CNC Methods: How to Manufacture CNC Machined Parts

Numerous innovative manufacturing technologies continue to emerge, CNC methods remains unparalleled in terms of reliability and efficiency. These common CNC methods create precision parts and rapid prototypes across various substrates.
CNC methods is not only benefit from the rapid development of automation, but also can produce manual machining can not be completed with a complex shape of the parts.
CNC methods can make production process of stable quality, high machining accuracy, high repeatability, adapted to the specific processing requirements. When CNC methods used in the case of multi-species, small batch production production is more efficient, can reduce the production preparation, machine tool adjustments and the process of inspection time, and due to the use of the optimal amount of cutting and reducing the Cutting time.
Sungplastic masters some CNC methods for the production of machined parts or prototypes, let’s learn and discuss together,

Turning

Turning is a key CNC machining technique. It involves rotating a workpiece while a cutting tool removes material. This creates cylindrical parts. It uses lathe machining to shape and contour parts with precision.

At the core of turning are the cutting tools. They come in various shapes and sizes for different machining operations. Made from tough materials like tungsten carbide, these tools are designed to remove material efficiently. They help achieve the right surface finish and accuracy.

Lathe Type	Key Features	Common Applications
Horizontal Lathe	Workpiece rotates horizontally, cutting tool moves parallel to the axis of rotation	Automotive parts, aerospace components, general manufacturing
Vertical Lathe	Workpiece rotates vertically, cutting tool moves perpendicular to the axis of rotation	Large, heavy-duty parts like turbine shafts, industrial equipment
CNC Lathe	Computer-controlled, allows for complex and precise turning operations	High-precision components, parts with intricate geometries

Turning is vital in many industries, including automotive, aerospace, and general manufacturing. It uses rotational symmetry and precise cutting tools. This way, manufacturers can make a variety of cylindrical parts with high quality and efficiency.

“Turning is the foundation of modern manufacturing, enabling the creation of countless essential components that power our world.”

Milling

Milling is a dynamic CNC machining process. It uses rotating cutting tools to remove material from a stationary workpiece. This technique is versatile, handling simple to complex geometries. Let’s explore the different milling methods and their capabilities in creating intricate parts.

Face Milling: Smooth Surface Finishing

Face milling uses a rotating cutter to remove material from the top or face of a workpiece. It excels at producing flat, smooth surfaces. This makes it ideal for applications that require precise, high-quality finishes, such as in material removal for aerospace components or complex geometries in medical devices.

End Milling: Versatile Shaping

End milling uses a rotating tool with cutting edges on the end to create various shapes and profiles. This technique is highly versatile. It allows for the production of features like slots, pockets, and contoured surfaces. End milling is particularly well-suited for multi-axis machining of intricate parts, showcasing its ability to handle complex geometries.

Profile Milling: Precise Contouring

Profile milling involves using a rotating cutter to remove material along the side or profile of a workpiece. This method excels at creating precise, complex contours and profiles. It’s a valuable tool in the production of highly detailed cutting tools and components with unique shapes.

By leveraging the diverse capabilities of milling, manufacturers can tackle a wide range of material removal challenges. From simple to highly complex geometries, the combination of versatile cutting tools and precise multi-axis machining techniques empowers the creation of intricate, high-quality parts across various industries.

Surface Grinding

Achieving exceptional flatness on metal parts by CNC methods is crucial in many applications, and surface grinding is the optimal method. A spinning disk coated with specific-coarseness abrasive grit creates a precise surface. The workpiece, mounted on a table, moves laterally beneath the abrasive wheel or remains stationary as the wheel moves. Care is taken to control tool speed and temperature due to the heat and mechanical stress involved.

Solid Sink EDM

Also known as Die-Sinker EDM or Ram EDM. This process employs a conductive electrode submerged in dielectric fluid, positioned close to the workpiece. The electrode’s shape corresponds precisely to the desired feature. As the electrode discharges, it forces metal particles off the workpiece’s surface. Solid Sink EDM is used for making pockets, holes, and square features in hardened tool steels that are challenging to create otherwise.

Wire EDM

Wire EDM relies on a copper wire conductor subjected to a high-voltage electric charge. A continuous feed of fresh wire from a spool steadily erodes the conductor during the cutting process. Wire EDM is suited for thick, hardened tool steel, facilitating the creation of circular or semi-circular features difficult to achieve with conventional tools.
Wire EDM is particularly suitable for creating complex shapes, intricate contours, and features with tight tolerances, especially in materials that are difficult to machine with traditional CNC methods.

Cylindrical Grinding

Combining surface grinding and lathe turning, cylindrical grinding involves holding the workpiece steady while a cylindrical grinding wheel rotates against its surface. It is one of CNC methods used for inside and outside diameters, achieving precise tolerances and a remarkably smooth surface texture.

Optical Grinding

CNC machining extends beyond metals to create specialized optics in glass or plastic. This necessitates precise surfaces and tight tolerances. Specialized grinding equipment utilizes multi-axis rotation to average out deviations from the nominal, ensuring exceptional precision and surface quality. Grinding paste is employed as both a lubricant and to achieve a polished finish.

