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How to Produce High-quality Parts With CNC?

It’s well known that the popularity of CNC equipment is getting higher and higher with the continuous improvement of CNC technology, and manufacturers will choose CNC to help us process parts. However, all technological improvements are mutual. The new technology requires more sophisticated parts to achieve, and perfect custom CNC parts need more advanced technology and equipment. How do you make high-quality parts? Today, the passage will analyze the factors affecting high-quality parts and the corresponding solutions. For a part, if we want to accurately manufacture it, we need to consider it from the aspects of design, processing, post-processing, testing and packaging, etc. Below we will introduce it in detail:

Design

To manufacture a high-precision, high-quality part, locate the part at the source design end at first, including whether the shape of the parts is reasonable, whether the selected materials can meet our needs, whether the tolerance setting can be achieved, and whether the cost is comprehensively considered.

1. The Shape design of parts

When we design a part, we will design the shape we want to achieve according to the needs of our own equipment, but we also have to consider whether the part of this shape can be perfectly processed and whether to divide it into several combination parts to combine.

Of course, there are other factors to consider, mainly including the following aspects:

1. Functional requirements: The shape of the part must meet its predetermined functional requirements, including the assembly of parts, motion trajectory, stress conditions, etc.

2. Manufacturing processCNC machining has its specific process requirements and limitations. For example, the depth of the cavity and groove, the radius of the inner edge, the minimum thickness of the thin wall, the diameter of the hole, and the size of the thread.

3. Assembly and disassembly: When designing the shape of the part, it is also necessary to consider the assembly and disassembly process of the part. For example, the matching gap, the positioning method, the fastening method, etc. of parts quality inspection need to be planned in the shape design to ensure the smooth assembly and the convenience of disassembly.

4. Cost-effectiveness: Shape design also needs to consider cost-effectiveness, including material costs, processing costs, assembly costs, etc.


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2. Material setting

After designing its shape, we need to choose the right material according to our specific use environment and way. The selection of materials also needs to consider many aspects, the details as follows:


Material properties: including mechanical properties (strength, hardness, toughness, etc.), physical properties (density, coefficient of thermal expansion, conductivity, etc.), chemical properties (corrosion resistance and chemical stability)


Machinability: The machinability of the material is directly related to the production efficiency and cost of the part. Materials that are easy to cut, forge, cast and weld are generally preferred.


Cost: Material cost is an important part of the manufacturing cost of parts, so it is necessary to choose materials with lower cost as far as possible under the premise of meeting the performance requirements


Reliability: The reliability of the material, including fatigue resistance, wear resistance, etc.


Other special requirements: According to the specific use of the parts and working environment, it also needs to consider some special requirements, such as insulation, diamagnetism and so on.


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3. Tolerance Setting  

The setting of tolerances is also related to the shape of the material and part. For example, we add a μm tolerance to a PU part, which is very difficult to achieve, because PU itself is very soft, conventional measurement will have errors, so it is very difficult to add too much tolerance to the plastic. If you want to achieve the accuracy of the μm level, it is best to choose a metal with good rigidity, and the μm level is best to meet the appearance size requirements of the parts, so as to reduce the defect rate. We can grind out the tolerance of the shape through a precision grinder, and the inside shape can only be processed by discharge or slow wire to produce its accuracy, which is a very high cost. So we also need to take these factors into account when designing tolerances. Under normal circumstances, high-precision tolerances only appear in mating parts, such as bearing positions, positioning pins, positioning holes, etc.

