Tag : tooling

precision machine shop

How to Choose the Right Tools for the Job: Examples of CNC Machine Tasks

Just because the world of manufacturing has changed doesn’t mean that people need to stray from the basics. It is just as important to choose the right tools for the job today as it was hundreds of years ago. In actuality, as technology has advanced, there are more tools at someone’s disposal than ever before. With more choices, it has become harder to select the right tools. Now, there are CNC manufacturing tools available in almost every precision machine shop, leaving people to select which types of tools are most applicable to this advanced technology. What are some of the examples of tools that a CNC machinist might require? How can the right tools be identified?

Starting with Computer-Animated Drawing (CAD) Model Design

The first step in the CNC machining process is the creation of a 2D or 3D model of what is going to be produced. Typically, this is done through computer-animated drawing, or CAD. This is computer programming that plays an essential role in the CNC process. CAD allows manufacturers to put together a picture with the necessary specifications (including dimensions and various geometries) that will allow the product to be completed.

The designs of CNC machined parts are typically restricted by the geometry of the machine process itself. CAD helps manufacturers identify potential problems and limitations of the end product before the process gets underway. In this fashion, CAD saves both time and money in any precision machine shop. By identifying and fixing problems before the first machine is moved, a tremendous amount of stress is saved.

Once the CAD drawing is complete, the file needs to be exported and converted into a format that is compatible with CNC machining. Common formats include STEP and IGES. It is important for manufacturers to take a look at the various software programs that are available for CAD. The more familiar people are with CAD, the more efficient the CNC machining process will be.

Building the CNC Machine: Examples of Possible Tasks

Now that the CAD drawing is complete, the next step is to build the CNC machine. Depending on the actions that must be done to build the final product, this machine can take many forms. Some of the tools that the manufacturer will need to find include machinery spindles, machine vises, drill bits, end mills, lathes and more. These tools then need to be attached correctly for the various steps to be performed. It is important for everyone to identify the various steps that must be completed and build their machine accordingly. Some of the types of CNC operations that might be performed using custom machined parts include:

CNC Drilling: Drilling is a machine process that relies on the use of drill bits with multiple points that will produce holes in the desires workpiece. Using CNC drilling, the machine will feed the rotating drill bit into the perpendicular plane of the workpiece. This produces holes that are aligned in a vertical manner with diameters that match the width of the drill bit. Using advanced CNC machinery, holes can also be drilled at an angular manner. Drill bits can also be used to perform tasks such as reaming, countersinking, and counterboring. If these tasks are required, advanced drill bits might be needed. Manufacturers in a precision machine shop should plan accordingly.

CNC Milling: Another possible CNC task is called milling. In milling, a rotating multipoint cutting tool is used to remove certain amounts of material from the workpiece. The CNC machine will typically feed the workpiece into the cutting tool in the same direction as the tool’s rotation. This produces a smooth surface while simultaneously removing material from the surface of the workpiece. Depending on the program, CNC milling can either be used to cut shallow, flat surfaces with flat-bottomed cavities (called face milling) or to produce deep cavities such as slots and threads (called peripheral milling). Depending on the type of milling that people need to perform, they might prefer one type of equipment over the other.

CNC Turning: CNC turning is another possible task that can be performed by advanced CNC machinery. In CNC turning, the machine (such as a lathe) will feed the cutting tool into the workpiece in a linear fashion. Then, using a single point, the machine will remove material from the circumference of the workpiece. This will be continued until the desired diameter is achieved. Therefore, CNC turning can be used to create cylindrical parts. Advanced CNC turning can also be used to apply advanced internal features to the workpiece. This includes threads, tapers, and slots. If advanced features are needed, the manufacturer may want to investigate advanced CNC turning tools that are capable of doing this.

As a summary, CNC drilling is used to produce cylindrical holes of varying sizes. CNC milling removes material from the workpiece and produces a wider variety of shapes. CNC turning is used to create round or cylindrical parts. All of these require different manufacturing tools that interact with CNC machines in a different way.

A Revolution in US Manufacturing with Prototype Machining from CNC Manufacturing

While these are a few of the most common tasks that can be carried out using CNC tools, there are numerous other examples as well. These include lapping, honing, grinding, broaching, and sawing. These are advanced tasks that can be combined with those above to create additional features in the final product. With the advent of advanced CNC programming, machines in any precision machine shop can be set up to perform multiple tasks at the same time using custom machined parts. This has changed what people expect of their original equipment manufacturer (OEM) because this technology can increase both productivity and accuracy. It is crucial for manufacturers to embrace CNC manufacturing and invest in the proper equipment to ensure these expectations are met.

Choosing the Right Tools: Help from the Experienced Professionals

As the world of Denver manufacturing continues to change, it will only become more important to choose the right tools. The expectations of the consumer are going to change and precision machine shop businesses need to rise to meet them. This means putting CNC manufacturing to work in the right way with the right equipment and the right team. Because of this, anyone who is working in a custom machine shop Denver needs to make sure that they have access to every tool. This is where it is crucial to have a high-quality CNC Machinist available. To learn more about CNC manufacturing and how it can change your Denver manufacturing company, contact Tag Team Manufacturing today. Someone is always available to provide assistance.

machine shop

5 Ways Your Machine Shop is Inefficient

In order to succeed, a machine shop needs to have an edge over its competitors. Looking for inefficiencies is a great way to start, and fixing those inefficiencies can give your machine shop the edge it needs.

