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  4. Explore 5-Axis CNC Machining – Precision, Efficiency, and Innovation

Explore 5-Axis CNC Machining - Precision, Efficiency, and Innovation

Explore the intricacies of 5-Axis CNC machining, a game-changer in precision manufacturing. Learn how this advanced technology enhances production efficiency, enables complex designs, and reduces operational costs, revolutionizing industries from aerospace to medical.

Understanding 5-Axis CNC Machining Service

5-Axis CNC machining service is a manufacturing methodology wherein you can work on the 5-axis of the product simultaneously. With the help of the Computer Numerical Control (CNC), you can develop multiple complex parts with specifications of very high precision.

The 5 axes that we will be using throughout the content are the 2 rotational axes and 3 linear axes. This means that the part can move on the 3 linear axes for detailing the X, Y, and Z-axis. Whereas, the 2 rotational axes provide freedom to rotate the part around on a 360-degree axis for high-precision manufacturing.

Due to the freedom of movement on the 5 axes, there is a substantial saving of time and material for getting the final product.

The 5-Axis CNC machining service provides a one-stop solution for numerous manufacturing options. This means that you will not have to re-work the product on a different machine once it comes out of the 5-axis machine. However, all of this is not possible without a skillful person operating the CNC machine. So, we say that CNC machining does provide many options for manufacturing. However, the quality and refinement come from the skill of the worker operating the machine.

5-Axis Cnc Parts

Materials Used in 5-Axis CNC Machining

Stainless Steel

Stainless steel is one of the most popular materials for manufacturing industrial-grade parts. However, for such materials of stainless steel, there is a requirement of high rigidity and strong torque to cut the stainless steel material. The HDC’s 5-Axis CNC machining service can cut easily through the stainless steel material. Not only this, but the machine can create unique and complex machining parts from the materials with ease. However, there is a requirement of the right skill-set to operate the machine so that the machine performs the best.  HDC can handle all types of materials, therefore, there is an option for you to work with HDC regardless of the material that you want to work on.

Aluminum and its Alloys

Aluminum alloys are the most sought-after materials in the aerospace and automobile industry. Furthermore, a number of other products where there is a requirement of high strength to weight ratio use Aluminum and its alloys. Usually, Aluminum sticks to the machining tool if incorrect methods of manufacturing are used. However, HDC’s skillful staff along with the state-of-the-art machining services provide the best solution for working on Aluminium products. The 5-axis machines are ideal for working on Aluminum and its alloys. Therefore, the parts made from Aluminum are of high quality.

Titanium

Titanium is perhaps one of the most difficult materials to machine. However, with the high skill level of HDC, we make it possible to machine Titanium. Therefore, with the help of the 5-axis machine, we can make unique and complex parts with Titanium. Mostly, titanium parts have a great application in the manufacturing of medical parts. Therefore, there is an additional requirement for greater accuracy when working with titanium. However, our expert team makes sure that the final product is of the best quality.cnc precision machining service 5

Other Metallic Alloys

Other metallic alloys like Inconel, etc. are easily machineable with the 5-Axis CNC machining service. One major consideration while working with metallic alloys is that it requires very high resistance to temperature and wear. However, with the 5 Axis CNC machining service, it is possible to achieve the design without compromising on the structure of the tools. This also enables the product to be of higher quality.

Non-metals, Plastics, etc.

Like the metals and their alloys, 5-Axis CNC machining service is great to work with on the non-metals. As a result, we can create complex and typical designs with the 5-Axis CNC machines. Moreover, due to the delicate handling requirements of plastic materials, the final product is of a higher standard and more refined.

Finishing Options Suitable for CNC Machined Parts

As finishes for CNC machined parts, there are numerous finishing options to create various aesthetics and features while including the desired performance characteristics. The selection of finishing option is based upon the nature of part material, its purpose and appearance expected thereof. Here are some common finishing options for CNC machined parts:
  • Anodizing: Suitable for aluminum parts, delivers corrosion protection and color variants.
  • Plating: It provides an additional metal layer for better visual appearance and corrosion protection.
  • Powder Coating: Durable finish available in different colors, meant for metal and plastic surfaces.
  • Painting: Flexible for customization and security.
  • Polishing: Polishes and improves the visual appearance of metal parts.
  • Bead Blasting: Ensures perfection and produces matte/textured surfaces.
  • Passivation: It strengthens corrosion resistance on stainless steel parts.
  • Electropolishing: Makes a shiny finish on stainless steel with increased anti-corrosive properties.
  • Laser Marking/Engraving: Adds permanent markings or information.
  • Chemical Treatments: Provides particular finishes or coating for parts.
The other options to consider for finishing your CNC machined parts are based on the material, functional requirements, appearance and possibly certain industry standards or regulations that may apply in your case. It is often the case of juggling between beauty, functionality and cost efficiency.

