Archive for the ‘Machining’ Category

Machining refers to the industrial process of cutting and fabricating metals and other materials into predetermined shapes and sizes. Machining process is controlled with the help of computer numeric control (CNC) software that guides the cutting equipment along the lines and arcs of a computer aided design (CAD) drawing.

A machining process may involve the use of different techniques depending on the number of parts being manufactured and the type of material. Machining techniques may include manual machining, which is used for cutting metal sheets in simple shapes such as circular, square, and rectangular. This process is however being replaced by automatic machining systems and processes that can cut any type of shape out of metal sheets needed for different purposes.

Chemical etching machining technique is mainly used for producing typical precision parts. The machining system offers a great flexibility for producing precision parts with unusual configuration as well as metals with tight tolerance within .0005′. Besides this, chemical etching machining is capable of producing small holes and bars that are not possible with other machining techniques. Another common process is Wire Electrical-Discharge Machining (EDM) in which the metal is separated from a conductive work piece by means of electrical erosion. During this process, the wire never touches the conductive work piece and leaves a path on the work piece, which is slightly larger than the wire.

Another technique known as the metal stamping machining phenomenon, which is also referred to as progressive die stamping or long run metal stamping, is extensively used in production of precision parts with thickness from .002′ to .135′. The technique is mainly used for processing typical low price parts that are formed into three dimensions.

Apart from these, some modern techniques are also in use such as abrasive water jet and laser machining that are more accurate and environment friendly as compared to conventional machining techniques.

Originally posted 2007-09-30 09:18:07. Republished by Blog Post Promoter

& P Wire, a family owned business in Milwaukie, Oregon, has expanded its manufacturing capabilities with a CNC 3D wire former. This wire bending equipment incorporates a wire butt welder that transfers the materials from the bender to the welder automatically. J & P Wire is a full service wire fabricator specializing in custom wire racks, point of purchase displays, wire gaurds, and wire basket manufacturing.

Milwaukee, OR (PRWEB) February 6, 2008 — J & P Wire, a family owned business in Milwaukie, Oregon, has been working in the wire forming and bending business for over 3 decades. This healthy legacy comes from investing in their people and manufacturing technology. The most recent addition to the Oregon facility is an automated CNC wire forming machine. Capable of creating intricate wire patterns, this CNC 3D wire former incorporates new fabrication capabilities and efficiencies. Additionally, it is equipped with a wire butt welder that transfers the materials from the bender to the welder automatically. Learn more at http://www.jpwire.com.

Being a full service wire fabricator, J & P Wire is excited to have a high precision 3D former. "Our customers appreciate the faster lead times and tighter wire forming tolerances," says Scott Ripley, production manager at J & P Wire.

Scott and/or Ryan Gibson are happy to demonstrate the rapid tempo and ease at which this wire former breezes through jobs. It straightens and forms gauges of wire starting with 11 GA (.120) on the small end through 5/16 (.3125) on the high end. 3-D wire bending yields high levels of accuracy, efficiency and versatility.

Today’s competitive manufacturing environment forces companies to invest in their capital equipment. J & P Wire is one of the fortunate companies to recognize this, making them able to compete on price and quality. With a portfolio full of wire point of purchase displays, racks, wire guards, and custom wire products, it’s obvious that J & P has a successful strategy.

"We offer a full suite of services to be the best outsource and manufacturing partner possible," says Scott. In addition to wire bending, they offer design services, as well as high volume tube, flat, and sheet metal forming.

About J & P Wire
Since 1971, J & P Wire Products has been designing and creating custom metal products for diverse industries nationwide. Our pursuit is to continue to develop and manufacture products for leaders in commercial, industrial and governmental agencies. The J & P Wire project portfolio includes wire point of purchase displays, custom wire baskets, wire guards, racks for industry and retail. Learn more at http://www.jpwire.com.

Originally posted 2008-02-12 03:09:45. Republished by Blog Post Promoter

Originally posted 2007-10-12 19:21:28. Republished by Blog Post Promoter

How To Use Diamond Tool To Cut Steel In Micro Machining?

The diamond tool is commonly used in micro-machining as it can withstand the micro hardening of the workpiece surface during micro-machining. This micro-hardening creates enough resistance to break the tool bit easily in micro milling, but not a diamond tool. Micro-machining using diamond tool could be performed at high speeds and generally fine speeds to produce good surface finish such as mirror surfaces and high dimensional accuracy in non-ferrous alloys and abrasive non-metallic materials.

However, if a diamond tool were to be used to cut steel, one of the most common engineering materials used in industries, the diamond tool will face severe tool wear. While diamond only softens at 1350 degree Celsius and melts at 3027 degree Celsius, and is also the hardest material in the world, it has a weakness. Diamond succumbs to graphitization, which means that it will change its crystal structure to graphite crystal structure at 200 degree Celsius in the presence of a catalyst metal such as carbon steel and alloys with titanium, nickel and cobalt.

