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In modern manufacturing, cnc-machining has become one of the key technologies to promote industrial development with its high efficiency and precision.The machining can be used in aerospace, automobile and medical devices through computer digital control to automate production of complex components. Whether it is precision machining lathe or efficient machining mill, CNC technology can complete all kinds of processing needs from metal to composite materials through preset programs, greatly improving production efficiency and product quality. With the rapid development of intelligent manufacturing, the application of CNC machining in the frontier fields of lightweight design and miniaturized components is expanding.
What is CNC machining?
CNC machining is an advanced technology for machining high-precision parts by using pre-programmed control machine tools. Widely used in aerospace, automotive and medical fields, metal or non-metal materials can be processed efficiently. Among them,grindingmachining is mainly to remove the tolerance of the material surface through high-speed rotating grinding wheels,while mIlling machining uses rotating multi-blade tool to complete cutting task of plane, groove or complex contour. Both use automated processes to ensure consistency and meet modern industry's high standards for components.
What are the CNC machining processes?
- How it works: By cutting workpieces with rotating, multi-edged cutting tools, such as end mills and ball cutters, flat, groove, curved surfaces or complex contours can be the machining out.
- Advantages: Support one-off molding of complex 3D structures, combine with multi-axis axis linkage technology such as five-axis linkage,and greatly improve processing efficiency.
- Application scenarios: Aerospace components (e.g. turbine blades), automotive molds, precision machinery components.
- JS company comes with a high-speed spindle (up to 200,000 rpm) and a smart chip removal systems to ensure a smooth surface.
- How it works: By rotating the workpiece and aligning it with a fixed tool, it can be processed into a fixed tool, cylindrical, conical, or rotating parts.
- Advantages: High machining efficiency, suitable for mass production of symmetric parts such as axles and flanges, tolerance control within ±0.005mm.
- Application scenarios: Auto transmission shafts, medical device screw, hydraulic cylinder.
- JS company adopts high rigidity chucks and thermal deformation compensation technology to ensure consistency of mass production.
- Principle: High speed rotating wheel or grinding head to remove material surface allowance, suitable for the final final precision machining of hard alloy or precision parts.
- Strengths: Surface roughness up to Ra <0.01 μm, commonly used in tool grinding and bearing raceway processing.
- Application scenarios: Mold polishing, aerospace fasteners, Optical lens molds.
- JS company combines intelligent cooling system and self-repairing wheel technology to extend service life by 300%.
It is a high-end technology in the field of CNC machining. It integrates multiple machining modules such as milling, turning, grinding, and so on,and supports synchronous linkage machining of multi-axis (usually more than 5 axes) workpieces.Can complete complex surface, irregular structure or precision components in one go, greatly improve production efficiency and accuracy.
Technical advantages of JS:
- The company adopts the international leading five-axis linkage machine tools, equipped with high rigidity bed body and precision transmission, can synchronize the difficult tasks of tilting surface processing, deep cavity carving and so on.
- Through the self-developed CAM software, JS company dynamically optimizes processing path, simulates cutting force, thermal deformation and other parameters in real time, and reduces the number of trial cuts.
- JS's multi-axle machine tool can be flexible between milling, turning, drilling and other processes, greatly simplified the production process.
What are the steps of CNC machining?
- Core tasks: Create 3D models using CAD software (e.g. SolidWorks, AutoCAD) to define part dimensions, tolerances, and surface roughness requirements.
- JS technology highlights: Supports the import of generic format files such as STEP and IGES,and is compatible with complex surfaces and irregular structural designs.
2.Process planning
- Material options: Available in metallic (aluminium, titanium alloy) or non-metallic (carbon fiber, PEEK) as required.
- Process parameter setting: Setting cutting speed, feeding speed, cutting depth, etc.
- Tool path optimization: High efficiency and low loss machining paths is generated through CAM software.
- JS technology highlight: independent development of process database to reduce test run costs by 30%.
3.CNC Programming
- Use CAM software (such as Mastercam, UG NX) to convert design patterns into machine-recognizable G/M codes.Setting up processing coordinate system, tool compensation value and safety height.
- JS technology Highlights: Supports multi axis linkage programming and macro program development to meet complex surface processing requirements.
4.Processing preparatory work
- Fixture design: Customized fixtures ensure workpiece positioning accuracy.
- Mould preparation: Install tool, calibrate tool alignment instrument, configure coolant.
- Machine tool debugging: Check machine tool status in advance through intelligent system developed by JS.
5.Machine tool processing
- CNC machine operation: After the installation of procedures, the machine automatically completes milling machining, lathe machining or according to the instruction manual grinding.
- Real-time monitoring: JS machine tools equipped with vibration monitoring and temperature sensor system, can automatically adjust processing parameters.
- JS technology highlight: Five-axis coupled machine tools support ± 0.005mm precision and increase processing efficiency by 50%.
6.Post-treatment and surface optimization
- Remove burrs and sharp edges, clean and rust prevention treatment.
- Surface treatment as required (e.g. anodic oxidation, sandblasting, plating).
- JS technology highlight: The self-developed environmentally friendly surface treatment technology improves the corrosion resistance of parts.