The Industrial Applications of 5-axis CNC Machine

HDC Precision Machining Service

The 5-axis machines find a great application in multiple industries around the globe. We have listed a few of these industries that make extensive use of the 5-axis manufacturing technology:

Aerospace Industry

As we all understand there is a need for extreme precision in the manufacturing of Aerospace parts. As such, there is little chance that any conventional manufacturing technique can provide the solution for such precision and complexity. In case the same parts are manufactured on a 3 or 4 axis machine it will take substantial re-fixturing steps to finalize the design.

However, with the 5-axis machine service, you can get the part done in no time and with the very little re-fixturing requirement. A practical application of 5-Axis CNC machining service in the aerospace industry is in the manufacturing of turbine blades. In order to achieve the complex curvature design of the turbine blades, a 5-Axis machining service is the best option for such an application. This is the tip of the iceberg. There are multiple complex parts of the Aerospace industry that make use of the 5-axis machines.

Automotive Industry

Like the Aerospace industry, the automotive industry makes use of the 5-axis machine for the manufacturing of complex parts. Furthermore, as you know there is a very specific tolerance level allowed in the automotive parts that are required to be maintained to get the desired part for the vehicles. In case there is a slight deviation from the required standards the part will be rendered useless. 5-Axis CNC machining service provides the best solution for the automotive industry. Therefore, 5-axis machining is the ideal solution for the manufacturing of automotive industry parts.

Medical Industry

The medical industry requires high standards of manufacturing. In addition, there is a requirement for additional certifications for the medical part to be acceptable. The medical parts are often used as implants or in machines that are critical for the health of the patient, no risk can be taken on their manufacturing. Therefore, the 5-Axis CNC machining service offers an ideal solution for the medical industry. With the help of a 5-axis machine, you can develop parts that are safe for use in the medical industry and are as per the allowances and limitations. As such, the medical industry finds a large number of applications for the 5-axis machines.

Power Industry

Another major industry where the 5-axis CNC machines are of great use is the power industry. In the power industry, there are multiple parts that make use of the 5 axis CNC machine for development. Ranging from blades of the wind turbines to the gas turbines of power plants there are multiple uses of the 5-axis machines in the power industry.

In addition, there are new parts in the power industry that have a very high level of precision requirement. All such parts are easily manufactured on the 5-axis CNC machines.

Precision 5 axis cnc machining services

5-Axis CNC Machining Services Offered by HDC

HDC offers some of the most advanced CNC machining services in the country. Our customers are from all over the world. All our clients are extremely content with our products. In order to have a better idea of what services we are offering at HDC, here is a brief list of services of HDC:

Aerospace Parts Machining

With the help of the 5-Axis CNC machining service, HDC manufactures state-of-the-art aerospace parts. We adhere to all the regulatory and technical requirements of manufacturing aerospace parts. Therefore, you will get the parts that are according to your specifications. Furthermore, you can discuss the requirement of your part with us and we will guide you to the best available solution that we have.

Plastic Parts Machining

HDC produces the finest plastic parts with the help of 5-axis machines. Our highly skilled team of experts ensures that the parts are as per the requirements of the client. With high-quality standards and processes, we ensure that our clients get the best machining services. Moreover, we can manufacture plastic and delicate parts in the shortest possible time.

OEM Parts Manufacturing

In case you are an OEM company and want to consult HDC for your latest component, please feel free to contact us at any time. You can share your requirements, specifications, and standards requirements with us. Our highly experienced team will provide you with the most cost-effective and time-saving solution for your product.

In case you want some consultation on the design specification that will best suit your requirement then our design team will guide you.cnc precision machining service 4

Small Parts Manufacturing

We also offer machining on minuscule parts. It is often a very delicate and difficult job to work with the minute parts. However, our team of experts at HDC knows their way around handling delicate parts. Our 5-Axis CNC machining service is perfect for manufacturing minute parts with a high level of precision. Therefore, you can just forget about everything once you have given the order.

Aluminum CNC Machining

Machining of Almunimum parts is our specialty at HDC. Though we mainly deal in Aluminum 6061 and 7075 grades, you can provide the Aluminum or its alloy that you want for the product. In case you want us to work with any other grade of Aluminum then we also have the expertise in it. Our team of experts specializes in manufacturing all types of Aluminum-grades and their alloys. Therefore, you will discover that all Aluminum parts will be made with a high level of precision.