Early Tool Decay or Tool Failure

It’s not common for your tools to fail or break often. Finding the right tool is important, but it’s also important to prolong the life of your tools. Some machinists think that using the tools too aggressively causes them to wear out faster, but if you aren’t pushing the tool to the full potential it can cause it to decay faster in some situations. There are different types of tool failure, which can include abrasive wear, chipping, or tool fracture. Understanding your tools can help you make sure that you are minimizing downtime, as well as saving money on any replacement costs.

By being able to identify different types of tool wear, you can be ready to fix any issues quickly and help extend the life of your tools. Abrasive wear will dull the cutting edge of the tool by mechanical abrasion from the piece. If you notice this type of wear, reduce the cutting speed or use coolant. Using high efficiency milling toolpaths can also help reduce wear. Chipping can be seen by a nick on the cutting tool, or seen on the finish of the part. Excessive loads can cause chipping. Reducing feed rates can help. Thermal cracking can be seen by cracks in the tool perpendicular to the cutting edge. This is caused by extreme temperatures and can be solved by adding a proper coating to give the tool heat resistance. When a tool fractures it causes complete loss of the tool, and this can be because of a wrong coating or the wrong speeds and feeds. Make sure to adjust speeds and feeds and optimize the right coolant use, in order to avoid any hot spots that can cause fracture.

Subpar Part Finish

With a subpar part finish you are not providing your customers with the highest quality product, and it will affect your buyer seller relationships. It also will not allow you to increase prices or attract potential customers in the future. Many factors can affect part finish, which include the material, hardness, speeds and feeds your shop is running, and tool deflection. You are employing machinists and should have the highest quality tools so make sure you are getting your money’s worth of both, and your products should have a good finish.

Inefficient Coolant Usage

Coolant can be expensive and is often an expense that many machine shops forget about. Too much coolant is often applied when it’s not needed, costing a machine shop more money. Some machines have a minimum quality lubricant function that applies coolant as an aerosol, so it’s provided just enough coolant to operate efficiently while saving the amount of coolant that can be used. Sometimes it is needed to drown a piece in coolant, but oftentimes it is not and you can get away with using less coolant to save money.

Coolant can be delivered in different forms, and if you choose the wrong pressure it can lead to tool damage, which you need to avoid. When applied as air, it does not cool as efficiently as oil or water based coolants, but it is good for sensitive materials. When coolant is applied directly to plastic it can cause rapid expansion or contraction. Use mist when heat is not a major concern. When applied as a mist, both the part and the tool don’t go through more stresses. When the coolant is applied as a flood, it can be a low-pressure method that helps flush chips from the part in order to avoid chip recutting and protect your tool from damage. High-pressure application can be similar to flood coolant, but can sometimes be enough to break diameter tooling so it must be applied carefully. This method is often applied into grooves that are already built into the tool. Look at the application of coolants as well as the coolants that you are using. You may be able to use less high-performance lubricant instead of a lot of lower performance options. Coolant can also be re-used to save money. We have a great system at Tag Team Manufacturing that allows us to re-use the coolant saving time and money in our machine shop.

Not utilizing tool versatility

Many CMC cutting tools will perform multiple operations. Depending on the job, you may be able to get away with a tool you already have instead of having to go out and purchase additional tooling.

There are a number of multi-function tools you should consider having in your shop. Not only can drill mills be used for drilling and milling, but they can also be used for grooving, spotting and chamfering. This means they provide five different uses. Undercutting end mills can also be used for some slotting and contouring operations, and depending on the situation, such as clearance challenges, this can actually be the first choice. Double angle shank cutters can be referred to as the “Swiss army knife of machine,” so you know they are a versatile tool. They have six different functions that include thread milling, chamfering, back chamfering, machine v-grooves, deburring, and countersinking. Flat bottom tools, including drills and counterbores, are best used for holemaking, but they can be used for a number of different functions. These functions include thin plate drilling, cross hole drilling, angled drilling, half hole drilling, removing drill points, and straightening misaligned holes. Adjustable chamfer cutters can do more than just chamfering and can be used for beveling, deburring, and spotting.

High Machine Downtime

If your machines aren’t running, then you aren’t getting the most of them. The key to helping your machine shop reach maximum efficiency is minimizing machine downtime. You can do this in a variety of ways, such as keeping like parts together. All you would have to do is swap in and out material and the machine can use the same cutting tool. This allows you to spend less time swapping out tooling and spend more time letting the machine do its job. This requires planning to help make the machine shop more efficient.

What Should You Do?

Implementing a proactive maintenance strategy instead of a reactive maintenance strategy can help you avoid some of these issues and gain a competitive advantage. Maintaining equipment so you have less failure and less machine downtime will make sure you aren’t scrambling to figure things out. Make sure you have a system set in place for inventory management, so you are managing costs as well as handling and storage. This is especially important for lubricants that are expensive and can take up a good amount of storage.