Machining is the process of removing materials accurately through a machine tool to obtain the required parts
The classic machining processes include lathe, milling, planing, grinding, boring, sawing, etc. The older generation of skilled workers manually control these machines to produce the industrial products we need. This is the beginning and foundation of our industry. With the development of technology, machine tools are transitioning to CNC gradually, which allows us to produce more complex products, and the accuracy of the products is greatly improved, and the structure can also be more complex.
We provide the process as following:
1. Lathe
A machine that rotating of parts primarily, the cutting tools will cut the parts by feed movement.
Instrument lathe, the simplest small lathe. Mainly manufacturing products with a diameter of less than 250mm, with a spindle speed of less than 2160r/min, mainly processing rough small parts, with a simple structure and extremely low cost. After modification and addition of flanges and tailstock devices, some slightly complex products can be processed. Currently, there are still some factories using the Instrument lathe for their hardware and electrical appliances, plumbing valves and pipe fittings, the advantage is mainly for simple machine adjustment and high feed efficiency,
ordinary lathe have horizontal and vertical models. The horizontal models include CA and CW, which are the most commonly used lathe machine and have the widest range of applications. Through the installation of mechanisms, various special processes can be developed, such as cyclone cutting, multi sided turning for 4 or 6 sides, spherical turning, etc. The development of such specialized machines can greatly improve efficiency and reduce costs, but the initial one-time investment will be relatively large,
Vertical lathe usually produce large products with large diameters, short lengths, and low efficiency, as the large products are prone to unstable while clamping and deformation when produced by horizontal lathe.
The CNC lathe,CK series, adopts CNC technology and can process small watch parts, large ship spindles, wind turbine spindles, etc. It can also process threads, holes, and knurls. If the CNC machine is equipped with a servo drive motor, it can also process large threads, internal oil grooves, and other features that require multiple repeated positioning processing. Generally, the feed rate of the CNC machine is not as high as that of ordinary lathe, but it is stablly at a constant speed and can achieve high surface and accuracy, And it release the operator's intensity, allowing for automatic execution of multiple processes through programs. This is also the mains processing equipment in our current foreign trade business. CNC machine manufactuing is very suitable for large-scale foreign trade products, as long as the fixture developed well, the machine can process according to the program, as long as the number of equipment is large, the production rate is very high, and the product size is stable.
For some products with special requirements, a slanted guide rail lathe has been developed , which can produce products with higher accuracy. And turning centers can produce complex processes such as turning, milling, and drilling in one clamping process, which is very advantage for producing small and complex products. Because one-time clamping and machining can ensure the Geometric Tolerance of the product and improve efficiency.
We use swiss machine to process extremely small products, which can be as small as the diameter of a watch accessory or even 1mm., with the large number of cutting tools, it can machining many features .
At present, we can provide machining for parts with a maximum diameter of 1200mm and a maximum length of 6000mm on a lathe, with a minimal accuracy of 0.01mm and a finish of Ra0.4.
2. Milling machine:
A machine tool that primarily cuts parts through the rotation of the milling cutter, the movement between the milling cutter and the workpiece to feed the cutting product to obtain the features we need,
ordinary milling machines can only process a single plane, and the cost of products with a single processing surface will be relatively low,
The milling machine with the addition of a 3-axis controlling is what we call a machining center(CNC), which will become very powerful and has become the mainstream machining equipment at present. Drilling, milling surface, and edge milling can be achieved by the machining center, which can complete multiple machining processes in one clamping process. Therefore, complex products with geometric tolerance requirements can be obtained, especially for some dimensions that cannot be measured by ordinary methods. The machining center can perfectly guarantee the geometric tolerance, which can be guaranteed well, With the increase of rotational axes, there are 4 and 5 axes. Currently, the machining center can process propeller blades, and the machining center is generally equipped with a tool magazine that can call up more than 10 to 40 tools to process products. Therefore, a lot of features that can be processed,
Due to the time-consuming of the clamping process in the machining center, people have developed specialized fixtures to clamp multiple products at one times and then process them simultaneously to reduce downtime. Additionally, if the product is finalized, dual workbenches are developed to ensure that the machine does not stop,
Some large products can be processed through gantry milling or 5-sided machining centers,
For special parts such as lettering and logo requirements, engraving machines are commonly used, with speeds up to 30000 rpm.
