Machining Basics

machining

As the core technology of modern manufacturing, machining, through lathes, milling machines, grinders and other specialized equipment for metal, plastic and other workpieces such as cutting, grinding, drilling and other procedures, precise control of the geometry of the parts, structural dimensions and surface finish, to ensure that from automotive engine components to aerospace precision parts of the whole field of manufacturing needs. With the deep integration of CNC technology and automated production lines, the machining process has realized the transformation and upgrading from traditional manual operation to intelligent programming control, which improves machining efficiency while effectively controlling production costs. The quality control system that strictly follows international standards ensures process stability in mass production through real-time monitoring of tool wear status and optimization of machining parameters. Under the current trend of Industry 4.0, machining is evolving in the direction of flexible production and digital management, providing reliable solutions for the customization of complex parts.

numerical control machining

CNC machining relies on computer programming to accurately control the trajectory of the machine tool, through the automated execution of turning, milling, boring and other precision machining processes, metal, engineering plastics and other raw materials are efficiently transformed into complex components that meet the design specifications. Its core advantage lies in the digital command-driven high repeatability and multi-axis linkage capability, which can be adapted to the full-scale manufacturing needs from micro-components of medical devices to large structural parts of energy equipment. Modern smart factories realize dynamic optimization of processing parameters and intelligent prediction of tool life by integrating CAM programming systems and online inspection devices, ensuring dimensional consistency in mass production while improving processing efficiency in high-end fields such as aerospace and automotive molds. With the deep application of Internet of Things technology and digital twin model, CNC machining is accelerating the evolution of cloud-based collaborative manufacturing and adaptive process adjustment, providing key technical support for intelligent manufacturing ecology.

Classification of machining

turning​
The workpiece is rotated by the lathe spindle, combined with the radial/axial feed movement of the tool, specializing in the internal and external round machining of rotary parts such as shafts, disks and bushings, and demonstrating the advantages of high-efficiency cutting in mass production of automotive drive shafts, hydraulic cylinder barrels, etc. It is capable of handling carbon steel, aluminum The CNC lathe is capable of thread turning and precision machining of eccentric structures in a wide range of materials from high-temperature alloys to high-temperature alloys.

milling​
The use of vertical/horizontal milling machine multi-flute tool rotary cutting, capable of complex cavities, three-dimensional curved surface molding processing, from the mold inserts of the parting surface to the robot joints of the joint groove are typical application scenarios, five-axis linkage CNC milling technology to break through the limitations of the spatial angle, impeller, propeller and other shaped parts in the field of processing is irreplaceable.

Grinding​
The use of grinding wheel particles for micron-sized material removal is the ultimate process for obtaining mirror precision in hardened steel, ceramics and other super-hard materials. Bearing races in the manufacture of precision spindles and the surface treatment of artificial joints for medical devices rely on this technology, and sub-micron dimensional stability is ensured by an on-line measurement system and environmental control in a constant temperature workshop.

Drilling, reaming, tapping and other processing​
Covering the complete hole solution from basic through-hole machining to precision thread forming, deep hole drilling technology to meet the needs of gun drilling, oil and gas pipelines and other special L/D ratios, the application of composite tools so that the drilling, reaming and tapping process can be completed in a single clamping, which significantly improves the machining efficiency of engine blocks, hydraulic valve blocks and other multi-hole system parts. Also commonly used in die casting mold Manufacturing.

Machining equipment

lathe

As the core equipment for rotary body machining, the lathe drives the bar or disk workpiece to rotate at a high speed through the spindle, and accurately completes the cylindrical turning, face cutting and thread machining by cooperating with the radial/axial composite feeding movement of the turret. Modern CNC lathe integrates power tool and Y-axis function, which can carry out milling-turning compound machining for stainless steel, titanium alloy and other hard-to-cut materials, and is widely used in mass production of automotive camshafts, hydraulic valve cores and other precision parts, and its dual spindle design can realize automated continuous machining.

machining center

With the spatial machining capability of multi-axis linkage, the milling machine realizes complex surface molding with the help of vertical/horizontal spindle driving face milling cutter, ball-end cutter and other tools, and the five-axis CNC milling machine breaks through the spatial angle limitation through table swinging, which demonstrates the irreplaceability in the three-dimensional surface machining of the blades of aero-engine and the inserts of the plastic injection molds. The machining center equipped with automatic tool changer system can complete the complete process of aluminum alloy frame parts from rough machining to finish milling at one time.

