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Processing

CNC

Difference Between CNC Turning & Milling

by Chirag
written by Chirag

Turning is one of the oldest manufacturing process, the traces of which dates all the way back to ancient Egyptian civilization. The purpose of turning is to create intricate and detailed parts, pieces, or components of any machinery. Thanks to lathe machines, the turning process has come a long way from manual turning to program-run CNC turning.

Using a turning lathe, the latest technology, and skilled machinists- CNC manufacturing service providers can now create custom-designed parts and components (also called workpieces) to the exact requirement of the client.

Another very popular CNC manufacturing process is CNC milling, and people often think of milling and turning as the same thing, but that’s not true. CNC turning and CNC milling are computer-run machining processes, but they serve two different purposes.

CNC Turning Vs CNC Milling

Both the CNC Milling and CNC turning process basically have the same purpose of making intricate and accurate parts and components that are very difficult to create by hand. And, both CNC Milling and CNC Turning do use computer codes written in G-Code language, but there is a very obvious difference in the workings of these two processes.

With CNC Milling, it is the cutters that move around the workpiece on different axes to morph the final product, whereas in turning, the cutters are rigid and parallel to the moving workpiece. Another difference is that CNC Milling is mostly to provide the final touches to the workpiece, for example, adding intricate cuts, holes, etc. Whereas the major use of CNC Turning is for making cylindrical parts from scratch.

CNC Turning Process

Whether you choose CNC Milling or CNC Turning to manufacture your parts, there is a certain process that you need to follow before your CNC manufacturers can start the manufacturing process. The following FOUR steps will put you on the right track to start your CNC manufacturing process.

  • Making a blueprint of your component in CAD(Computer-Aided Design).
  • Converting the CAD blueprint into G-Code.
  • Setting up the lathe.
  • Starting the manufacturing process.

Types Of CNC Turning Process

Just like every other CNC manufacturing process, turning also has a lot of other types to prepare different types of parts. Because the turning process has wide applications, there are lots of types of turning. Here are some of the most common CNC turning processes.

  • Straight Turning or Roughing: The most common form of turning that cuts any extra material from a workpiece to develop a cylindrical piece with a uniform diameter.
  • Taper Turning: Taper turning also is for creating cylindrical shapes but with the difference in diameter. Taper turning is when the cylinders need to have a decreasing diameter. 
  • Spherical Generation: To prepare the perfect sphere, manufacturers use the Spherical Generation turning process.

These THREE turning processes are the most common in the industry; however, these do not provide the finishing touch to the workpiece. For the finishing touches, the turning lathes provide FOUR more processes depending on your parts and the type of finish you need.

So, even though all these processes are different from each other, using only one will not give you the desired results. To get the best out of CNC Turning, you will have to go through TWO or THREE steps. 

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Injection Molding

Significant Considerations For Injection Molding

by Chirag
written by Chirag

Injection molding is one of the most popular manufacturing processes in existence. It is highly used in the mass-production of plastic parts, and the process involves the use of an injection molding machine, also known as a press. The popularity and success of this method have led to a lot of injection molding companies being established. In this excerpt, we look at considerations for injection molding.

Things you need to do before producing parts using injection molding

Before you start using this technology to manufacture parts, below are some things you should consider;

1. Finances

The financial considerations are perhaps the most significant. Note that you need to account for the entry costs, production, and design preparation costs. It would help if you accounted for the costs of entering into this industry. This may include the cost of purchasing the materials and the machinery required. At the same time, you ought to determine the number of parts you want to make and how much it would cost to get the materials and complete the production process.

When planning for financial responsibilities, most people forget about the design process. The design process can be split into two categories. These are the part and tool design categories. Each of these processes requires money to complete. When considering all these financial elements, you need to also think about how much profit you will make. The last thing you want is to spend too much money in the process and not make any profit in return.

2. Designing

Next to the financial considerations, the design considerations are also essential. Creating the design is perhaps the most critical part of the process of injection molding. The part design will influence the overall outcome of the production process. When designing the piece, you should have injection molding in mind. It would help if you simplified the geometry and minimized the number of parts when designing the part so that the production process is easy.

