ft in diameter with face heights of more than 80 in. Various profiles may be rolled by suitably shaping the drive and idling rolls.
"Extrusion In extrusion (Fig. 6), the workpiece is placed in a container and compressed until pressure inside the metal reaches flowstress levels. The workpiece completely fills the container and additional pressure causes it to travel through an orifice and form the extruded product.
"Extrusion can be forward (direct) or backward (reverse), depending on the direction of motion between ram and extruded product. Extruded product can be solid or hollow. Tube extrusion is typical of forward extrusion of hollow shapes, and backward extrusion is used for mass production of containers.
"Piercing is closely related to reverse extrusion but distinguished by greater movement of the punch relative to movement of the workpiece material.
"Secondary Processes Besides the primary forging processes, secondary operations often are employed. Drawing through a die is a convenient way to eliminate forged draft (Fig. 7a). The mode of deformation is tangential compression. The diameter of the drawing ring can be slightly smaller than the outer diameter of the preforged shell to control or reduce wall thickness and increase the height of the shell in a drawing or ironing operation.
"Bending can be performed on the finished forging or at any stage during its production.
"Because forging stock may assume complex shapes, it is rare that only a single die impression is needed. Preforming the forging stock--by bending or rolling it, or by working it in a preliminary die--may be more desirable. Gains in productivity, die life, and forging quality often outweigh the fact that preforming adds an operation and attendant costs. Forging in one final die impression may be practical for extremely small part runs.
"Since bending of larger parts requires a machine of long stroke, special mechanical or hydraulic presses are often necessary. Simple shapes can be bent in one operation, but more complex contours take successive steps. If complex shapes are to be formed in a single operation, the tool must contain moving elements.
"Special Techniques After deformation, forged parts may undergo further metalworking. Flash is removed, punched holes may be needed, and improved surface finish or closer dimensional accuracy may be desired.
"Trimming-- Flash is trimmed before the forging is ready for shipping. Occasionally, especially with crack-sensitive alloys, this may be done by grinding, milling, sawing, or flame cutting.
"Coining--Coining and ironing are essentially sizing operations with pressure applied to critical surfaces to improve tolerances, smoothen surfaces, or eliminate draft.
"Coining is usually done on surfaces parallel to the parting line, while ironing is typified by the forcing of a cup-shaped component through a ring to size on outer diameter. Little metal flow is involved in either operation and flash is not formed.
"Swaging--This operation is related to the open die forging process whereby the stock is drawn out between flat, narrow dies. But instead of the stock, the hammer is rotated to produce multiple blows, sometimes as high as 2,000 per minute. It is a useful method of primary working, although in industrial production its role is normally that of finishing. Swaging can be stopped at any point in the length of stock and is often used for pointing tube and bar ends and for producing stepped columns and shafts of declining diameter.
"Hot Extrusion-- Extrusion is most suitable for forming parts of drastically changing cross section and is, therefore, a direct competitor to continuous upsetting and the horizontal forging machine. In Fig. 8, a bar section of car efully controlled volume is heated, descaled, and placed into the die. Under pressure of the closely fitting punch (Fig. 8a), the material first fills the cavity, then part of it is extruded into a long stem. At the end of the stroke (Fig. 8b), a valve body is obtained that needs only grinding of the seating surfaces.
"There are a number of variants of the extrusion process, many of them patented. The slug may be hollow (machined), pierced in a separate operation or in the extrusion process itself. In all instances, the quality of heating, the efficiency of scale removal or prevention, and the effectiveness of lubrications are matters of greatest importance. The variety of shapes produced are numerous. Dimensional accuracy, surface quality, and productivity are high, and a greater degree of deformation can be achieved in a single operation than in any other forging method."
Aerospace 3D Printing Market 2021 Global Trends
When it comes to the aerospace industry, 3D printing is one market that is seeing new trends.
According to MarketWatch:
"Aerospace 3D printing refers to the technology that transforms the way of building new products like a different part of the aerospace and defense sector. 3D printing technology is gaining momentum in the different fabricating as well as manufacturing sectors owing to its high potentials.
"The 3D printing technology includes the manufacturing of physical objects through the printing of one layer at a time with the use of digital models and other special devices for material deposition. The aerospace 3D printing technology is used in the aerospace industry for the swift manufacturing of the plastic interior parts and prototype components. The technology helps in speeding up and enhancing the overall manufacturing process. The global aerospace 3D printing market will witness growth during the forecast period.
Market Opportunities
"The ability to create customizable products, reduction in manufacturing errors, enhanced accuracy, and efficient use of raw materials are some of the key drivers of the market. The environment-friendly attributes of the aerospace 3D printing are further expected to boost market growth. The wide use of the technology for printing of the structural components and engines in the aerospace sector further fuels the growth of the industry.