Processing Section

After the part design is completed and reviewed, you can get to CNC to process, and what problems do we need to pay attention to when processing? Here they are:

1. Inspection of Materials

When we get the drawing, we will first customize the material. Generally, when we customize the material, we will customize the material slightly larger than the overall shape of the part for processing, because the surface of the raw material itself will have some defects, and we must remove these inherent defects to process the parts we need. Generally, when customizing materials, the processing amount of about 5mm will be added on each side, that is, the parts with the shape of 100*100*100, we need to customize 105*105*105 materials. After the customization of the material, we need to carry out a raw material test on the material. The convenience of the test includes appearance defects, whether there are impurities, and whether the label is consistent with the drawing. For some parts with internal strength requirements, we also need to carry out ultrasonic flaw detection analysis to analyze whether there is a hole inside the material, otherwise, when the processing is half of the time to find that there is a problem inside the material, it will cause a waste of time and cost.

2. Analysis of Processing Technology

After getting the materials, we need to analyze the processing technology of the parts, evaluate and analyze the numerical control part and the mechanical part respectively, and make a reasonable processing instruction. The purpose of doing this is to prevent missing the post-process and not to arrange some details in time. When analyzing the processing technology, it will analyze what equipment needs to be used to process, what kind of tool to choose, whether there is a need for secondary processing and the recording of the post-processing process.

3. Machine Tool Matching

After analyzing the processing technology, it will be arranged on the machine tool for processing. Choosing what kind of machine tool to process our parts is also a matter that needs reasonable consideration. For example, we can use conventional three-axis CNC for products that are not difficult to process. It will also be more efficient. At the same time, according to the tolerance of the parts, the processing accuracy of the general CNC machine tool is about 0.02, and when it is necessary to process more precise parts, it is necessary to consider whether to choose an advanced machine tool with better accuracy or to leave the accuracy to the grinder or slow wire after the process.


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Postprocessing

After the parts are processed on the CNC, it is necessary to check whether post-processing operations are required according to the process instructions of pre-production. Post-treatment processes include tapping, reamer reaming, grinding, polishing, electroplating, etc. Things to look out for in the post-processing section include the following:

Tapping teeth—whether the depth and size of CNC machining holes are in a reasonable range;

Reamer reaming—whether the reamer reaming margin is reasonable;

Grinding—if the spare amount of CNC and surface machining tool grain can be completely ground off;

Polishing—whether it will cause a certain image of the shape and size of the product;

Electroplate—if the size changes after electroplating and how to avoid or deal with it.


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Detection Package

After all processes are completed, a comprehensive inspection of the product is required. The scope of detection includes size, appearance, surface, hardness, and whether there is leakage processing. At the same time, it is also necessary to fill in the full inspection report. Under normal circumstances, we test 5 pieces of a part to complete the completion of the inspection report. If an anomaly is found, it is necessary to timely feedback to the relevant part and submit the abnormal part. After the quality inspection is completed, the parts can be packaged and shipped, and the packaging should also be handled, and the surface should be protected to avoid secondary damage to the parts due to shaking or friction during the transportation process.

 

From the above, we can see that the processing of qualified high-quality parts needs to consider a lot of links, and each stage of control is very important. A link out of the problem, the whole part will appear bad or scrapped situation. If you have high-quality parts to process, it is recommended that you still find a more reliable and powerful supplier to help you solve this matter. For example, in China, Richconn is very good at the production of high-precision parts. They are not only through the ISO9001 certification, but also through the self-developed system to control the execution of parts from order to shipment. Every link will have professional personnel to follow up.

Why recommend Richconn?

First of all, Richconn has more than ten years of processing experience in the field of CNC machining. They not only have advanced processing equipment, but also have a group of technicians who accompany it to development. At the same time, Richconn is constantly updating technology and attracting excellent practitioners to meet the needs of the market, in addition to it has the following advantages:

  • Richconn has always been challenging to process high-quality precision parts, including CNC aluminum parts, CNC milling parts in medical devices and aerospace.

  • Richconn has strict tolerance control in order to meet customers’ needs and spare no expense to purchase advanced three-dimensional testing equipment.

  • Richconn has a reliable and large supply chain to support their post-treatment process, whether it is post-treatment processing or surface treatment, they can do it easily.

  • Richconn has the support of reliable logistics companies, no matter what country you are in, or which city is in demand. They can all be delivered on time.


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