- High precision and high efficiencyComputer control allows for precise management of position and speed, enabling high-precision machining. It can handle not only mass production but also prototype manufacturing.
- It is possible to process complex shapes.It can handle shapes and intricate processing that are difficult to achieve manually, and can consistently manufacture parts of various shapes and sizes.
- Automation is possible.Because the process is automated, the burden on workers will be reduced, and improvements in accuracy and productivity are expected.
NC cutting
Overview of NC Machining
This machining method uses numerical control (NC) devices to precisely cut metals and resins. Because the movement of the tool is controlled by a program, it can reproduce complex shapes with high precision, making it suitable for high-mix, low-volume production.
Characteristics of NC cutting
NC cutting process
The basic machining process for NC cutting follows this flow:
- Creating design dataBased on 3D data designed using CAD (Computer-Aided Design), an NC program for machining is created.
- Program creation using CAMCAM (Computer-Aided Manufacturing) software is used to define machining paths based on design data and generate programs for use on NC machines.
- NC machine setup and material loadingSet the material in the NC machine and set the tools and machining conditions.
- Execution of cutting processUsing an NC program, the NC machine automatically cuts the material and forms the specified shape.
- Finishing and inspectionFinishing work is performed as needed, and dimensions and quality are inspected.
Types of NC cutting processes
There are several methods for NC machining, depending on the purpose and type of machining.
- millingThis method involves rotating a cutting tool to cut the material, and is suitable for surface machining, groove machining, and forming complex shapes.
- Lathe machiningThis method involves applying a cutting tool to a rotating material while it is being machined, and is used for cylindrical shapes and shafts, among other applications.
- DrillingThis is a machining method for creating holes, where a drill bit is used to create through holes or stepped holes in the material.
- GrindingThis method uses a grinding machine and grinding wheels to precisely cut materials, and is used for finishing and micro-machining.
- 5 axis machiningThis method involves moving a tool with five degrees of freedom, including a rotation axis, to machine complex 3D shapes in a single operation. It is used for machining highly complex shapes in fields such as aerospace and medical applications.
Advantages of NC cutting method
Suitable for parts requiring high precision.
Stable qualityComputer control ensures consistent quality even with repeated processing, making it suitable for mass production.
Reducing labor costsAutomation minimizes manual work by employees, leading to reduced labor costs.
Complex shapes can be processed.Because it can accurately process shapes that are difficult to achieve manually, it is possible to manufacture complex and precise parts.
High productivityBecause mass production is possible using the same program, production efficiency is improved.
Points to note when performing NC cutting
- Tool wear managementDue to the high-speed cutting, tool wear is accelerated. Appropriate replacement and maintenance are necessary.
- Optimization of cutting conditionsIt is important to set appropriate cutting conditions (speed, feed rate, depth of cut, etc.) according to the material and machining shape. Inappropriate conditions will not only lead to increased tool wear but also affect the finish and accuracy of the product.
- thermal managementHigh-speed cutting can easily generate frictional heat, which may affect the dimensional accuracy and finish of the material. Appropriate temperature control should be implemented, such as by using a coolant.
- Vibration managementVibration can cause the machined surface to become rough and reduce accuracy, therefore, machine rigidity and proper fixing are required.
- NC program verificationProgram errors can lead to machining errors and tool breakage, so we check them beforehand through simulations and test machining.
- Proper management of materialsChoosing a material suitable for machining is crucial. Depending on the material, machining can be difficult and tool wear can be severe, so careful material selection is essential.
Main applications of NC cutting methods
NC machining is commonly used in the following fields:
- Automotive industryMachining of high-precision parts such as engine components, gears, and shafts.
- aerospace industryMachining of lightweight and complexly shaped parts, turbine blades, structural components, etc.
- Medical devices: Machining of implants, prosthetics, and precision parts.
- electronic equipmentProcessing of smartphone casings, precision case components, etc.