Market Segmentation
"The global aerospace 3D printing market is segmented based on form, material type, technology, process, industry, application, and region.
"Based on the form, the global market of aerospace 3D printing is divided into powder, liquid, and filament.
"Depending on the material type, the global market is subdivided into metals, plastics, ceramics, and other material types.
"Based on the technology, the aerospace 3D printing market is segregated into selective layer sintering (SLS), polyjet printing, stereolithography, direct metal laser sintering (DMLS), digital light processing (DLP), laser metal deposition (LMD), fuse deposition modeling, laminated object manufacturing, and electron beam melting (EBM).
"Based on the process, the global market is divided into material extrusion, powder bed fusion, direct energy deposition, material jetting, binder jetting, sheet lamination, and vat photo-polymerization.
"Based on the industry, the aerospace 3D printing market includes aircraft, spacecraft, and unmanned aerial vehicles. The aircraft segment is anticipated to grow at a rapid pace during the forecast period.
"Depending on the application type, the global market is segmented into structural components, engine components, and space components. The segment of engine components is expected to witness growth during the forecast period.
Geographical Segmentation
"Based on geography, the global market of aerospace 3D printing is segmented into the South America region, Asia Pacific region, Europe region, North America news, and the Middle East and Africa region.
"The North America region is estimated to witness the highest growth during the forecast period owing to the continuous developments in technology and an increase in government support. The Asia Pacific region will also witness growth in the coming years.
Key Players of Global Aerospace 3D Printing Market –
"The key players of the global aerospace 3D printing market are Honeywell International, Boeing, GE, Airbus, and AERIA Luxury Interiors, Rolls-Royce. Other significant players are Sandvik, 3D Systems Corporation, Solvay S.A., and Organovo Holdings Inc.
Latest Industry News
"In June 2019, Rolls-Royce, a leading player of aerospace 3D printing, announced its plan to print the aerospace parts with the use of quad-laser technology of SLM Solutions."
Predicting 2021 Trends in the CNC Machining Industry
CNC Machining has seen some innovation during the past year. Consider these trends.
According to The Science Times:
"The circumstances of 2020 have accelerated the CNC industry's technological innovation. With an increased focus on automation and waste reduction, accompanied by a renewed sense of urgency, 2021 promises a series of exciting trends that will change the face of the industry.
"'Right now - as it's harder and harder to find good programmers and operators of machinery - with manufacturing being on the rise, many companies are looking more to automation and machines with attached robots to help keep up with the pace of the market,' explains says Tom Kohm, President & CEO of Premier Equipment, the largest seller of used CNC machines.
"Below are four more CNC trends likely to emerge in 2021.
1. Manufacturing as a Service Will Continue Gaining Popularity
"Manufacturing as a service (MaaS) has made its way into the CNC industry over the last couple years, but look for it to gain broader acceptance going forward. MaaS uses networked resources to accomplish manufacturing tasks. CNC machines are located in a central location and the cost of maintenance and operation is spread across subscribers.
"MaaS gives companies added agility, productivity, and cost savings through reduced labor expenses. As fallout from the 2020 pandemic persists, look for companies to explore an expanding network of supply chains through MaaS.
2. The IIoT Will Dominate Emerging Technology
"IIoT stands for "The industrial internet of things." IIoT allows networked CNC machines to communicate with one another without the need for a human operator. While the IoT itself is nothing new, it has recently found its way into the precision computing of the CNC machining industry.
"Through IIoT, companies can make their manufacturing processes quicker, safer, and higher quality. We can expect a greater level of process automation in 2021 as the industry will be searching for methods of increased efficiency and reduced waste.
3. The Use of 6-axis Machining Will Expand Rapidly
"The 6-axis CNC milling machine first emerged sometime in 2019. For years, the 3-axis machine was the go-to machine. In recent years, the 5-axis machine, capable of performing seamless rotations around the X and Y axes, has become popular. The 6-axis machine allows an additional rotation around the Z axis, making for incredibly fast cut times. Look for the 6-axis machine to become an industry staple this coming year.
4. There Will be an Increased Focus on Waste Product Reduction
"It is no surprise that COVID-19 has sent supply chains worldwide into a tailspin. While raw materials have always been a precious resource, 2021 will be marked by increased attention to wise materials usage. One strategy is creating scale models of components using 3D printing methods rather than experimenting with design on actual CNC equipment.