How do CNC machining demonstrate its advantages in complex part production compared to traditional machining?
Machining cnc through computer digital control technology has completely changed the limitations of traditional machining, especially in the manufacture of complex parts demonstrated a significant advantage.Here's a specific comparison:
| Comparing dimensions | Traditional machining | CNC Machining | Advantages of JS Company |
| Accuracy control | Above ±0.02mm, relying on manual experience. | Real-time error compensation in ±0.005mm range. | Five-axis coupling accuracy was ±0.003mm. |
| Complex structural processing | Step by step, the irregular surface is difficult to form. | To complete (a turbine blades, for example) a multiaxial coupling. | Support for mass production of aerospace class composite components. |
| Automation | Man-led, time-consuming process connections. | Fully automated processes with 80% reduction in manual intervention. | Unmanned workshop to achieve 24 hours continuous production. |
| Material adaptability | Conventional metal and plastics only. | Efficient processing of refractory materials such as titanium alloys ceramics and composites. | Mature cases of medical titanium alloys and aerospace superalloys. |
| Material adaptability | Knife wear is serious, single piece cost is high. | 300% increase in tool life and reduce marginal costs through mass production. | Processing costs for new energy battery trays have been reduced by 25%. |
How to extend the service life of CNC machining lathe?
CNC machining lathe, as the core equipment of high precision manufacturing, has a direct impact on production cost and efficiency.By implementing scientific maintenance strategy and standard operation, the service life of equipment can be significantly extended while maintaining the stability of its performance.The methods are as follows:
1.Strict implementation of routine maintenance plan
- Cleaning and lubrication: Daily cleaning of debris and oil stains within the machine tool and regular replacement of guide rail lubricant (recommended every 500 hours) to avoid accelerated wear and tear of metal debris.The JS company case shows that standardized lubrication can extend the life of a guide rails by 40%.
- Fastener inspection: Check bolts, nuts and other connectors regularly to prevent loosening, so as not to cause vibration or accuracy deviation.
2.Standard operating procedures and training of personnel
- Standardized operation: Develop operating procedures to prohibit overload handling (such as exceeding the maximum torque or speed of the machine tool) to avoid malfunctions due to improper operation.
- Skill training: Regularly train operators in CNC programming, equipment debugging, etc., to improve their ability to judge abnormal working conditions (such as tool wear warning).
3.Regular and preventive maintenance
- Quarterly maintenance checklist: Check wear and tear of transmission components such as screws and bearings.Test the pressure of the hydraulic system and the sealing the pneumatic element.
- Annual overhaul: Works with equipment manufacturers to carry out deep maintenance, replace breakables (such as seals and filters), calibrate grating gauge and encoder accuracy.
How to achieve micrometer level CNC machining?
1.Hardware foundation of high precision machine tools
- Multi-axis coupled rigid structures: Five-axis coupled machine tools (such as the high-end German model provided by JS) combine linear guides and ceramic bearings to reduce motion friction; beds are made of granite or polymer composites to suppress vibration and ensure long-term thermal stability (±0.002 °C/h).
- Super-precision precision spindle system: Spindle speed up to 100,000 RPM, equipped with static bearing or magnetic levitation technology, output less than 0.5 μm, support for microcutting.
2.Ultra-hard tool and coating technology
- Tool material selection: Single crystal diamond (PCD), cubic boron nitride (CBN) or ceramic tool preference, hardness in HV8000 or above, suitable for hard materials such as hard alloy, ceramics.
- Nanocoating process: Diamond coating or titanium nitride coating is formed on tool surface by physical vapor deposition or chemical vapor deposition to reduce friction coefficient and extend service life 5-10 times.
3.Environmental control and process stability
- Thermostatic constant humidity workshop: Temperature controlled at 20±0.5°C, humidity maintained at 40%-60% to reduce the impact of thermal expansion and shrinkage of materials on accuracy.
- Air purification system: use of HEPA filter (filtration efficiency 0.3 μm >99.97%) to avoid dust pollution on workpiece surfaces.
4.Optimizing Digital Process Parameters
- Cutting parameters match: Micro-cutting strategies, such as machining silicon wafers with diamond cutters with feed speed less than 0.01mm/r and cutting depth less than 1 μm, avoid tool chipping.
- Adaptive control system: Real-time monitoring of cutting force, vibration and temperature, dynamic adjustment of spindle speed and feed speed through PID algorithm to ensure processing stability.
5.Special materials and surface treatment processes
- Ultraprecision grinding and polishing: The surface surface roughness Ra <0.01 μm mirror level) was achieved by chemical mechanical polishing (CMP) or elastic emission processing (EEM).
- Special material adaptation: For superhard materials such as sapphire and silicon carbide, EDM is combined with CNC grinding.
How does JS company solve the problems of tool wear and thermal deformation when processing difficult to cut materials such as titanium alloys?
