Machining- From Conventional Methods to Advanced Operations Like 5-axis Machining

Machining forms an integral part of manufacturing industry and incorporates various operations to give shape to a workpiece or a given material by cutting the material according to the blueprint or engineering drawings. Machining setup includes the work piece, the tool and the machine. During Machining process a relative motion is produced between the tool and the workpiece through the primary motion called Cutting Speed and the secondary motion called Feed. To generate the object as per the drawings, tool size, tool shape, relative motions, level of contact with the tool and amount of material penetration or slicing of surface material plays an important role to achieve the desired result. The traditional machining processes include Turning, Milling, Drilling, and Grinding.

Turning is used to produce cylindrical shapes by slicing off external surface of the workpiece with a single-point cutting tool mounted on a lathe machine - controlled manually or through a computer. During turning the tool remains parallel to the workpiece axis. There are two types of turning process -Taper turning and the Contour Turning. In taper turning the cutter tool is kept an angle to the work axis while in Contour turning, the distance of the cutting tool varies from the work axis to produce the required geometry. Advances in automation have really complemented Machining operations to produce accurate and modular components, flexibly and cost-effectively.

Another important machining process is Milling which is used to obtain flat, angular or curved surfaces by feeding a work piece against a rotating multiple tooth cutter. It is done with the help of a Milling machine. Various types of milling process include, Peripheral Milling, Face Milling and End Milling. In peripheral milling, the axis of cutter rotation is parallel to the workpiece surface.

Face milling operation produces a flat surface by guiding a wider mill across the surface of the workpiece. In case of End Milling the cutter rotates on an axis vertical to the workpiece to create pockets and contours in a workpiece. There are two important methods of milling viz, Up Milling and Down Milling. In Up milling the direction of the cutter rotation is opposite to the feed motion. In Down milling the direction of cutter rotation is same as the feed motion. The chip formation in down milling is opposite to the chip formation in up milling. Drilling is another material removal method involves piercing holes in a solid object or a metal using a tool that has two cutting edges.

With the advent of latest technologies in machining, controlling machines by numerical command has enabled manufacturing operations to become quite streamlined and fully automated. CNC or Computer Numerical Control Machining is used to generate 3-D structures through computer controlled commands through selective removal of material from a workpiece. CNC machining eliminates use of manual drawing of the workpiece as it uses help of CAM software. In case of any faults CNC Machining programs send an alert to the operator's mobile phone. Apart from using CNC in conventional machining, it is widely utilized in Robotics, Electromechanical machining, Welding and Laser cutting. CNC Machining tremendously decreases the cost of machining, improves operational capability, and reduces time cycle enabling product uniformity and consistency.

Modern manufacturing processes requiring accuracy are very much dependent on Precision Machining methods. Precision Machining involves an automated process that can work with precision CNC machining systems (computerized machines) to produce highly detailed parts effectively and quickly. Precision Machining is used for CNC milling, grinding, and turning operations. Precision Machining is widely used in industries like Aerospace and Plastics for consistency, reduced time cycles and cost effectiveness. CNC machining is the best way to ensure high volume in production.

Another machining operation that is gaining prominence is called 5 Axis Machining. It allows machining of a part along 5 axes of motion compared to 3 axes in one setup. While this can certainly be a cost saving factor, 5 Axis machining is used more often for complex contour work, which may need simultaneous movement of all 5 Axes. Current generation 5 Axis machines offer excellent tolerances of 3 microns. 5 axis machining is most commonly used in the aerospace industry to produce airframe and turbine engine components. Now, many machining companies use latest 5-axis Machining centers that have tilting rotary table to handle high volumes & high accuracy ensuring efficient production.

Machining, CNC Machining, Precision Machining and Machining 5-Axis is our forte at Loveridge Machine Company. Come to us for your

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