CNC Beyond 2021
"Despite this year's unanticipated market interruptions, manufacturing continues to be an essential, booming industry. In order to be more adaptable in the face of future crises, companies are turning toward automated manufacturing methods to ensure wise stewardship over their resources and products. Look for rapid advancements in CNC machinery to lead the way over the next year and beyond."
What is Precision Machining, and How Do You Get Involved?
New to Precision Machining? Consider this.
According to Goodwin University:
"...Precision machining is an evolving area of manufacturing, and something that impacts our daily lives. As a result, it is a key contributor in the field today. But what is precision machining, exactly, and how do you get involved?...
"Precision machining is a process that removes excess, raw material from a work-piece, while holding close tolerance finishes, to create a finished product. Simply put, it means shaping large pieces of material into more precise parts, so that they can meet very exact specifications. This process involves cutting, milling, turning, and electrical discharge machining, and is generally performed using Computer Numerical Control (CNC) equipment.
"Precision machining produces quite a bit of both large and small objects that we use in everyday life. Believe it or not, every little piece of an object requires some level of a machinist’s skills. Likewise, a tool or machine that has been worn down will often require machine tool calibration, welding, or grooving by a precision machinist. From the production of automobiles to surgical devices and aircraft parts, precision machining is involved in every technology and industry. So, basically – if a product contains parts, it required some precision machining.
"Successful precision machining requires the ability to follow extremely specific blueprints made by Computer Aided Design (CAD) or Computer Aided Manufacturing (CAM) programs. This CNC machining technology creates 3D diagrams or outlines needed in order to produce a machine, object, or tool. The blueprints must be created with great detail to ensure quality and success.
"While most precision machining companies work with some form of CAD/CAM programs, they still often work with hand-drawn sketches in the initial design phase.
"Precision machinists work with a variety of materials such as bronze, glass, graphite, plastics, steel, and other metals. Depending on the size of the project and the materials involved, various precision machining tools and techniques will be used. Machinists must, then, be well-versed and experiences with these different processes and equipment. They may use any combination of drill presses, grinders, lathes, milling machines, saws, and even high-speed robotics to get a job done.
"Precision machining is a bucket within the CNC machining and programming field. Therefore, to land a career as a precision CNC machinist, you must have a working knowledge and skill in CNC technology.
"It is not always enough to be able to “run” a machine. Modern employers prefer certified, trained, and educated CNC machinists to join their working teams..."
Forging Facts
New to forging? Consider these facts.
According to :
What is Forging?
"Forging is manufacturing process where metal is pressed, pounded or squeezed under great pressure into high strength parts known as forgings. The process is normally (but not always) performed hot by preheating the metal to a desired temperature before it is worked. It is important to note that the forging process is entirely different from the casting (or foundry) process, as metal used to make forged parts is never melted and poured (as in the casting process).
Why use forgings and where are they used?
"The forging process can create parts that are stronger than those manufactured by any other metalworking process. This is why forgings are almost always used where reliability and human safety are critical. But you'll rarely see forgings, as they are normally component parts contained inside assembled items such a airplanes, automobiles, tractors, ships, oil drilling equipment, engines, missiles and all kinds of capital equipment - to name a few.
Who buys forgings?
"Forged parts vary in size, shape and sophistication - from the hammer and wrench in your toolbox to close tolerance precision components in the Boeing 747 and NASA space shuttle. In fact, over 18,000 forgings are contained in a 747. Some of the largest customer markets include: aerospace, national defense, automotive, and agriculture, construction, mining, material handling, and general industrial equipment. Even the dies themselves that make forgings (and other metal and plastic parts) are forged.
How big is the forging industry?
"The forging industry is composed of those plants that;
a) make parts to order for customers (referred to as custom forgings);
b) make parts for their own company's internal use (referred to as captive forgings); or
c) make standard parts for resale (referred to as catalog forgings).
"The largest sector - custom forging - accounts for over $6 billion dollars in sales annually. These custom forgings are produced by about 250 forging companies in approximately 300 plants across the U.S., Canada and Mexico.
How many people are employed by the forging industry?
"Approximately 45,000 people from coast to coast are employed by the forging industry in the United States and Canada. Because the modern forging process is capital intensive (requiring an abundance of heavy equipment for manufacture and the people to run and maintain it), most forging plants are small businesses which generally employ between 50 to 500 employees each, with a few larger facilities employing over 1000 people.
What metals are forged?
"Just about any metal can be forged. However, some of the most common metals include: carbon, alloy and stainless steels; very hard tool steels; aluminum; titanium; brass and copper; and high-temperature alloys which contain cobalt, nickel or molybdenum. Each metal has distinct strength or weight characteristics that best apply to specific parts as determined by the customer.
What kind of equipment is used to make forgings?