There have been various attempts to improve the tool life of the diamond tool while cutting steel so as to improve the efficiency and profitability of this operation. Such processes include micro-cutting the steel workpiece in a carbon-rich gas chamber as well as a cryongenically cooled chamber. However, these methods require costly equipment modification and restrict direct supervision of the micro-cutting process.

The latest breakthrough came when the diamond tool was subject to ultrasonic vibration during micro-cutting. It has been shown that a diamond tool subject to ultrasonic vibration can cut the steel well enough to produce a mirror surface finish with acceptable tool life. The ultrasonic vibration at the diamond tool tip allows the tool face to cool down considerably during the cutting process and delays the chemical reaction between the diamond tool and the steel workpiece. As a result, the diamond tool life is increased by a few hundred times.

For example, a single crystal diamond tool with feedrate 5 micron/revolution, cutting speed zero to 5m/min and depth of cut 10 micron was attached to a ultrasonic vibration generator so that the diamond tool tip vibrated about 4 microns while it was used to cut stainless steel. The mirror surface finish of the cut steel surface was measured at 8 nm Ra!

With more and more machining companies moving into the niche micro machining field, such ultrasonic vibration assisted cutting can only help the progressive company to achieve process leadership and innovative differentiation.

Author Ken Yap is a director of Suwa Precision Engineering Pte Ltd in Singapore and represents metal stamping, precision machining, miniature precision balls and PCB manufacturers from Suwa, also called "The Oriental Switzerland" in Japan due to its Swiss resemblance for rich watch-making industry, its mountainous terrain and its precision component making industry.

About the Author

Ken Yap is a director of Suwa Precision Engineering in Singapore, and represents precision component manufacturers from Suwa, Japan. He is also a partner in Attisse Pte Ltd providing business consultancy and research services to Japanese investors.

Originally posted 2007-10-30 09:19:01. Republished by Blog Post Promoter

CNC Stomp Pad 7 | Part Griding

When you cut something out with a plasma cutter there is slag left over you have to remove. This slag is officially called "dross" when it come to plasma cutting. In this video we rough grind the cnc stomp pad to remove the dross. I call it rough grind because later we will use a DA Sander to smooth it all out.

Originally posted 2007-12-04 05:01:38. Republished by Blog Post Promoter

Ceriotec Corporation has announced that it will invest another US$1 million in new CNC Swiss screw machines in 2006 to increase its Swiss screw machining capacity and productivity.

Suwa, Nagano, Japan 27/Jan/2006 – To expand its production capacity and machining productivity, Ceriotec Corporation has announced that it will invest another US$1 million in new CNC swiss screw machines in 2006. The company has invested a total of US$5 million in CNC Swiss screw machines over the 5 previous years.

"We have gradually replaced our cam operated Swiss type screw machines with the latest CNC Swiss style screw machines. Besides allowing us to eliminate the need for cams and their added costs, these latest CNC Swiss screw machines make us more competitive as they increase efficiency by about 30% and allow us to respond rapidly to short production runs and rush order jobs," says Hiroaki Oguchi, President of Ceriotec Corporation.

Established in 1951, Ceriotec Corporation has been using swiss screw machines or swiss automatics to supply Japanese watch-making, IT electronics, consumer electronics, telecommunications and automotive industries with miniature complex profile turned parts from diameter 0.1mm for over 50 years.

Swiss screw machining is used to make small, slender, complex and precision components. In the swiss screw machine, the bar stock material is gripped tightly and advanced by the sliding headstock through a guide bushing to the machining section. The machining section consists of stationary tools which are applied to the emerging bar stock. As only the part of the bar to be machined is exposed from the guide bushing, there is minimum deflection which allows the turning of small accurate precision parts. If the part is longer and needs more grip support at the front end, a sub spindle can be applied to grip it to reduce deflection during cutting. Accurate and close toleranced parts are possible with tight toleranced guide bushings and finely ground bar stocks.

Says Mr Oguchi, "Originally designed by the Swiss to make miniature watch parts, Swiss style screw machines have become the machining solutions for many turned parts manufactured from difficult to machine alloys and exotic metals. Swiss screw machines excel in manufacturing a complex profile part in one turning operation, thus eliminating secondary processes and costs. We look forward to business enquiries through Suwa Precision Engineering, our marketing office in Singapore."