The design of the tool is also essential. It would be best to make sure that the mold tool design is free from any defects to prevent production issues. Note that the presence of defects during production could cost you a lot of time and money. Therefore, you need to take your time during the tool designing process. Naturally, you will need an expert team for this part of the process.

3. Production

After designing the part and the tool, the next natural step is production. Note that plastic injection molding is an automated process. This means that it does not depend on a lot of human input. This means that once the machine is set up and the raw materials are fed, the rest of the work is done automatically. Therefore, to ensure that the process runs smoothly, you need to ensure that the machine is set up correctly. It would help if you were careful in the assembly process.

Conclusion

The injection molding process is not as intricate as most people assume. The production process itself is pretty easy because it is automated. However, the challenging part is designing the tool and the desired part.

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CNC

Ultimate Guide to Purchasing the Right Press Brake

by Chirag
written by Chirag

A press brake is important CNC equipment. As a manufacturer, you want to ensure you get a machine that suits your applications. Before you purchase the cnc press brake, you need to understand different aspects, such as precision, processing range, performance, and function of the machine. You should note that a press brake is a significant investment and if you buy the wrong one, then your production costs are likely to increase. These are the critical things that can help you make a sound decision.

Parts You Produce

You have to buy a press brake that can do the finishing task, rather than getting one with minimum tonnage and shortest worktable. Ensure you check the steel sheets available plus their length and thickness. For instance, if you are using low carbon steel, then you do not need a lot of bending force. Another critical thing you should consider is the length of the material.

Deflection

When bending a long workpiece, you need a CNC press brake with deflection. The length of the workpiece should be directly proportional to the deflection. A shorter press brake with minimal gasket adjustment is needed to create qualified products. Some press brakes have hydraulic deflection, which helps reduce the machine adjustment.

Material Texture

If you are using low carbon steel, then the bending force ought to be increased by about 60% of the stainless steel bending force. However, if you are using soft aluminum, then you need to reduce the bending force by a similar amount. The press brake manufacturer can provide you with a bending pressure parameter. Also, you need to take into account the bending angle radius. If you are performing free bending, you should consider the clearance between a die and punch.

Type of Press Brake

When buying a press brake, you ought to know the type of machine you want. In this way, you can determine whether this is the best fit for your shop or not. The common press brakes are CNC, hydraulic, servo, mechanical, and hydraulic. You can find some with a combination of different mechanisms.

Hydraulic press brakes are common because they can handle heavy loads and are easy to use. If you are dealing with thick materials, this is the perfect press brake to suit your needs. However, if you want an energy-efficient press brake, then you should consider the electronic press brake. Other than being energy-efficient, it is easy to fix and maintain. Also, it has higher accuracy than the hydraulic one. You will find this machine available in different sizes to suit various applications.

Select Right Tooling

The tooling you require depends on the various types of materials the shop works with. Ideally, you need tooling that offers you the best tooling profile. You should ensure you do not exceed the required press brake loads or tooling. If you want to use the tooling with the press brake and ensure it is in the right condition and compatible. Look out for wear marks from punches to shoulder.

Find a Reputable Press Brake Manufacturer

It is advisable to find a reliable CNC press brake supplier or manufacturer. Usually, manufacturers have experts who can help you get the right machine to suit your needs.

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Processing

How rotogravure printing cylinder works

by Chirag
written by Chirag

Printing has gone from the traditional way of imprinting colors on substances with the use of perforated carton papers, paints, and brushes. The rotogravure printing cylinder is one of those amazing developments in the printing press. As a printer—beginner or expert—, who wants to enjoy a smoother and easier work level, this is a system you should know.

This article will show you everything about the rotogravure printing cylinder, how it works, the benefits of using it, and the kinds of materials you can use it on. Follow through the article for enlightenment.

What is a rotogravure printing cylinder?

A rotogravure printing cylinder is a printing tool that has been around for ages and has enjoyed tons of improvement and upgrades, used for retaining different pigments of ink for painting. The ink is held on to the cylinder with the use of tiny cells that expel the ink onto the substance on which the printing will be done.

