5 Axis Machining
5 axis machining can improve the machining precision, quality and efficiency of the free-form surface of precision components. 5 axis machining is referring to the ability of a CNC machine to move a part of a tool on five different axes at the same time. 3-axis machining centers move a part in two directions (X and Y), and the tool moves up and down (Z). 5-Axis machining centers can rotate on two additional rotary axes (A and B) which help the cutting tool approach the part from all directions. With a 5 axis machine, you can reduce setup time and increase accuracy on each part.
Mold components are what make the mold work and the mechanisms used to deliver a quality end product. Mold components include mold bases, pins, ejectors, lifters, bushings, guides, alignment devices, gating system, cooling system and so on. Each part of them of different requirements of its materials to achieve the best performance. See below tables about materials selection about the different part of a mold.
Custom CNC Machining
CNC milling is one of the most popular CNC machining processes including both drilling and cutting processes; CNC milling uses a rotating cylindrical cutting tool just like in drilling. But, unlike the single axis motion of the latter, the cutter and workpiece in a milling machine can move along three, four and even five axes allowing it to produce shapes, holes, and slots with tight tolerances. In addition, the workpiece is often moved across the milling tool in different directions, unlike the single axis motion of a drill.
Precision CNC Machining
Precision CNC machining is a fancy term for tools such as routers, grinders and milling machines that are guided by computer instead of by hand. It means highly-automated, working from programmed code that tells them where and when action needs to be taken, and only require human intervention at the beginning and end of the job.
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A Complete Guide to Precision Components
Modern industry and all the gadgets which make our lives easier exist because of precision engineering. This branch of manufacturing combines mass production with the fine work necessary to make precision components. These are more resistant and last longer than parts which result from manual labor. Precision engineers design and come up with innovative ideas for top-notch machine parts and instruments.
What are precision components?
The process of making these items is very accurate and follows specific steps. Their manufacturing requires expertise, high-end technology, and complex processes. Producing companies use stainless steel, nickel, aluminum, titanium, and other durable materials to make them.
Baffle rings, circular holders, inserts, milled parts, plugs, unions, and bleeds are just a few examples of machined components.
Why Are Precision Components a Good Investment?
Technology evolves and as a result, there is an increasing demand in precision parts. The top reasons to put your money in this sector are:
High Level of Accuracy
Precision machined parts come with no flaws because they are not manufactured by workers. As a result, human errors do not occur. Plus, the apparatuses that produce them have special detectors to identify the production flaws. The device stops working when there is an error in the production process. As a result, you will not waste your money, efforts, and material on nonfunctional items.
Efficient and Effective
Lots of modern apparatuses, tools, and instruments have in their composition smaller or bigger parts. These work together to assure the perfect functioning of various machinery.
Precision components are almost error-free and as a result, the industrial, medical or transportation equipment is more effective. Mass production is faster and it is not interrupted by machinery flaws.
Resistant and Durable
Machined parts have in their composition materials which can face the destructive action of different physical and chemical processes. Corrosion does not diminish their quality and properties.
Easy and Fast to Assemble
Five-Star ManufacturersAbout Us produce and deliver precision parts with features that allow users to piece them together without losing precious time. The greatest advantage is that work at the assembly lines is done faster. This allows you to save significant funds and invest them in other departments or more ambitious projects.
Decreased Percentage of Raw Material Wastage
The squandering of important amounts of raw materials represents one of the greatest problems of component manufacturers. Hundreds of products can have the same error and there is no other solution but to get rid of them. As a result, the good parts will have higher prices because they have to cover the loss.
The precise production of different components solves this issue. Waste of materials is reduced to a minimum and the final items have competitive rates.
Industries which rely on precision components
Precision parts serve different fields such as:
• medical equipment
• automotive industry
• IT industry and robotics
• petrochemical industry
• armaments industry
• space exploration
• telecommunications industry
• other top-notch technologies
An increasing number of companies require highly accurate machined parts in order to boost their productivity.
Precision Components and Medical Devices
Apparatuses used in doctors’ surgeries and hospitals have the purpose to treat patients and perform delicate procedures. Therefore, their construction follows exact instructions and needs specialized parts.