Titanium alloy is known as the king of hard cutting materials because of its high hardness, toughness and poor thermal conductivity. Through the following innovative technologies, JS company systematically solves the problem of tool wear and thermal deformation,and achieved high efficiency and precision cnc machining:
1.Stiffness enhancement and thermal deformation control of machine tools
- High rigidity bed frame design: The combination of marble base and polymer concrete structure improves the stiffness of the machine tool by 300% and effectively suppresses vibration induced by cutting force (e.g. amplitude < 0.01mm during titanium alloy milling).
- Intelligent thermal compensation system: Real-time monitoring of temperature change of spindle and guide rail of machine tool spindle, dynamic compensation of thermal displacement errors by closed-loop control algorithm, guarantee titanium alloy lathe machining and milling accuracy ±0.005 mm.
2.Professional Tools and Cutting process optimization
- Superhard tool material: CBN (cubic boron nitride) coated tools and PCD (polycrystalline diamond) tools were developed independently according to the characteristics of titanium alloy, with hardness at HV8000 or above, high temperature resistance increased by 50%, and tool service life increased by 3-5 times.
- High-pressure cooling technology: In milling and lathe machining, 20MPa high-pressure coolant is injected directly into the cutting area of the tool, which can take away more than 80% of the cutting heat and avoid the phenomenon of high-temperature bonding (chip accumulation) of titanium alloy.
3. Grinding machining special solution
- Slow feed strong grinding: Titanium alloy precision parts (such as aviation fasteners) use ultra-hard grinding wheels (such as ceramics combined with CBN grinding wheels) and low speed high feed strategies, with a single grinding depth up to 0.2mm and a 40% efficiency increase.
- Electrolytic on-line finishing (ELID) technology: In grinding process,the grinding wheel is dynamically trimmed by electrolytic action to maintain sharpness of the grinding wheel, so that the surface roughness the grinding wheel is controlled to be less than 0.4 μm.
4.JS company's technical verification and case studies
- Aircraft titanium alloy blade processing: Combining high pressure cooling with CBN cutters, the single-knife cutting length is more than 500 meters and the surface integrity reaches Ra<0.8 μm, satisfying the stringent requirements of aviation engines.
- Mass production of Medical titanium alloy implants: Micro lubrication (MQL) technology is used instead of traditional cutting fluids, reducing processing costs by 60% while avoiding the risk of material hydrogen embrittlement of the material.
Summary
In the field of high-end manufacturing, cnc-machining technology has been the core force driving the upgrading of the industry. JS has broken the processing bottleneck of titanium alloys, superalloy and so on by the deep accumulation and deep fusion of grinding technology in cnc machining field. Through intelligent process control, specialized tool development, and thermal deformation compensation technology, JS Company not only achieves the ultimate accuracy of complex parts (± 0.005mm), but also provides efficient, low-cost solutions for aerospace, medical technology, and more, redefining the limits of precision manufacturing. Choosing JS is choosing to move on to a higher quality, more secure future.
Disclaimer
The content of this page is for informational purposes only.JS SeriesNo representations or warranties of any kind, express or implied, are made as to the accuracy, completeness or validity of the information. It should not be inferred that the performance parameters, geometric tolerances, specific design features,material quality and type or workmanship that the third-party supplier or manufacturer will provide through the jusheng network. This is the responsibility of the buyerAsk for a quote for partsto determine the specific requirements for these parts.please Contact us Learn more information.
JS Team
JS is an industry-leading companyFocus on custom manufacturing solutions. With over 20 years of experience serving more than 5,000 customers,we focus on high precisionCNC machining,Sheet metal fabrication,3D printing,Injection molding,metal stamping,and other one-stop manufacturing services.
Our factory is equipped with more than 100 state-of-the-art 5-axis machining centers and is ISO 9001:2015 certified. We provide fast, efficient and high-quality manufacturing solutions to customers in more than 150 countries around the world. Whether it's low-volume production or mass customization, we can meet your needs with the fastest delivery within 24 hours. chooseJS TechnologyIt means choosing efficiency, quality and professionalism.
To learn more, please visit our website:jsrpm.com
FAQs
1.Is CNC machining environmentally friendly?
Modern CNC equipment supports dry cutting (coolant free) and cutting liquid recovery techniques, with coolant consumption reduced by more than 90%. It recycles waste liquid, filters, purifies, reuses, lowers costs and protects the environment.
2.Is CNC machining suitable for small batch or custom orders?
Yes, CNC programming is flexible, especially for small batch or custom orders.By means of computer program control, the replacement of workpiece only requires to adjust the program, greatly shortens production lead time, suitable for the minimum order amount of workpiece, such as medical customization or scientific research prototype development.
3.What are the factors influencing the price of CNC machine tools?
machine tool type (e.g. five-axis coupling), brand (import/domestic), configuration (spindle speed, servo system, tool system), bed material, intelligent function (automatic knife changing,cooling system), etc. High-end fittings, imported brands and customisation demand will add significantly to costs.
4.What are JS company's unique advantages in CNC machining?
JS has a five-axis machine tool,independent process database and intelligent monitoring system, processing efficiency is 30% higher than its peers. The cutting parameters are dynamically optimized by combining artificial intelligence algorithm to increase tool life by 300% and machining efficiency by 30% more than the industry average. And provides the whole process service from design to detection.
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