Machining: Techniques, Methods, and Applications in Modern Production
Machining is a commonly used industrial process that enables the precise shaping of materials such as metals, plastics, as well as wood. In this article, we present key information about machining technologies, methods and applications to help readers understand its essence and importance in various industries and industrial applications.
What is machining?
Machining is the technological process of removing material from the surface of an object in order to give it the correct shape, dimensions and a perfect finish. The various methods used in this process allow precise and reproducible results to be obtained, which is an important element when using the a.n. process.
Basic machining steps
Several basic stages can be distinguished in the machining process. The first is pre-machining, which involves preparing the material for further operations. This is followed by the actual machining, which may include turning, milling, drilling or grinding, depending on the method chosen. The final stage is the finishing machining, aimed at achieving the appropriate surface quality and dimensions of the component. The entire technological process is strictly controlled to ensure repeatability, accuracy and precision.
Difference between machining and other shaping methods
Machining is a subtractive processing method (removing excess material to achieve a specific geometry), which differs from other shaping methods such as point machining (the outline of the machined surface is a representation of the trajectory traced by the tip of the blade) or abrasive machining (where the removal of surface layers of material is carried out using abrasive tools).
With machining, material is removed continuously, allowing for desired and repeatable results. Each type of subtractive manufacturing has its advantages and disadvantages, but machining is considered the most versatile and precise method of shaping products in production.
Types of machining
There are many types of machining in the metalworking industry to produce a variety of shapes and dimensions of parts. The most commonly used methods include turning, milling, drilling and grinding. Each of these methods has its own specific applications and is characterised by different levels of precision and productivity.
Traditional vs modern machining
The division of machining can be represented by the evolution of technology as it has changed the process over the years. Traditional methods, such as turning, milling, drilling or grinding, rely on manual control of lathes, milling machines, drills or grinders. Modern methods, such as CNC machining, allow the process to be fully automated. With maximum exclusion, of the possibility of error.
CNC machining: technology
Computerised Numerical Control is a modern method that uses computer numerical control (CNC) to precisely direct cutting tools. Very precise and repeatable results can be obtained with this type of machining, resulting in higher quality of the desired products. This machining also makes it possible to shorten production times, reduce costs and increase the flexibility of the process due to the ability to change machining parameters flexibly.
The most common metalworking methods
Among the types of metalworking, there are some of the most popular methods that are widely used in industry. Here are some of them:
- Turning – involves removing material by rotating the workpiece around an axis and moving the cutting tool along the surface.
- Milling – a process in which the cutting tool (cutter) moves relative to the workpiece, removing material layer by layer. (More)
- Drilling – a method of creating holes in a material using a drill that rotates and simultaneously moves along the axis of the hole. (More)
- Grinding – the process of smoothing the surface of an object using a grinding wheel that rotates at high speed.
Machining technology process
Machining technology comprises various methods and processes that aim to remove material from a workpiece to obtain a specific shape and dimensions. The technological process consists of several stages that are closely interrelated.
Pre-machining
Pre-machining is the first stage of the process to prepare the workpiece for further machining. In this stage, excess material is removed, allowing the correct form and dimensions to be obtained. Pre-machining is crucial to the entire process, as it affects the quality and precision of the finished product.
Finishing machining
Finishing machining is the final stage of the technological process to obtain a finished product with the required quality and precision. In this stage, any imperfections created during the previous stages are removed and the surface of the workpiece is smoothed and polished. Finishing machining is necessary to obtain a product that meets customer requirements and quality standards.
Example: Workpiece – Roller
Processes:
- Bar cutting
- Frontal area planning
- Rough turning to outer contour
- Outer Surface finish turning
- Pocket milling
- Hole machining
Cutting speed: A key factor in efficiency
Cutting speed is one of the most important parameters affecting machining efficiency. The right choice of speed, allows optimum use of tools and machines, resulting in higher product quality and shorter production times. The cutting speed depends on factors such as the type of material, cutting tool, machine and process parameters. Choosing the right cutting speed is crucial to achieving optimum results in the machining process.
Machines and tools used in machining
Different types of CNC (computer numerically controlled machine tools), often automated or robotised, are most commonly used in the machining process.
Depending on the application, different types of cutting tools can be distinguished, such as:
- Drills – for drilling holes.
- Taps – for tapping holes.
- Milling cutters – for milling surfaces and grooves.
- Lathe knives – for turning on lathes.
- Broaches – for machining holes of special shapes.
Specialised tools are also used, such as multifunction tools, which allow several cutting operations to be carried out simultaneously
CNC vs Conventional Machine Tools
Conventional machine tools are machines that require manual set-up and manipulation by an operator. In contrast, CNC machine tools (numerically controlled machines) are equipped with a control panel (computer) that controls the movements of the cutting tools. When comparing these two types of machine tools, the following differences can be noted:
- Precision: CNC machine tools offer higher precision and repeatability than conventional machine tools.
- Automation: CNC machine tools allow the machining process to be automated, resulting in higher productivity.
- Complexity: CNC machine tools enable more complex cutting operations.
- Cost: CNC machine tools are more expensive to purchase and maintain.
Industrial application of machining
Machining is used in the manufacture of various machine components such as shafts, gears, piston rods and cylinder housings. It makes it possible to obtain the precision components that are necessary for the component to function properly. Advantages of application:
- high precision and repeatability,
- ability to produce complex shapes and details,
- shorter production times,
- reduced production waste.
There are many companies on the market that specialise in machining. Choosing the right machining supplier is crucial to the success of a project. When choosing a supplier, it is worth considering:
- experience and competence,
- range of services offered,
- production capacity,
- completion times,
- opinions of other clients.
Summary
Machining remains an irreplaceable technology in modern industry, combining traditional methods with modern developments such as CNC. As the technology develops, its importance will continue to grow, enabling the production of increasingly complex and precise components. Companies investing in modern machinery and cutting tools can expect to increase the efficiency and quality of their products, which is extremely important in an era of increasing market demands.
We encourage you to familiarise yourself with the rich offer of CPP “PREMA” S.A., which can be an important element of success in the implementation of advanced production projects. Machining is the future that is already shaping modern industry.