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Is Precision Machining is a lost art? Not at GUTENG Solutions. Precision machining remains an essential service utilized in creating parts, and components of many tools and items we use and depend on in everyday life. In fact, precision machining supports technology where visionary companies are supporting advanced efficiencies on older technology and also creating hardware supporting the very latest developments in technology. But what exactly is precision machining? Here we take a closer look at what precision machining is and how it is utilized to support advances in modern manufacturing.

WHAT IS PRECISION MACHINING?

Precision machining is a type of technical manufacturing that is essential in creating and designing machines, parts, tools, and other hardware that are essential in modern manufacturing to maintain process controls and tolerances that function under extremely tight specifications. It is used to make up the many large and small objects and their components that we use in everyday life. If an object is made up of many small parts, these will often need to be made with precision machining to ensure they fit together precisely and function properly. Precision Machining can be defined as utilizing the highest function of a tool, program, engineering talent or equipment thus pushing the limits of design feature creation and materials science and performing these operations under the tightest tolerances defined by any sub-set of these manufacturing parameters. Obviously, precision machining has evolved over time, and advancements in all related technologies help push the limits that define precision machining and improve performance consistently. The real art in precision machining comes with the marriage of computer controlled design and human engineered design for the creation of unique features and highly controlled output and functionality driven by advancements in fluid dynamics, chemical control, mechanical, climate extremes and durability required in modern hardware technologies.  Precision machining is particularly important to create tools and parts in a way that is precise, stable, and can be repeated with consistency, accuracy, and durability.

WHAT IS PRECISION MACHINING USED FOR?

Precision machining is a subtractive process used in cases where material needs to be removed from a raw product to create the finished product. Precision machining can be used to create a wide variety of products, items, and parts for any number of different objects and materials. These parts usually require tight tolerances variation from nominal dimensions and from part to part, which means that there is not much room for error in the production of the piece. Repeatability and well-controlled tolerances are hallmarks of precision machining.

Components, parts and finished durable products that are designed to maintain extremely tight tolerance margins and a high degree of durability are essential and common drivers for utilization of precision machining. For example, parts that need to work together as part of a machine may need to always align within a certain margin of 0.01mm to 0.05mm. Precision engineering and machining help to ensure these parts can not only be made precisely but can be produced with this level of accuracy over and over again.

Another common application for precision engineering may be when tools or components need repair or restoration. After being used for some time, the tools or components of an object may need machine calibration, grooving or welding to restore them to their original state. This can also be done by precision machining.

HOW DOES PRECISION MACHINING WORK?

Precision machining is a subtractive process where custom software, engineered tools, and process steps are utilized with raw material such as plastic, ceramic, metal or composites to create desired fine-featured products. Precision machining often follows the instructions given by computer aided design (CAD) and computer aided manufacturing (CAM) programs. These programs and the blueprints enhance the ability to meet tight tolerances. While most designs end up as engineered and computer aided designs, many start out as hand drawn sketches in the initial phases.

WHAT TOOLS AND MATERIALS ARE USED FOR PRECISION MACHINING?

Precision machining can be used with a number of raw starter materials including (but not limited to) plastic, ceramic, metal, composites, steel, bronze, graphite, and glass. In order to make precise cuts and intricate removal of the raw material, a combination of tools may be used. These tools vary depending on the raw material. Frequently used tools include milling machines, lathes, Electric Discharging Machine (aka. EDM’s), saws, and grinders. Most commonly used manufacturing equipment is computer controlled heavy machinery that is designed and utilized to remove substrate material creating finely detailed components and piece parts. In some cases, even high-speed robotics and photochemical processes may be used to achieve the desired result for the final product.

Precision machining is an essential process for creating both large and small items and parts according to strict manufacturing guidelines specifications and critical tolerances. For more information on precision machining and how it can benefit your business, get in touch with GUTENG, the Bay Area’s machining expert.

WHAT ARE THE CAPABILITIES OF PRECISION MACHINING?

In our first post in the machining basics series, we looked at what precision machining is, and how it might be useful to a range of businesses and industries. Precision machining covers a wide range of functionalities to fit the requirements of different machinery and industries. This diversity and flexibility are vital to the effectiveness and performance of precision machining in making a wide variety of parts and products, even within very tight and specific constraints. The capabilities of precision machining are what achieves these outstanding and accurate results. In this post, we look at what precision machining capabilities are, and what they mean for your machining requirements.

WHAT IS PRECISION MACHINING CAPABILITIES?

The capabilities of precision machining refer to the capacity to which machinery and technology from a Precision Machining provider can accurately and precisely create a part according to tight specifications. The capabilities of precision machining refer to the level of precision a provider can make a part, object or component, no matter how large and complex, or small and precise. Because of the extremely precise and accurate level, many parts need to be made to, maintaining this level of accuracy across a range of different object sizes and shapes is essential. The capabilities of precision machining are what achieves this.

ASPECTS OF PRECISION MACHINING CAPABILITIES

Precision machining capabilities can be determined by the skill of the designers, and availability of machinery and tools offered by the precision machining provider. Precision machining providers often need to provide parts and products in a range of different materials, which may require different tools and skills to engineer. Quality precision machining providers work for a range of different clients and can engineer parts for different industry areas, including both commercial and government markets.