Customizing Parts

Another interesting service that we are offering at HDC is the customization of parts. In case you have a part that has already been finalized and you want to change its design then HDC can offer its services to you. Our team specializes in the customization of products on the 5-Axis CNC machining service. With high precision machining, the product is customized as per your requirement.

Benefits of Choosing HDC 5-Axis CNC Machining Service

We have a long list of benefits that you will get in working with HDC for  5-Axis CNC Machining. However, here is a brief list of the benefits that you will get in working with HDC:

Development of Complex parts

As you understand by now that 5-Axis CNC machining service gives you greater control over the development of parts. Therefore, we can manufacture more complex parts with higher complexities than other production methods. HDC’s team of experts provides a great option for you to get the most complex parts with the highest level of finishing from HDC.aerospace parts cnc machining manufacturing 3

Lower re-fixturing requirements

Due to the highly skillful team of HDC, there is little or no requirement of re-fixturing on parts. Especially, when these parts are manufactured through the 5-Axis CNC machining service. Therefore, you will get reliable parts that have the best turnaround time and high quality.

Minimal Production charges

Due to the features available on the 5 axis machines, HDC makes sure that the part is complete in one step. As it is known, that as many times as the part will be put through the re-fixturing there will be additional costs and time. However, with the highly skilled workers of HDC, there is little or no re-fixturing required. As a result, the parts are complete in the shortest possible time, making it much more economical than most manufacturing processes. Subsequently, you will get to save a good amount in working with HDC.

Higher finish quality

Since the 3-axis machines use more time and have limited options on the size of the cutters, the 5 Axis CNC machining service provides a better finish on the surface. This is because of the shorter cutters that are available in the 5-axis machining. Due to the shorter cutters, the vibration of the machine is substantially lower. As a result, the final product is much finer and of higher quality.

Lower production times

Due to the higher skill level of HDC workers and state-of-the-art 5 axis machines, the production time of a product is substantially lower. Furthermore, due to the machines’ capability to work on complex angles in the shortest possible time, the entire process of developing even the most complex parts is very little. In comparison, if the same product comes from a 3-axis machine, then the production time is much higher than the 5-axis machine.

Understanding 5 Axis Machining Center

aerospace parts cnc machining manufacturing 2

The 5-axis CNC machine is also called a 5-axis machining center. You can see that this precision CNC machine device utilizes a broad range of cutting tools in order to separate materials to form a workpiece. Its name refers to the number of angles and directions the cutting gadgets can move to accomplish your component perfectly.

The Cost of a 5 Axis Machining Center

When trying to purchase a 5-axis CNC machine, you should know that the building and excellence of the appliance itself are costly. There are also factors that resulted in its high price. This kind of machine is designed to give you high precision and accuracy.  5 axis machines need high-precision rotary tables, as well as the trunnions, are essential, and these devices are undeniably expensive. You can also find some 5-axis machines that are constructed with an unconnected and secluded electrical cabinet to avoid heat caused by the powerlines and circuits.  Whether it is just a hobby to you or you are a professional one and wanted to continue it into business, this is a guide for you to know how much to expect when planning to buy a new machine:
  • Hobbyist-grade CNC router                                     $1k-3k
  • Professional CNC router                                         $5k-100k
  • Entry-level (or toolroom) 3-axis                               $60k-100k
  • vertical machining center
  • Production 3-axis                                                     $150k-300k
  • vertical machining center
  • Entry-level 5-axis mill                                               $200k-500k
  • Production 5-axis mill                                               $500k+
  • Entry-level (or toolroom)                                           $30k-60k
2-axis lathe
  • Production 2-axis lathe                                             $60k-250k
  • Multi-axis multi-spindle                                              $500k+
multi-turret vicious beast of a lathe with a robot

The Cost of CNC Machining Per Hour

custom cnc titanium parts 8CNC machining approaches are expensive by the reason of having a high degree of mechanical ability and the amount of sophistication needed. In spite of the fact that CNC machining is pricey, you’ll find it really worth the cost. 

Computer numerical control or CNC machining manufacturing is priced between $75 to $200 per hour. 

The Price of CNC Machined Parts

There are details of your design that may have an effect on how much it will be priced depending on how it will be produced. The more complicated and intricate your components are, the longer they will take longer to produce. 

Additionally, your order volume will also affect the pricing. A small volume of orders is cheaper than a big volume of products, however, orders with big quantities have a lower cost per each of the items. 

You will encounter 3-axis CNC machining services as well as CNC milling machines that cost around $40 per hour. CNC turning costs $35 per hour. On the other hand, multi-axis machines are definitely more expensive, they are mostly $75 to $120 per hour or exceed up to $200.