About Suwa Precision Engineering Pte Ltd: Suwa Precision Engineering Pte Ltd is the marketing office for a group of Japanese precision engineering parts manufacturers from Suwa in Nagano Prefecture, which is the home base of major corporations such as Seiko Epson and Nidec Sankyo. These manufacturers have more than 40 years each in manufacturing precision products and components such as stamping dies, precision metal stamping (deep draw and high speed), precision swiss turned components and miniature balls from diameter 0.1mm, precision gears and pcb in small footprint (1mm by 2.5mm).

More information on Ceriotec Corporation is located at http://www.suwaprecision.com.

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Contact Ken Yap for more helpful information on the company: Tel: 65-67492045 Email: sales@suwaprecision.com

About the Author

Author Ken Yap is a director of Suwa Precision Engineering which represents Japanese companies specializing in precision metal stamping, swiss screw turning and manufacture of stepper motor housings, miniature gear pumps, and hinge components for cell phones.

Originally posted 2007-09-24 12:18:05. Republished by Blog Post Promoter

Here are a few different things that are going on with CNC Routers.

RFQ: Help me finish my cnc router in Colorado Springs
I’m looking for help with some aluminum/metal parts to help me complete my cnc router project. I have the rails for all the axis. I’m planning to build a box out of 8020 material for the x surface. Here’s what I need help with: …

Large Format CNC Router
Working area :1300*2500mm, Foundry lathe bed.

Step 30: Router Mount Part 1
CNC Router Complete Video Tutorial Series. Learn how the router mount is made. Ranked 3.43 / 5 | 206 views | No comments. Click here to watch the video Submitted By: phooddaniel Tags: CNC Router Machine homebuilt diy mount.

Originally posted 2007-09-12 17:07:06. Republished by Blog Post Promoter

Laser machining technology uses high intensity laser beams of varying widths for a variety of applications such as slotting, cutting, and creating holes. It can be used in fabrication of different types of materials such as metals, plastics, vinyl, glass, marble, and graphite. Other materials that can be fabricated using laser machining include nylon, ceramics, carbon fiber, composites, soft rubber, and thin metal foils.

Laser machining systems are used in conjunction with computer numeric control (CNC), which makes it ideal for use with thin walled tubing, boasting beam widths down to .0005′. In this process, the machining operator uses computers to control machine tools for manufacturing complex and intricate parts in metal and other materials.

A laser machining process involves the use of conventional as well as fiber optic beam delivery systems, which allow precision positioning while cutting metal or other materials. It is used to cut burr-free parts that are required in a number of industries such as aerospace, automobile, shipping, and others. The process is fast, efficient, and can be repeated any number of times depending on production volumes. It is used to create grooves that are cut to a specific depth with one pass of a laser beam without severing any material from the work piece.

Laser machining is used for producing a knurled or roughened surface on hard materials such as metals and fragile materials such as ceramics and glass. The technology is also used for marking material surfaces. In the process a high intensity laser beam is passed through a stencil of a mirror and onto the area of the material or work piece that is being marked.

Research is underway to develop advanced laser machining techniques that will allow the production of microscopic devices for use in medical industry. This will help in fighting deadly diseases such as cancer in the near future.

Originally posted 2007-10-11 13:23:08. Republished by Blog Post Promoter

OnSynopsis:
Fanuc Power Mate (Models D, F) has an option called Workpiece Number Search. Using this option, the PMC can initiate the execution of a specified part program. This is especially useful in cases where the Power Mate is used to control special purpose machines that produce a known set of components. Such applications are found in batch production factories.

How it Works:
To synchronize the PMC and CNC functions, there is a communication area in the Fanuc Power Mate where the PMC & CNC exchange signals. These are a set of bytes and there are two areas namely:

a) The G area – signals from the PMC to the CNC

b) The F area – signals from the CNC to the PMC

By selectively loading G009 with a value in the range 1-255, the CNC will execute a program between O001 to O255.

To read the complete article please visit http://www.controlon.com/resources/default.aspSynopsis:
Fanuc Power Mate (Models D, F) has an option called Workpiece Number Search. Using this option, the PMC can initiate the execution of a specified part program. This is especially useful in cases where the Power Mate is used to control special purpose machines that produce a known set of components. Such applications are found in batch production factories.

How it Works:
To synchronize the PMC and CNC functions, there is a communication area in the Fanuc Power Mate where the PMC & CNC exchange signals. These are a set of bytes and there are two areas namely:

a) The G area – signals from the PMC to the CNC

b) The F area – signals from the CNC to the PMC

By selectively loading G009 with a value in the range 1-255, the CNC will execute a program between O001 to O255.

To read the complete article please visit http://www.controlon.com/resources/default.asp

ABOUT THE AUTHOR

Originally posted 2007-10-22 11:33:11. Republished by Blog Post Promoter

Originally posted 2008-02-12 00:43:38. Republished by Blog Post Promoter