Machining Technology

In recent years, machining technology has advanced significantly, bringing the industry into a new phase of higher precision and faster efficiency. Today, we’re excited to share the latest machining techniques with you.

01 Different Machining Equipment

In machining, different types of equipment have unique “skills,” each responsible for specific tasks. Choosing the right equipment and using it effectively is key to improving efficiency and product quality.

1) Conventional Lathe

The conventional lathe is a well-known “old friend” in machining, primarily used for processing shafts, disks, and other workpieces with rotational surfaces. By coordinating the rotation of the workpiece with the movement of the cutting tool, it can precisely machine outer diameters, internal holes, and tapered surfaces. Widely versatile, it meets most machining needs with a precision of up to 0.01mm, making it an indispensable “foundational player” in factories.

2) Conventional Milling Machine

A conventional milling machine is mainly used for machining flat surfaces and grooves. It achieves this by rotating the spindle to drive the cutting tool against the workpiece. With high flexibility, it’s suitable for small- to medium-sized parts, typically achieving a precision of about 0.05mm. It is often used for initial machining or scenarios requiring moderate precision.

3) Grinding Machine

The grinding machine specializes in precision surface finishing. Using a high-speed rotating grinding wheel, it achieves superior surface smoothness. Grinding machines typically offer machining precision of up to 0.005mm, and for smaller parts, even 0.001mm. It’s an essential tool for ensuring the surface quality of workpieces.

4) Bench Work (Handwork)

Bench work refers to traditional manual machining processes such as filing, sawing, drilling, and tapping. It’s ideal for small-batch production or detailed finishing of parts. While CNC equipment has reduced the demand for bench work, it remains irreplaceable for adjusting complex parts and assembly tasks.

5) CNC Lathe

The CNC lathe is the modern production “efficiency champion,” combining the functionality of a traditional lathe with the precise control of CNC technology. It’s particularly suitable for processing high-precision parts. Through programmed automation, it offers high efficiency and stable machining precision within 0.01mm, making it an ideal tool for complex parts and large-scale production.

6) CNC Milling Machine

The CNC milling machine excels at handling complex-shaped products. With multi-axis linkage, it can perform ordinary milling as well as process 3D surfaces and mold components. It achieves precision within 0.01mm.

7) Wire EDM (Electrical Discharge Machining)

Wire EDM is designed for processing high-precision through-holes, slots, and other intricate shapes. Slow wire EDM can achieve precision up to 0.002mm, making it ideal for high-precision machining in the mold industry. Medium-speed wire EDM, with a precision of about 0.02mm, is suitable for scenarios with slightly lower accuracy requirements.

8) EDM Machine (Spark Erosion)

The EDM machine specializes in handling complex shapes and hard materials, such as grooves, small holes, and irregular holes often found in molds. Since the process involves no cutting forces, it produces no burrs or tool marks, ensuring high-quality results. With a precision of up to 0.005mm, it is a “master” in mold manufacturing and machining high-hardness materials.

02 Machining Process

Machining is a precise and intelligent craft, centered around the "process plan", a detailed operational guide that outlines the steps to transform raw materials into finished parts that meet specifications. The process plan is like a construction blueprint, defining each step of the machining process and its methods to ensure efficiency and order throughout production.

The entire machining process is typically divided into several operations, with each operation further broken down into steps such as setup, workstation tasks, machining steps, and tool paths. The quality of process design depends on the complexity of the part, precision requirements, and production scale. For example, mass production of large parts may require efficient CNC equipment, while single or small-batch production might rely on traditional lathes or bench work for support.

Developing the process plan is a critical step in machining. It must ensure the precision and surface quality of the part while striving for maximum efficiency. Flexibility in the process plan is also important to adapt to various machining needs.

Common Process Highlights

1. For holes with precision less than 0.05mm, conventional milling is not sufficient; CNC machining is required. For through-holes, wire EDM can also be used.

2. For precision holes in hardened materials (through-holes), wire EDM is needed after hardening. Blind holes require rough machining before hardening and finishing afterward. Non-precision holes can be completed before hardening, leaving a margin of 0.2mm per side for heat treatment.

3. Grooves narrower than 2mm require wire EDM; for grooves 3–4mm wide with significant depth, wire EDM is also necessary.

4. For hardened parts, a rough machining margin of at least 0.4mm should be left, while for non-hardened parts, the margin should be 0.2mm.

5. Plating thickness is typically 0.005–0.008mm, and machining dimensions should account for pre-plating measurements.

03 Process Time

Process time refers to the time required to complete a specific operation and serves as a key indicator of labor productivity. It is essential for scheduling production plans, calculating costs, determining equipment and staffing needs, and planning production areas. As such, process time is a critical component of the process plan.

When setting process time, it should align with the production conditions of the company. The goal is for most workers to achieve the set time with effort, advanced workers to exceed it, and less experienced workers to reach or approach the average advanced level with effort.

As production conditions improve, process times should be periodically reviewed and updated to maintain a fair and progressive standard.

Process times are typically determined through collaboration between technical staff and workers. Methods include estimating based on past experience and relevant technical data, comparing time standards for similar parts or operations, or measuring and analyzing actual operation times.

Formula for Process Time

Process Time = Preparation Time + Basic Time

Preparation Time: The time workers spend on tasks such as reviewing process documents, obtaining raw materials, installing and adjusting fixtures, setting up machines, and removing fixtures.
Calculation: Estimated based on experience.

Basic Time: The time spent on the actual machining process, such as cutting metal.