Calculation Method for CNC Machining Pricing

I’m certain that you know CNC machining is the most cost-effective technique suitable for low or high production. You can’t underrate its functionality in constructing materials like metals. If you are wondering, I’ll show you some of the factors that determine CNC machining costs.custom cnc titanium parts 3

-Materials (metal/plastic)

-Machine cost (3-axis and multi-axis machines)

-Labor (Programming, Set up, Post-processing)

-Toolings

-Surface finish

There are also ways to lessen the CNC machining cost.

– Reassess the material

-Optimize design

-Outsource your necessities (Developed countries vs. Asian countries)

Calculation Method for Hourly Wages in a CNC Machining Shop

Most of the machining shops you know are calculating their hourly rate by dividing the cost overhead/project and the hours of the machine work.  Example:      8,000,000  ÷  40,000 = 200 (machine hourly rate) The machine shop rate per hour may have different concepts:
  • Ordinary Machine Hour Rate- contains only the overhead charges, it is variable and straightly ascribe to the functionality of the machine. Such costs are maintenance, fuel, power, etc. The entire sum of these expenses will be divided by the number of machine-hours. 
  • Composite Machine Hour Rate- this practice includes not only the expenses mentioned above but also the expenses that are fixed costs. Examples of those are rent, labor, rates, etc.

The Calculation Method for CNC Machine Tool Capacity

Knowing the production capacity of one CNC machine is significant to the machinist and also important to the customer in order to meet their fast production requirements. stainless steel cnc machining services 9

Full Daily Production Capacity

The daily production capacity is also known as the machine hour capacity. We can say for example that you have 14 CNC machines that are running for 24 hours, every day. You can say that your overall production capacity is 336 machine hours per day.

(Number of machines x Operating hours)

Single Part Production Capacity

With this procedure, you indicate the number of hours in producing one part, it is equivalent to the daily production capacity, divide by the time of producing one part. 

336 (daily production capacity)  ÷  1 hour (time of producing a part) 

= 336 pieces a day

Understanding CNC Machining 

CNC stands for Computer Numerical Control, and CNC machining is a computerized manufacturing process. You can make your industrial manufacturing process fully automated and more efficient with CNC machining.

Cnc Machining

CNC machining uses CNC software to operate all the motions and movements of production equipment. It can handle various types of sophisticated machinery such as grinders, lathes, and turning mills to shape, cut, and create different prototypes.

You can use CNC machining to operate the industrial machine and cutting tools used for shaping materials like metal, wood, plastic, foam, and many more.

A CNC machinist combines various technical drawings, mathematics, mechanical design, and computer programming skills in the manufacturing process.

Applied Industries of CNC Machining

Some industries need high precision in the manufacturing process for the sake of life and death. Component failure in those sectors can put lives at stake. They use CNC machining to manufacture products with high precision. Some industries have their own CNC machine to manufacture products as they need. Other businesses prefer a professional CNC machining company to fulfill their needs. Here is the list of some industries that use CNC machining
Medical Industry 
The medical industry highly depends on CNC machining for its customized devices and tools. Some of those are:
  • Orthotic devices
  • MRI machines
  • Shielded enclosures
  • Implants
  • Electronic tools for monitoring devices
  • Research equipment
  • FDA-approved production
Cnc medical Parts
Aerospace Industry
Aerospace is another industry where CNC machining is highly needed. Here are some parts where CNC machining is mandatory:
  • Airfoils
  • Manifolds
  • Antennae
  • Bushings
  • Landing gear parts
  • Electrical connectors
Transportation Industry
Like the aviation industry, many products of the transportation industry need the help of CNC machining. Transport vehicles need durable and robust components to transport heavyweights across countries. The transportation industry needs parts for:
  • Freight trains
  • Passenger rail
  • 18-wheel transport trucks
  • Shipping vessels
  • Passenger vehicles
  • And others
Electronics Industry 
The electronic industry uses CNC machining for manufacturing small components for various purposes. Some of those products are:
  • Amplifier housings
  • Electrical insulation
  • Heat sinks
  • Radiofrequency interference shielding
Military and Defense Industry 
The military and defense industry needs various parts that can endure even the harshest environment. To achieve that, they use CNC machining to manufacture many items such as:
  • Transportation components
  • Communications components
  • Plane parts
  • Electronics
Cnc Machining Military Parts  Other than these industries, many other sectors use CNC machining for various purposes.