It’s also important that a provider is experienced and able to work in a number of areas, such as Machining and Prototype Design, Volume Manufacturing, and Contract Manufacturing. Skilled precision machining providers can even design modify existing standards and functionality of the parts so that they work in the same way as the original parts as per the manufacturer’s design and construction. This capability provides versatility and options for clients and businesses searching for a unique part.

Precision machining can work with a range of materials, including polymers, plastic, aluminum, stainless steel, copper, titanium, tungsten, Kovar, Ni 200, Inconel, Nitronic 60 and more. The tools used in precision machining are specially designed to create parts and products according to very stringent specifications and tight tolerances.

TOOLS DETERMINING PRECISION CAPABILITIES

The tools and machines used to create precise components need to be of high quality, and able to function according to very stringent specifications. There is a wide range of tools used for different aspects of precision machining. These tools are often controlled by CNC or computer numerical control. This type of control converts very precise designs produced by computer aided design (CAD) into numbers that are used as coordinates to control the precision machining process. This helps to ensure accuracy and adherence to tight tolerances, no matter the nature of the part being made.

Each tool has different capabilities, determining the diameter in inches in size and specific characteristics of the materials and the shapes and dimensions of parts that can be created. The tooling along with its specific design features, coating, ability to work dry or with lubricants will result in varying degrees of product complexity and yield.

Ultimately, the scope and versatility to which tools and machinery can be used to create different parts and objects encompass the capabilities of precision engineering.

A PRECISION MACHINING EQUIPMENT BREAKDOWN

Precision machining is the process of creating intricate and precise parts, components and objects that are used in our everyday lives. Precision machining creates parts according to tight tolerances so that they fit specifically and precisely into the object or machine they are made for. Because precision machining needs to be so accurate, the materials and machining equipment used for precision machining must be very specific. Here we look at some of the most common machining equipment used in precision engineering.

OVERVIEW OF PRECISION MACHINING TASKS

In general terms, precision machining tasks can be divided into milling, turning and boring. Precision machinery focuses on creating a part or object by subtracting material, as opposed to adding material to create the right shape. In some cases, cutting machinery is also included under precision engineering.

Milling processes involve using cutting and grinding tools to remove material to create a part. Turning machines rotate the material and use cutting tools to shape and modify the part. Boring machinery functions by drilling holes in the material using precise rotating cutting tools. The following precision machining tools each fit into one of the above categories.

SWISS MACHINES

Swiss machines provide accurate and precise function according to specific instruction encoded by CNC (computer numerical control). Swiss machines were originally used to create parts for Swiss watches and can compose tiny components from just 0.75 inches in diameter. Swiss machines are very effective at machining small parts and long, slender parts without causing displacement or vibration. The Swiss machine provides control by holding the workpiece in place, while the tool rotates around it. Swiss machines can also be modified to accurately shape and compose your unique part. Swiss machines can process on 7-axis, up to 9-axis for more complex and intricate parts.

LATHES

Lathes are a precision machining tool that rotates the workpiece against a cutting tool. Lathes can also be controlled by a computer that allows for intricate designs to be created from Computer Numerical Control. In most precision machining workshops, lathes can have varying capabilities with up to 5 axis machining, producing parts with diameters from 0.062 to 22.00 inches. Lathes can often be customized to provide varied functions according to your specific needs. With the assistance of Computer Aided Manufacturing, design files can be directly imported to the lathe function to more accurately and quickly manufacture the parts.

MILLS

Milling machines can be vertical or horizontal, depending on the spindle, and are generally used to cut, shape and grind materials to size. In a milling machine, both the workpiece and the tool may move to create the shape and dimensions that are required. Because heat and friction can be generated in the functioning of a precision milling machine, cutting fluids, lubricant and coolant may be used to generate the most precise and even machining. Spindle chillers may also be used to help maintain machine accuracy despite temperature fluctuations or heat generation.

ELECTRICAL DISCHARGE MACHINES

Electrical Discharge Machines (EDM) is used to cut metals that are electrically conductive. The EDM machine uses an electrically charged wire or electrode to cut or punch the metal. There are two main EDM machine types – wire electrical discharge machining and sinker electrical discharge machining. The wire EDM machine uses a wire to cut through metal to obtain the desired shape. In sinker EDM machining, a power supply produces a spark between the electrode and the metal, which cuts the metal. Electrodes can be designed and manufactured in house by precision machining companies to achieve the precise requirements needed.

LASER ENGRAVING

Laser engraving is another way to make precise marks and cuts on metal for precision machining. A laser is installed on a rotary attachment, which allows flexible functionality for etching or engraving a part. Laser engraving may be used for aluminum or plastics and can be used to make marks on medical tools. Laser engraving can also add an essential aspect to precision engineering by allowing custom logos, serialization, and QR codes to be imprinted on parts or products.

While many tools may be used by precision machining companies to produce precise and accurate parts, the list above includes some of the precision machining equipment most commonly used by precision machining companies.