Precision parts used in the medical domain include:
o PEEK implants which have in their composition a special transparent polymer with organic properties. They experience increasing popularity because of their non-invasive and safe nature. Doctors use them for implants in the spine or the thoracic region.
o Dental implants are necessary for complicated oral interventions at teeth level.
o Different types of screws, hooks, and plates for the bones, orthopedic implants, and devices for the spinal column which allow individuals to perform daily activities despite their medical condition.
o Components for optical apparatuses, medical fans, and prosthesis
o Clamps, clips, and rings
In modern medicine precision and reliability are of utmost importance. All the more as high performance is required every day.
Machined Parts for the Automotive Industry
Highly accurate components for cars and other means of transportation have in their structure carbon, resistant alloys or qualitative steel. The manufacturing process implies the use of bore grinders, deburring tools, robot operated honing machines, computerized twin spindle tuners, and other state-of-the-art machinery.
The automotive industry needs the following precision components:
o rotor assemblies, precision thrust bearings, and hydraulic components
o clutch parts, shims, gaskets
o flange hubs
o fasteners, different varieties of bolts, and nuts
o filtration and test sieves
o sensor and airbag components
o spider and turned pieces
o gearshifts and park locks
The miniaturization tendency that characterizes the nowadays automotive domain poses new problems. Engineers must come with viable solutions to provide the market with competitive and adequate products.
Electronics and Precise Parts
The rapid development of modern gadgets leads to a fast increase in the number of transistors per every square inch. As a result, personal computers, radio receivers, smartphones, consoles, and televisions have reduced dimensions and occupy less space. The structure of electronic precise components changed in terms of size and extra power.
Companies and individual buyers ask for precise components such as:
o connectors of different categories – D-SUB, IDC or FPC
o fuse holders
o cable heads
o circuit breakers
o terminal blocks
o axial and radial fans
o relays and heatsinks
o embedded systems
o RF modules
o electronic enclosures
Parts with tiny characteristics are difficult to produce. Their manufacturing calls for specialized machinery which has an incredible production speed.
Aerospace Precise Components
Aeronautics and space industry are the most advanced domains in the world. Most planes are used for several decades. At the same time, technology advances rapidly and so do the requirements for passengers’ safety and comfort. Maximum precision is essential in this field.
Machined parts developed for planes and other flying apparatuses include:
o toggle and hoist links
o hinges and pistons
o outer and inner flap actuators
o valve bodies
o locking mechanism for doors
The challenge for both the aerospace and defense industry is how to produce more with fewer resources and how to continue the development of innovative precision parts.
5 Materials use for Precision Components
Precision machined parts are made of elastomeric materials, offering high accuracy, tight tolerance from a dimensional perspective, and qualitative surfaces. The materials can handle extreme temperatures and pressures having outstanding reliability.
Why is Titanium So Special?
The use of titanium alloys for aerospace structures has been rising continuously since 1980. These alloys were first used in military projects and later became widespread in the construction of commercial aircraft.
Five-Star appreciate titanium for its superior qualities such as:
o the positive balance between resistance and weight
o resistance to corrosion
o mechanical properties which preserve themselves in time
o degree of deformation at temperature differences
Titanium alloy is valued within the aerospace industry because of its low specific weight and particular mechanical properties. Its processing needs the development of clipping forces which exceed the ones used for steel production.
This element has reduced density (around 60% of iron density) which can be strengthened through alloying and transformation processes. Titanium is nonmagnetic and has superior features which allow a good thermic transfer. It has a high melting point equal to 31350F.
An important bonus is its non-toxicity which makes it compatible with human bones and tissues. For this reason, the producers prefer it for medial and optical precision components. Its durability, resistance to corrosion, bio-compatibility, and adaptability to marine environments recommend it for machined parts designed for chemical and petrochemical industry.
Aluminum and Its Advantages
The most widespread metal in nature, aluminum represents 7,4% of the Earth’s crust. Manufacturers like its ease of processing, resistance to corrosion, and low density.
Aluminum presents a high power-weight ratio and great hardness to fracture. These features make it an economical and efficient material, perfect for military and commercial equipment.