Types Of CNC Machining

CNC machining can operate many complex functions with minimal human effort. It offers multiple advantages over machining that does not have the power of the CNC program. CNC machining significantly reduces cycle times and delivers highly optimized finished products. Here are the types of CNC machining you will see in many industries.
  • CNC Lathes and Turning Machines
  • CNC Milling Machines
  • CNC Laser Machines
  • EDM or CNC Electrical Discharge Machines
  • CNC Plasma Cutting Machines

Work Process of  CNC Machining

CNC machining is a fully automated system. All you need to provide the digital files and deliver appropriate instructions about tooling and trajectories. For producing a particular part, the machining process and design require many tools. CNC machining experts can make digital tool libraries to work with the physical machine. CNC machines can automatically switch tooling using these digital instructions. This robust process makes them a manufacturing workhorse. A typical CNC machining process follows the following steps:
  • CAD model designing
  • Transforming the CAD design to a CNC program
  • Preparing the machine
  • Final Execution

The Importance of CNC CAD Model Design

CAD design means Computer-Aided Design. The CAD design of a 3D or 2D solid part is the first step of a CNC machining process. You can do it with your in-house CAD designer, or you can take help from a professional CAD design agency.

CAD model for Cnc Machining

A CAD design software such as Autodesk is necessary to create the CAD design. You can use any CAD design software to create your CAD design. With the CAD design, a designer creates a model or renders the parts of a model. The produced CAD design also contains technical specifications, such as geometrics, dimensions for the parts.

One vital thing to consider before making the CAD design is your CNC machine and tooling specification. How you should prepare your CAD design primarily depends on the type of your CNC machine.

Typical CNC machine tooling is cylindrical. So, with the standard CNC machining process, you can only achieve a curved corner section. Therefore traditional CNC machining has some design limitations, and you can not output every design model from regular CNC machines. Moreover, the properties of the materials you will work on, tooling design, and machine’s work holding capabilities also restrict the design capabilities. The part size, minimum part thickness, features, and the complexity and inclusion of internal cavities also depend on those factors.

After the designer completes the CAD design, he/she exports the file to CNC file formats such as IGES or STEP.

The Method of Transforming A CNC CAD Design To A CNC Program

A CAM or computer-aided manufacturing application runs the formatted CAD file. This software extracts the part geometry and produces the code that will operate the CNC machine. With the power of this code, the CNC machine will manufacture the custom-designed part. So the complete process is like this.

The designer will create the part’s CAD design -> CAM software will convert the design and send it to the CNC machine -> CNC machine manufactures the part according to the design.  

A CNC machine uses multiple computer programming languages such as M-Code, G-Code to convert the CAD design into a digital command. G-code or general/geometric code is the most common CNC programming code. The G-code controls the movement of the machine tools like turning on/off, the velocity for a particular location, selecting the path, etc.

CNC machining program

The M-code or Miscellaneous functions code, on the contrary, controls auxiliary functions of the CNC machine. The applications that M-code performs are removing and replacing the machine cover at the beginning or end of production.

A CNC machinist loads the CNC program and prepares the machine to manufacture.

Prepare And Execute A CNC Machine

You have to set the CNC machine before performing the CNC operation. The first step is to affix the workpiece into the CNC machine. You have to fix the material into machine vises or a work-holding device or onto machinery spindles. Then you have to attach the tooling such as endmills, drill bits to the appropriate machine components.

Preparation for CNC machining

After everything is set up, the operator will run the CNC program.

The CNC program controls every action of the CNC machine. CNC program tells the integrated computer of the CNC machine how it should dictate the tooling actions and movements. The integrated computer manipulates and controls the machine tolling. After the program sends the commands, the CNC machine starts the process. The program guides the machine throughout the working process, and the machine produces the custom-designed part you were looking for.

The Common CNC Machining Operations

Many industries such as construction, aerospace, agriculture, automotive, or even use CNC machining to manufacture various parts. Even CNC machining is essential for producing multiple military types of equipment. That tells a lot about the wide range of applications that a CNC machine can perform. Though CNC machining can do many operations, most industries use CNC machining for the following operations:
  • Drilling
  • Milling
  • Turning
  • CNC Grinding
  • CNC Routing
  • CNC Plasma Cutter.
  • CNC 3-D Printer
  • CNC Pick and Place

Different Types of CNC Machining Techniques

CNC Drilling

Everyone knows what drilling is. This is a machining process that uses multi-point drill bits to create holes in a material. The CNC drilling is no exception, but it a more precise manner. Here the CNC machine uses a rotating drill bit on the workpiece.

CNC drilling

In most cases, the CNC machine uses the drill bit perpendicular to the workpiece and drills the exact sized hole of the drill bit. However, you can perform angular drilling operations with specialized CNC machine configuration. You can perform countersinking, reaming, tapping, and counterboring with the CNC drilling operation.

CNC Milling

The machining process of removing material from a workpiece with a multi-point cutting tool is known as milling. The manual milling machines feed the working material in the inverse direction to the rotating cutting tools, whereas CNC machines feed in the same direction.