The rotogravure printing cylinder has been around for years and has been used by several professionals and big names in the industry. Based on the advancements in the printing world, it is not becoming an even more accepted way of printing on thicker surfaces. Let’s take a look at the process.

How rotogravure printing cylinder works

The cylinder serves as the printing plate in other printing styles. With the rotogravure printing cylinder, the photo that is to be printed is etched onto the cylinder with a certain kind of acid. This photo is etched onto several cylinders in a pattern of cells. Each cylinder carries a different color but the same picture. When these cylinders are pressed against the substrate, they create an exact representation of what was etched on to the cylinders.

One thing you need to take your time with is the precision of the cells’ dimensions. You have to make sure they are precise to the solution or product you want to have. You must note that the deeper the cells, the thicker the color you will have on your substrate.

You will fill just the cells up with ink and leave the other parts of the cylinder clean. If there’s an area of ink on the other parts of the cylinder, you want to ensure that you have it properly cleaned and scraped before you start printing, or you will end up with rough work.

When the cells have pressed on your substrate and have recessed, the cylinder rotates back to fill the cells up with more ink for more printing. The process is repeated until all the printing work has been completed.

Rotogravure should not be mistaken for photogravure, which is a much cheaper version and variation of gravure, involving etching the photo on a copper, which is then wrapped around the cylinder before the whole printing process begins.

Conclusion

Rotogravure has been in use over the years and is still one of the standing printing methods till today. I hope this article helps you to properly understand how rotogravure works.

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CNC

Why Manufacturers Prefer CNC Machines

by Chirag
written by Chirag

Several decades ago, machinists were the talk of time and were responsible for crafting everything to perfection. Similar skills are still required, but when talking about producing a given piece on a large scale and with higher precision, nothing beats computerized machines’ superiority. That’s where CNC Machining comes in.

Following the invention of personal computers, numerical systems have penetrated almost every industry. Nowadays, custom CNC machining is an essential part of modern machining technologies. Unlike traditional machining, CNC machining involves the operator working with the main software in motoring machine tools as well as creating programs. Therefore, it’s easily said that CNC machining is an immense upgrade. So, what are the advantages of CNC machining?

Worker Safety

Unlike traditional machining, CNC machining has ensured that the worker’s safety is at the highest level. The operator is well protected from sharp parts by protective gear. Thanks to the glass, the operator clearly sees everything going on. Moreover, the operator is not necessarily required to get closer to the mill or spindle, or even anywhere close to the cooling fluids that could be dangerous to the skin.

Precise Machining

It goes without saying that CNC Machining brings the highest level of precision. With the machine, it’s very easy to carve out a product from material exactly as required. Therefore, it’s effortless to create a plethora of components with complex shapes within a short period.

Stable Replication Accuracy

You can’t think of something more stable than a proven computer program. Once the design is introduced into the computer, the machine is capable of repeating the manufacturing process over and over again.

Given that the precision is from the step-motors, it means that the movement is always similar, meaning you’ll always get the highest level of precision.

Labor Economy

In a nutshell, CNC machining improves automation. They require little attention once set in motion. The tools move automatically, with the operator only required to check whether there are errors in the setup or the program.

Therefore, there’s a lot of free time for an operator to be used on different tasks. The company can even retain fewer operators, meaning a lot is saved.

Flexibility

In the past, things were done differently in that a milling machine had to do planes or groves, drilling machines make holes, and a lathe to do tapers and cylinders. However, with CNC machining, all those tasks can be combined in a single machine tool.

Given the ability to program a trajectory of a tool, one is able to replicate any movement on any given machine tool. Therefore, the industry can be able to keep up with consumer demand.

Range of Materials

Another benefit of CNC machining is the fact that they can be used in the manufacturing of products from a plethora of materials. They include steel, bronze, polymers, and aluminum.

Fewer Test Runs

CNC machining has its way of avoiding test runs. For instance, it employs a visualization system to enable the operator to see what may happen to stock once all tool passes are done.

Together with minimum setup errors, the advantages of CNC machining are too many that manufacturing industries have grasped and are working to their advantage.

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