Air exposure determines the formation of a layer of aluminum oxide on the surface of the material. This layer endures the action of most acids, but it is more sensible to alkaline substances.
Its superior thermic conductivity transformed it in an important material for cooling and heating devices. Although lighter than most metals, aluminum has great mechanical strength. This feature counts a lot for aeronautics.
The metal can be recycled for an unlimited number of times without losing its characteristics. Also, it has a unique and unrivaled combination of features which make it a versatile, functional and attractive material for precisions parts.
The Pluses of Stainless Steel
Stainless steel is an alloy of iron-carbon and chrome which displays a significant resistance to electrochemical corrosion. The ease of processing gives all finite products a smooth surface with reduced roughness.
This alloy is favored for its:
o endurance to temperature variations
o ease of recycling and reuse
o good thermic conductivity
There are different types of stainless steel. These are grouped in the following categories:
o austenitic and super austenitic
o hardened as a result of precipitation
Ferritic steel is used for the production of architectural tiles, covers for washing machines, and injection molds for heavy industry. Austenitic and Super austenitic steel enters in the composition of kitchen appliances. Duplex steel combines the features of ferritic and austenitic steel. It is used in the manufacture of products that require high resistance.
Beryllium and Its Characteristics
Beryl is found in deposited located in the Ural Mountains, Brasilia, Colombia, and Namibia. In 1828, Friedrich Woller and Antoine Alexandre Bussy managed to isolate the metal. It was a moment of significant importance because beryllium has lots of features such as:
o a high melting temperature
o powerful conductivity for electricity and heat
o an outstanding elasticity
o good permeability for X-rays
o resistance to oxidation
The metal has found its use in the field of nuclear energy because it lowers the speed of neutrons. Its lightness and elasticity fit the specifics of the aeronautic industry. Plus, its affinity for oxygen allows beryllium to be amongst the most appreciated deoxidizers. Lots of precision parts for medical, electronics, telecommunication, and defense have beryllium in their structure.
The Properties of Nickel
This is a white-silvery metal with plastic and magnetic features. It is durable, corrosion-resistant, and ductile. Its density has values of 8,902 grams per cubic centimeter and its boiling point reaches 4949.60F. It melts at temperatures equal to 26510F. Nickel is a good electric and thermal conductor.
It displays endurance to the negative action of organic and inorganic substances. However, it is sensible to sulfur. Manufacturers prefer it for galvanization processes because of its tolerance of atmospheric corrosion.
The metal enters in the composition of nickel-chrome alloys. There are lots of batteries which owe their functioning to this metal. It is also used for the fabrication of tube or thin sheets. Engineers have identified lots of applications for this element in domains such as mechanics, aviation, rocket science, and chemical industry.
Precision Components Manufacturers and Their Tools
Popular and appreciated around the world, machine tools with numerical control are instruments which allow the manufacturing of precise components. These may have different forms and dimensions according to the buyers’ demands.
Devices with numerical control have two parts: the machine and the CNC equipment. The most widespread machines are the ones for:
• stamping and embossing
• plastic injection
• plasma cutting
A machine tool performs pre-established movements following certain specific axes which the program takes into consideration. The numeric control the axis has linear or rotary movements. These are performed by the mobile parts of the device.
CNC machines do not need templates and models. Plus, it is easier to change the settings of numeric programs than the ones of rigid programs fixed by cams and patterns.
Features of the CNC Milling Tools
Milling is the procedure of processing by cutting of flat, cylindrical or shaped surfaces with the help of milling machines.
Superior milling is the outcome of a qualitative surface and short cycle times. To obtain such results, producers need a high-speed main shaft, a smart software, and a versatile CNC system. These can use the full potential of machines according to different materials and productions demands.
In the case of production lines with a high volume, the number of precisions parts produced per hour plays a vital role. To obtain a component in 1,7 seconds the manufacturing processes must be optimized with smart function which allows anticipation and learning.