CNC Milling

You can perform face milling, such as cutting flat, shallow surfaces and flat-bottomed cavities into the working material. Moreover, you can perform peripheral milling like threads and slots into the working material.

CNC milling can also perform drilling and boring operations, but costly options only for drilling purposes.

CNC Turning

The machining process of removing material from a workpiece with a single-point cutting tool is called Turning. The CNC turning machine is also called a CNC lathe machine, and it employs the cutting tool along the workpiece’s surface in a linear motion. The cutting tool then removes the material from around the workpiece before you achieve the desired diameter.

CNC turning

Thus the CNC machine manufactures various cylindrical parts such as tapers, slots, and threads with internal and external features. The turning process of a CNC machine can perform multiple operations such as facing, boring, thread cutting, and grooving.

CNC Grinding

In CNC grinding, a CNC machine uses a rotating grinding wheel for removing material, providing a precise finishing to the final product. The final product quality of CNC grinding is very high. Therefore the process is used in the last step of the manufacturing process.

CNC Routing 

CNC routing performs the same operations as CNC milling, and the main difference is the type of materials you can use in both processes. CNC routing is ideal for softer materials as the output power of this process is less. If you are dealing with rigid materials such as metal, CNC routing is not a wise option.

CNC Routing

However, CNC routing is a fast process, and it decreases the manufacturing time. Plasma – CNC plasma cutters are used to cut metal and wood (2 dimensional) and do not require as much power as a CNC router. These machines use a plasma torch to penetrate wood or sheet metal. 

CNC Plasma Cutter

CNC plasma cutters work on wood and metal. It is a 2-dimensional operation and does not need as much power as a CNC router. In this process, the CNC machine uses a plasma torch to go through thin sheet metal and any kind of wood.

CNC Laser Cutter

The operation of the CNC laser cutter is similar to the CNC plasma cutter. You can use the CNC laser cutter on metal sheets and wood. Moreover, you can use it to cut plastic materials.

CNC 3-D Printer

3D- printer is becoming popular day by day, and you can also use the CNC machining technology in a 3D-printer. CNC 3-D printer works similarly to CNC laser but slowly uses an extruder and constantly deposits plastic for producing the desired product.

Understanding CNC Pick and Place Device

This type of CNC machine can pick up various electrical components and place them in the electronic equipment. Pick and place CNC machines come with multiple nozzles to operate electronic devices. This type of CNC machine is widely used to manufacture computers, tablets, cellphones, etc.

Importance of CNC Machining 

custom cnc parts 04CNC machining is a widely used technology these days and is used in various fields. From Hobbyists to military service, CNC machining can deliver many advantages. CNC machining can turn raw material into a precisely finished final product and, at the same time, costs money and effort. CNC machining is a fast and efficient process and very safe to use too.

Products Can Be Made Using CNC  Machining

With CNC machines, the possibilities are infinite. You can manufacture seemingly any type of product using CNC machining technology.

We often see CNC machining manufactured products in our lives such as pens, rims for tires, paintball guns, ventilators, guitars, various wooden blocks, and much more. CNC machines have the unmatched advantage of working on multiple materials such as plastic, wood, metal, etc.

CNC machining not only provides precise products but also speeds up the manufacturing process. It also reduces the production cost.

CNC machines come in various forms and can produce different types of products and parts for multiple industries. For example, a 3-axis CNC milling machine can manufacture regular geometric-shaped products. For more complex parts, you can use a 5-axis CNC milling machine.

For its precise operational ability, CNC machining is a must-have technology in various industries such as medical, aerospace, automobile, defense, etc.

CNC machining can manufacture basic, delicate, intricate, and flexible types of products. And the most important advantage that you will get from a CNC machine is that it produces very little waste, and the production process is 100% human error-free.custom cnc parts 03

Meaning of 3-Axis, 4-Axis, And 5-Axis CNC Machining

Milling is an essential CNC machine operation. The operating process of a milling machine determines the operational capability of that machine. According to those capabilities, there are 3 types of CNC milling machines. They are 3-Axis, 4-Axis, And 5-Axis CNC milling machines.

The main difference between these 3 CNC machining is the movement of the workpiece. Ina 3-axis machine the workpiece doesn’t rotate on any axis. Therefore, it is not possible to work on more than one surface with a single setup.

A 4-axis machine on the other, the workpiece rotates 360 degrees about the X-axis. Therefore it becomes easier to work on all four surfaces with a single fixture.

And, lastly, there is a 5-axis machine that provides an extra angled surface to work with.