Electron Beam Machining (EBM)

Electron Beam Machining utilizes a high-velocity electron beam generated in a vacuum to remove material from the workpiece. The focused electron beam’s high energy density enables precise and deep machining. EBM is often used for drilling, cutting, and welding applications in aerospace, automotive, and semiconductor industries.

Waterjet Cutting

Waterjet cutting relies on a high-pressure stream of water mixed with abrasive particles. The abrasive waterjet can cut through a wide range of materials, including metals, ceramics, glass, and composites. Waterjet cutting is known for its versatility and is often used for intricate and detailed cuts, as it produces minimal heat-affected zones.

Plasma Cutting

Plasma cutting employs a high-temperature, ionized gas (plasma) to melt and remove metal material. It is particularly effective for cutting thick metals and is widely used in industries such as construction, shipbuilding, and metal fabrication.

Ultrasonic Machining

Ultrasonic Machining involves the use of high-frequency vibrations transmitted to a tool, along with an abrasive slurry. These vibrations, typically ultrasonic frequencies, create abrasive action that removes material from the workpiece. It is often applied to hard and brittle materials, making it suitable for precision machining of ceramics, glass, and advanced composites.

Chemical Machining

Chemical machining, also known as chemical milling, uses chemical etchants to selectively remove material from the workpiece. It is especially useful for producing complex and lightweight structures in aerospace and automotive components. Chemical machining is often employed in the manufacturing of aircraft and spacecraft components.

Electrochemical Machining (ECM)

Electrochemical Machining utilizes electrochemical processes to dissolve and remove material from the workpiece. It is employed for machining complex shapes, including those with internal cavities, and is ideal for heat-sensitive materials and superalloys. ECM is commonly used in the aerospace and medical industries.

Abrasive Flow Machining (AFM)

Abrasive Flow Machining employs a viscous abrasive media that flows through the workpiece, effectively removing material. It is used for deburring, polishing, and radiusing edges, particularly in applications where traditional machining CNC methods may be impractical. AFM is used in industries such as aerospace, automotive, and medical device manufacturing.

Laser Machining

Laser Machining utilizes a high-energy laser beam to precisely cut, engrave, or mark materials. It offers high precision, minimal heat-affected zones, and is suitable for a wide range of materials, including metals, plastics, and ceramics. Industries such as electronics, aerospace, and medical device manufacturing often rely on laser machining and other CNC methods for intricate work.

Gun Drilling

Gun drilling is a special CNC machining technique. It creates deep, straight holes with great precision. This method is changing industries like oil and gas, firearms, and aerospace.

Gun drilling makes long, narrow holes with amazing accuracy. It uses a unique tool and coolant to do this. This way, it can make holes that are over 100 times longer than they are wide.

Gun drilling is great for drilling deep holes. It’s perfect when you can’t use regular drilling methods. It can drill through complex parts with ease, meeting tough standards.

Technique	Hole Depth	Aspect Ratio	Precision
Traditional Drilling	Up to 10x Diameter	Up to 10:1	Moderate
Gun Drilling	Up to 100x Diameter	Up to 100:1	Exceptional

Gun drilling is very precise and accurate. It’s the best choice for making high aspect ratio holes or precision boring. It uses CNC technology to make complex, long-lasting parts for many industries.

If you’re looking to improve your manufacturing or need a solution for deep hole drilling, gun drilling is a game-changer. Learning this CNC technique opens up new possibilities and changes how you do complex machining.

Broaching

Broaching is a key CNC machining method. It’s great for making internal keyways, splines, and gear teeth. It uses a special tool called a broach to cut out shapes with great detail.

Broaching machines come in two types: horizontal and vertical. They move the broach through the workpiece to shape it. This method is used in many fields, like cars and big machines, for parts that need gear teeth and splines.

Broaching isn’t just for inside parts. It can also make outside shapes and surfaces. This makes it a very useful tool in making all sorts of parts. It’s known for its ability to make precise, linear cutting-based features for many uses.

Sungplastic’s CNC Machining Service for Your Vital Projects

These CNC methods offer diverse capabilities and are applied in various industries, contributing to the precision and efficiency of manufacturing processes. The choice of CNC methods depends on the specific requirements of the project, including material properties, tolerance levels, and the desired surface finish.

At Sungplastic, CNC machining service can greatly reduce the number of fixtures, processing complex shape parts that do not need complex fixtures. If you want to change the shape and size of the parts, you only need to modify the parts machining program, suitable for new product development and restyling.

Whether you need large part machining, high volume production, rapid prototyping, precision machining, the CNC methods we have at our disposal will meet your needs. We have experienced engineers and technicians, advanced technical equipment, perfect production lines, as well as docking competitive price advantage of raw material suppliers, to ensure production quality quality and on-time delivery.

If you need custom parts, please contact us directly to request a quotation today.

CNC Machined Parts Made by Sungplastic

Since 2002, we have provided high-quality CNC machining services to a wide range of industries. CNC machined parts include metal parts, plastic parts, etc. Common metal materials include aluminum, aluminum alloy, steel, stainless steel, copper, etc. Plastic materials include ABS, PP, PC, nylon, acrylic, POM, etc. In our product library you can see hundreds of different projects.