State-of-the-art Milling Tools give the workers the possibility to:
o program the machinery
o create processing cycles for applications such as cutting, grooving, drilling, and outlining
o program the measuring cycles
o estimate the duration of the processing time
o measure the part which needs processing
o calibrate the instrument
To maximize production, we need smart software function which prevents the damage of instruments and tools. At the same time, they eliminate the necessity to slow down or to interrupt the fabrication activity.
Intelligent Drilling Machines
Column or radial drilling machines are powerful, compact, and versatile. They can be used deep and angular drilling and for threading. Some machines have a panel which moves continuously backward and forwards and the drilling in downward oriented. The component to be drilled has a fixed position.
These instruments present several verticals, horizontal, and controlled axes, a riveting saw, a circular canvas for rivets, and a horizontal drill. More advanced models have leaser measuring systems to determine the exact length of the precision components.
There are also machines which have high-speed gear changers which allow the rapid alternation of milling, drilling, threading, and boring processes in 0,7 seconds. As they are equipped with fast shafts they decelerate and accelerate rapidly between two tools changes.
Smart Grinding Machines
To enhance the quality of surfaces and the yield of grinding application, the CNC system must accept functions developed to optimize grinding processes.
There are different types of grinding:
o cylindrical which used to boost the quality of lathe manufactured precise components
o flat grinding which has the purpose to make shapes and surfaces
o 5 axes grinding which is aimed at manufacturing tools
CNC grinding machines have software systems which measure the pressure and the noise generated during the grinding process. If the material characteristics or the cutting operation decrease the resistance of the cutting tool, the software accelerates the rectification disk. If the noise and the pressure indicate an increase in resistance, the speed of the tool diminishes.
To prevent collision risks in the case of grinding machines with multiple axes and to protect valuable parts, manufacturers can purchase smart anti-collision software.
CNC tools are indispensable for the fabrication of precision components. They make more effective and efficient the manufacturing process because of their high precision, increased working capacity, and longer lifespan.
The Ultimate FAQs Guide to Precision Components
Q1. What type of precision parts are needed to piece together different industrial items?
This task is performed by fasteners. Manufacturers use stainless steel alloys in their composition. There are lots of fasteners on the market. Screw and blots are familiar even to people who do not display a particular interest in machines. Other categories are more complex and designed for more advanced fields like aeronautics and defense.
Q2. Do CNC machines have any weaknesses?
CNC machines have lots of benefits which improve the quality of precision components. They have some weaknesses which do not mage to outcome their extraordinary features. The installation of these tools requires important funds. Thus, a small company might not afford them.
CNC machines are profitable only for large productions. If a few pieces are fabricated, the costs might exceed the ones involved when manufacturing items with a traditional tool. As the number of precision components increases, then the CNC machine turns into a profitable one.
Maintenance costs are considerable and demand trained staff. Plus, the company must establish a trust collaboration with a serious and competent supplier of CNC parts.
Q3. What is surface coating?
The surface coating includes a vast array of industrial processes which change the surface of a manufactured item to obtain a certain feature. They can enhance the aspect, adherence, wettability, chemical resistance, hardness, and lifespan of a precision component. The most common surface coatings are anodizing, electroplating, electrophoresis, and mechanical grinding.
Compared with the ordinary machine tool, the characteristic of CNC machining as following:
- With high precision, reliable quality.
- Carrying on multi-coordinate linkage, processing parts with a complicated shape.
- Saving the preparation of production time; only adjust CNC procedure when the machining parts are changed.
- Owning high precision and strong rigidity automatically. As well as choosing favorable processing.
- High automatic, meanwhile reducing the labor force.
1. Materials: Steel, stainless steel, aluminum alloy, engineering plastics, copper, brass, bronze alloy are available. Click here to check more details
2. Surface treatments are available: Polishing, Plating, Anodizing, Zinc plating, Nickel plating, Powder coating, Chromed, Brushing
3. Rich experiences in manufacturing area for more than 13 years
4. Five-Star tooling company has 2 factory, one is in SHENZHEN and another one is in Dongguan, we are 100%manufacturer, ensure quality and lead time better.
5. For better systematic quality management, Five-Star tooling company passed ISO9001:2015 and ISO14001:2015, more certification for our company please check here.
6. Advanced Equipment and Skilled Technicians to ensure more precision and good quality.