Benefits Of 5 Axis CNC Machining

5-Axis CNC machining is more sophisticated than traditional CNC Machining. Regular 3-axis machines move in three directions (X, Y, and Z coordinates), but the 5-axis adds two more rotary axes allowing them to work on complex-shaped workpieces. Here are five benefits you will get from the 5-Axis CNC machining.

Fewer Setups

You can machine virtually every visible surface with 5-axis machining technology without the clamping and bottom portion. For this facility, you don’t need to set up multiple fixtures for different surfaces. Thus you can minimize your manufacturing costs significantly. 

Complex Shapes

The capability of working with complex shapes is the most important benefit of 5-axis machining. The additional movement provides complicated machining angles and arcs. Without this facility, you will need multiple fixtures to work on various angles, increasing your production cost and increasing production time.cnc machining medical devices 6

Relational Accuracy

When the setup changes, the accuracy will change. When you remove a part from the machine, you can achieve precise alignment again. As CNC machining is all about precise operations, even a slight loss of accuracy can be costly. 5-axis machining feature to feature accuracy for your final production.

3+2 Axis Machining

You can machine with simultaneous movement in 5-Axis with the 5-axis machining process. But some parts need 3+2 movement. Luckily you can also achieve this in a 5-axis machining process.

In the 3+2 machining technique, the workpiece stays fixed on either side of the fifth axis and does not move simultaneously. For some parts, you will need this CNC machining process.

Better Surface Finish

The fourth and fifth axis rotation can bring the workpiece closer to the cutting tool. Therefore, you can use a shorter cutting tool to perform your operation. A shorter cutting tool has less susceptibility against vibration and can generate higher cutting speeds. As a result, with 5-Axis machining, you will have better-finished products.

Quality Control In CNC Machining

CNC machining companies use quality control procedures to measure the quality of a CNC machine’s product. Every production unit must follow specific quality control procedures and CNC machines are no exception. CNC machining Quality Control If you appoint a  CNC manufacturing company to aid your manufacturing process, you are looking for a macroscopic tolerance limit. For example, if you are producing oil line valves allowing 1mm tolerance, thousands of cars will leak oil. Similar things will happen in other industries’ products that need minimal tolerance. Quality control ensures the tolerance level will stay as minimal as possible following the industry-standard margins of that product.
  • The first rule of quality control is to ensure the machine has proper CNC equipment such as a milling machine, grinder, router, etc., to create the product or the prototype. You should purchase your equipment from a registered dealer. If you are hiring a CNC machining company, ask them to provide a warranty for their service.
  • A professional CNC machining company will maintain the optimum quality by following a proper maintenance protocol and frequent calibration. Some maintenance protocols do not include spindles on the CNC equipment. But if they are included in every maintenance protocol, that significantly reduces the downtime.
  • It is better to conduct an inspection using your own quality control procedure. It is better to have a QC tester on your plant.
  • Every professional CNC company keeps a record of its production. Checking those records is another good quality control inspection process. Records of previous inspections and showing them using data tables and charts shows the capability and QC standard of a CNC machine company.
  • Sound Predictive Maintenance Programs cover the variability management system of a CNC machine. It also covers the maintenance and reliability of the CNC machining process. Therefore, execute a sound PMD program.
  • The CNC machining operations are as good as the hand behind the machine. Sometimes less skilled persons operate the machine, which results in faulty material or products with increased tolerance. To overcome this skill gap, the manufacturer can contact the local CNC machine institution and ensure highly skilled CNC machinists.
  • Get an ISO certification. For example, companies with ISO 9000 certification have improved business functions and execution. They ensure better business implementation, reduces reworking, reduced scrap, and of course, lower cost. Besides, ISO certification plays a vital role in marketing and sales.

The Efficiency of CNC Machining

cnc prototype parts 1For the conventional machining process, the CNC machining process is highly efficient. CNC machining can use a higher automation level which reduces the probable error during the manufacturing process.

Human error plays a vital role in the manual machining process, but in CNC machining, the chance of human error is minimal. Therefore, you will get a final product with minimal error in a cost-effective way. Here are the reasons why CNC machining is highly efficient than other machining processes.

Productivity

As CNC machining can perform complex actions simultaneously on its own, you don’t have to observe the actions all the way. The working process is entirely automated and produces the materials taking the instructions from the CNC program.

With a complex 5-axis machine, you can perform even more complex operations once in a while. The whole process shortens the production time and enhances the efficiency of your production.

Consistency

The CNC machining process removes the possibility of human error entirely. Therefore, the machining technology is more consistent than the typical manual machining process. This machining process ensures faultless and uniform productions. For this reason, products that need compatible products with minimal tolerance level uses CNC machining.