"Although the styles and drive systems vary widely, a forging can be produced on any of the following pieces of equipment.
"Hammers with a driving force of up to 50,000 pounds, pound the metal into shape with controlled high pressure impact blows.
"Presses with a driving force of up to 50,000 tons, squeeze the metal into shape vertically with controlled high pressure.
"Upsetters are basically forging presses used horizontally for a forging process known as "upsetting".
"Ring Rollers turn a hollow round piece of metal under extreme pressure against a rotating roll, thereby squeezing out a one-piece ring (with no welding required)."
What Is Custom CNC Machining & When Do You Need It?
New to Custom CNC Machining? Consider this.
According to Manufacturing.Net:
"Custom CNC machining entails creating parts that do not exist anywhere else. It can take any form of CNC machining including CNC turning, CNC milling, and EDM among others, that a company may have the capacity to provide. A custom part may be as simple as a gear. But, you may need the gear in particular nonstandard size, material, or is a new invention that suppliers don’t have yet, calling for tailored production of the part.
Which Industries Require Custom CNC Machining?
"Almost all industries require tailored CNC machining. If a company is searching for accurate CNC parts that sometimes are complex to produce using traditional methods, CNC machining comes in handy. Some of the industries that require custom CNC machining include:
"Aerospace and Defense – items produced for this industry include flight safety items and other equipment needed for a specific aircraft
"Agriculture - some of the things tailored for this industry include farm vehicles and farming tools
"Automotive - motorcycle parts, metal parts, and all accessories needed for any automobile
"Construction - here, you might need heavy construction equipment that doesn’t exist anywhere especially if your construction is taking a unique design
"Firearms - any part big or small that is needed for ballistic devices
"Electronics – including the production of semiconductors parts, enclosing cases, and others
Why You Should Choose Custom Machining
"Unlike manual work, CNC machines can work continuously without plunging quality. Besides flexibility, safety and absence of the need to take a break from working, here are other advantages of choosing this manufacturing process.
1. High Precision and High-Quality Parts
"CNC machining allows the production of demanding applications. Even with small diameters and unique features on a part, the high precision ability of CNC production ensures you get precisely what you need. Moreover, the production machine consistently allows the production of similar parts over and over until the last piece you order.
2. Timely Production
"CNC machining involves removing blocks of raw materials until you achieve the desired shape. A computer controls the production machine ensuring the speed is maintained at a set limit. Considering the machine is adjusted to follow specific procedures, it is hard to encounter an error that might lead to repeating the process. Moreover, a company providing CNC machining consists of profound CNC engineers with experience in producing various parts, translating to a quick turnaround.
3. Affordability
"When a product is uniquely designed, it is hard to find it in multiple stores. If you find it in any store, then it is expensive. By choosing custom machining, you eliminate the possibility of spending more than you should and still get a high quality product.
Types of Custom CNC Machining
"Custom CNC machining can be achieved through various processes depending on what a client needs. A manufacturer can choose one type of machine over another depending on the size, accuracy, and material needed for the production. Here are some types of custom machining we do.
Manual Lathes
"This process involves turning whereby the part been created is spun while a cutting tool is curving the part. This type of custom machining is common when creating round parts.
5-Axis CNC Machining Centers
"As you have seen above, CNC machines are capable of producing precise parts. However, for a company to remain competitive, it invests in the highest-end equipment and technology to produce ultra-high precision items. CNC machining centers is a type of machining needed when a client is looking for advanced, consistent, and efficient parts. This 5-axis machine moves in five different directions to create high-level accurate parts.
Prototype Plastic Machining
"While 3D printing is the common form of acquiring plastic parts, it might not apply when you need non-printable parts. Prototype plastic machining involves designing accurate concepts and producing precise parts from raw plastic material while considering factors such as pre-heat and tool paths. This type of machining is ideal when creating small parts that can’t be achieved when using any other method of production. For example, an optical part with a small radius of 0.05mm is only achievable through prototype plastic machining.
Metal Machining
"Metal machining refers to the accuracy of producing a part as per the client’s design. The end product should meet a customer’s requirements. Several factors including room temperature play part in ensuring the metal part is produced as the client wants.
Materials Available for Custom machining
"When you choose custom machining, you get high quality products whether you want the items in a rare material or otherwise. There shouldn’t be any limitation subjected to the quality of custom parts that your industry needs. Below are several materials we assure you to produce in high quality whether you need one item or many, at an affordable price.
"Aluminum - examples of aluminum we have include 5052, 2024, 7075, and even aluminum alloys
"Steel - Toughmet, 15-5, A2, carbon steel, and more
"Copper
"Brass
"Plastic such as PVC, Acetal, ABS, and more..."