The milling machine can process products with a diameter of 1200 and a height of 1000,
The dimensional accuracy can reach 0.01mm. Finish Ra1.6
Planer:
The main method of cutting products is through the linear motion of the tool on the surface of the workpiece. It is generally used for larger products, and the cutting feed is relatively large. and the similar machine such as keyway broaches and gear shapers for the inner hole. Internal splines, internal gears, etc. It is quite widely used,such as we use gear shaping technology to process the drive shaft on agricultural shrub mowers.
grinder
It is used to grind and remove excess material on the surface of parts through the rotation of grinding tools. The feed rate is very small, and high-precision products can be processed. There are centerless grinding, external circular grinding, internal circular grinding, and surface grinding, which can improve the surface roughness and accuracy of the product,
Mainly processing the drive shafts and pin products for equipment. Moreover, it can process products with higher hardness, such as hardened steel and hard alloys, which can solve the problem of some turning and milling parts where the workpiece cannot be processed due to its high hardnes that after heat treatments
The accuracy can reach 0.005mm. The smoothness can reach Ra0.2.
Boring machine:
The main machining process is cutting products by the rotation of the boring cutter. The boring cutter or the movement of the product is the feeding, mainly processing deep holes, large holes, or two side faces of the shell, such as holes, grooves, or precision machining of multiple holes in one clamping process to ensure the mutual position between the holes. This type is generally suitable for processing large box parts., The high-pressure water pump body for fire protection produced by us for Japanese customers has two flange surfaces with high concentricity requirements on both sides of the box. If one side is processed and then re clamped to find the center, it will be time-consuming and cannot be guaranteed. The use of a boring machine solves the concentricity problem effectively, and the machining rate is improved when two knives are used together,
Sawing machine:
The saw machine has saw blades and saw blades cutting,
Saw blades generally have rough cutting surfaces and unstable dimensions, but the equipment is simple and the cost is low. Saw blades have relatively high cutting accuracy and dimensions, and were originally developed for non-ferrous metals. Currently, many new energy products are directly cut with saw blades without the need for further machining. With the development of technology, people can also obtain high-precision and smooth surface products when using saw blades to cut ferrous metals, However, the rigidity and requirements of the equipment are also relatively high.
If it is a non-ferrous metal, the finish can reach Ra1.6 with an accuracy of+/-0.1mm
Drilling machine:
The rotation of the drill bit is the main cutting process, the axial movement of the drill bit is the feed motion. Although the process is simple, many occasions cannot be separated from drilling processing. Additionally, it can provide tapping and reaming processing. For products with more holes, porous drills can be used to process 4-8 holes at one times, not only saving positioning time, but also ensuring the size between hole positions.
Electric spark machining: It is a machining process that mainly uses electrodes discharge with specific geometric shapes to burn the geometric shapes on metal (conductive) components. Currently, the mold industry uses electric discharge machining , which is used to process hard, brittle, and complex shapes that traditional processes are difficult to complete, but the cost is relatively high and the efficiency is slow.
The process design of machining products is very important. Considering deformation and machining allowance issues, a good process sequence can ensure the accuracy of the product. We have a good and experienced team to develop a suitable process path for you, and adopt matching processes to provide reliable and economical solutions for your product. And we can also provide assistance in design and development, as well as optimize design based on actual production processes to obtain cost-effective products.
Available materials: gray cast iron, HT200, HT300, ductile iron: QT400-700, high chromium cast iron. Carbon steel, alloy steel, stainless steel, copper aluminum alloy, plastic POM, nylon, titanium alloy, and other products are used in various industries, such as automotive parts, engineering machinery, agricultural machinery, household hardware, hydraulic, medical, aerospace, high-speed rail, shipbuilding, etc,
There are many specialized machine equipment for machining, and engineers independently develop machine tools for processing certain features according to processing requirements. Although they are single, they have high efficiency and good quality. There are many such factories in Ningbo, and it is these intelligent engineers who bring us cost-effective products. Relying on the comprehensive and extensive industrial supply chain in Ningbo, we can provide processing services for all the above processes currently. We will choose the appropriate processing technology based on the product characteristics to save costs and ensure delivery time for you. Will better assist your business development.