Cost-Effectiveness

You can perform various complex operations with a single setup in the CNC machining process. Moreover, CNC machinists need less operational training than typical manual machining machinists. As the number of productions increases, your costing for unit production decreases. So, though CNC machining is expensive, it reduces your production cost significantly for a large amount of production.

Safety

Conventional machine operations have various safety issues for machinists and products. But in CNC machining, everything is controlled by the CNC program, and the machinists have no safety concerns during the operation.

Versatility

You can reprogram a CNC machine in a short time and manufacture a completely new model or part. The CNC machining process is suitable for both long and short-term productions. But a manual machining process needs more time to reset and manufacture new types of products.

The Best CNC Machining Machine

Swiss and German brands are more popular CNC machining machine brands. Here are the names of top-selling CNC machining machine brands all over the world:cnc lathing parts 1
  • Okuma
  • Mikron
  • Hermle
  • Haas
  • Mazak
  • Bumotec&Starrag
  • Liechti
  • DMG Mori
  • Willemin-Model
  • Chiron

Find The Most Suitable CNC Machining Supplier

You can face some hard times searching for the most suitable CNC machining supplier under your niche if you are a newbie. Even experienced customers sometimes face difficulties in finding the best CNC machining supplier. But if you follow the following steps, hopefully, it will be a straightforward process for you to find an ideal CNC machining supplier:

Visit the Manufacturer

We will highly recommend you visit the manufacturer before making a final decision about your CNC machining manufacturer. Because many foreign buyers often contact a trading company online instead of the original company. Therefore, make sure you visit the company to make sure you are dealing with the right people.

Customers’ Feedback

You should pick a CNC machining manufacturer company with customers’ testimonials and provide you with their contact information for further verification. You should ask for every detail about their customers and don’t tell them which one you are going to contact. Thus you will be able to learn whether they are providing authentic testimonials or not.

choose your cnc machining manufacturer carefully

Check the Payment Terms

Typically Chinese CNC machining manufacturers ask for a 50% down payment and 50% after production. We recommend finding a company that agrees to take a 30% down payment and 70% after getting the copy of the bill of lading.

Ensure that the company agrees on quality inspection before they make the final shipment. And you must ensure the quality check yourself or with a third-party quality inspection agency.

Manufacturer’s Location

China is a vast country, and sometimes Chinese manufacturers only provide the province’s address. But you should ask them the location of their factory. Thus you will be able to find out the nearest port from the factory. This is important because this distance will affect the road transport cost.

Ask for Samples

Before making the final purchase, always ask for a sample from the supplier. Typically for new customers, a company willingly wants to show a sample without or minimal payment. Bear in mind that trading companies ask for a high price for samples. So, if the sample’s price is higher, you should understand you are dealing with a third party, not a company.

 Customer Service

Customer service is very critical. Send them an email and find the response time. Use other mediums of customer service that the company offers and see the response time and service quality. DO NOT make a deal if their customer service is not satisfactory.

MOQ or Minimum Order Quantity 

MOQ must be clarified before you make the final agreement. To be sure about the minimum order quantity, you should send them the drawing of your part of the product. Try to get as minimum MOQ as possible.

Request Their Legal Documentation

Before choosing a CNC machining manufacturer, you should ask for their documentation. Ask for their registration number, license number, ISO certificate, COC samples, QC certificates, raw materials certificate, etc.

Supplier’s Responsibilities

Ask the manufacturer whether he/she will be responsible for delivering the exact parts as you describe in the drawing. Also, clarify who will take responsibility if you get faulty products. A good supplier will take responsibility. Do not go for a gentlemen’s agreement; tell them to give you the commitment in writing.cnc milling quote 1

Third-Party Inspection 

Before importing your CNC machined supplies from China, you MUST make a final inspection. Use a third-party inspection team to do the job for you. Hire a company and tell them to inspect before your manufacturer makes the last shipment.

Cost Consideration When Custom CNC Machining Parts

A wide range of factors that should be considered for designing custom CNC machining parts with respect to cost variables include the choice of cheaper materials, reducing waste through efficient designs and simplification of multi-faceted details whereas eliminating nonessential features from tooling requiring optimization balanced product batch size tolerance setting appropriate finishes labor costs location facilities requirement or prototypic evaluation potential suppliers hurrying tim With these factors into consideration, costs will be kept under control and you can ensure a cost-effective CNC machining projects with the necessary technical specifications.

Conclusion

CNC machining is a process that makes the modern manufacturing process more robust and efficient. Many industries have their own CNC machines to manufacture their required products. And others take the help of a professional CNC machining shop. It largely depends on your requirement.

But, one thing is for sure, you can not manufacture precise parts without CNC machining

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