drilling machine

As a professional solution provider in the field of deep hole machining, the drilling machine realizes accurate hole machining by driving twist drills, deep hole drills and other tools through a high-speed spindle, and the gun drilling technology together with a high-pressure cooling system can complete deep hole drilling with an L/D ratio of more than 30:1. Intelligent drilling center integrates reaming and boring process modules to meet the demand for efficient machining of multi-specification holes such as energy equipment tube plates and automotive transmission shells, and is equipped with a laser tool setting instrument to realize real-time compensation for drill bit wear.

grinder

The last line of quality defense for precision manufacturing, the grinding machine adopts CBN grinding wheels or diamond grinding wheels to dress super-hard materials such as hardened steel and cemented carbide with nano-scale precision, and the CNC profile grinding machine can stably maintain the micrometer-scale contour precision of bearing raceways and screw threads through a closed-loop feedback system. Centerless grinding machines equipped with on-line measuring system provide fully automatic grinding solutions for large-volume high-precision parts such as guide pillar of optical instruments and hydraulic valve spools, etc. The environmental control of constant temperature workshop ensures the processing stability.

Other machining equipment

numerical control machine​
As the core carrier of intelligent manufacturing, CNC machine tools seamlessly connect multi-axis linkage and CAM programming system to directly transform 3D modeling data of complex parts into precision machining instructions, showing technical advantages in multi-process integrated machining of aerospace titanium alloy structural parts and medical device implants. Intelligent machine tools equipped with adaptive control systems can sense the fluctuation of cutting force and tool wear status in real time, and combine with the industrial Internet of Things platform to realize the cloud optimization iteration of machining parameters, providing flexible production solutions for automotive molds, optical devices and other precision manufacturing fields.

laser cutting machine​
Relying on high-power fiber laser and galvanometer positioning technology, the laser cutting machine realizes micron-level precision cutting of stainless steel, aluminum alloy and other metal plates by non-contact processing, and its intelligent monitoring system can automatically identify the oxidized layer of carbon steel and adjust the position of the focus, which significantly improves the efficiency in the processing of new energy automobile battery trays and electronic component heat sinks. The 10,000-watt laser cutting equipment breaks through the bottleneck of thick plate cutting, and with the automatic loading and unloading robotic arm, it provides all-weather continuous operation capability for the construction machinery and shipbuilding industries, and the heat-affected zone control technology effectively guarantees the subsequent welding quality of precision parts.

water jet cutting machine​
Adopting the cold cutting process of ultra-high-pressure water jet mixed with garnet sand, the water cutting machine maintains the original properties of materials in the processing of carbon fiber composite materials and marble shaped decorative parts by virtue of the unique advantage of no thermal deformation. The five-axis dynamic cutting head realizes precise separation of three-dimensional contours of ceramic coatings on turbine blades and food-grade plastic containers through spatial angle compensation technology. Its environmental protection feature completely eliminates the dust pollution generated by traditional cutting, and it has become the preferred process for high-standard machining scenarios in the medical consumables and architectural curtain wall industries.

Machining process

Cutting Principle

Cutting tools

cutting fluid

Machining Process

Machining quality control

Machining Error Analysis

Quality control methods

Machined surface quality

Machining dimensional accuracy control

Processing Equipment Safety Regulations​

Pre-startup inspection of equipment​
Verify the pressure stability of the hydraulic system (20-25MPa) and the sealing of the pneumatic pipeline, use infrared thermography to detect the spindle motor winding temperature abnormality, and check the dual protection settings of the CNC system for soft limit and hard limit. For five-axis machining centers need to additionally check the rotary table locking mechanism, laser interferometer detection guideway positioning accuracy error ≤ 0.02mm, to ensure that the carbon steel workpiece clamping magnetic suction cups residual magnetic strength ≤ 5 gauss.

Equipment Operating Procedures​
Strictly implement the SOP parameter setting specification: the rough milling cutting speed of cast iron is limited to 150-220m/min, and the carbide tool feed rate is adjusted according to the gradient of ap=2mm×ae=35mm. When machining titanium alloy, the micro lubrication (MQL) system must be activated and the concentration of smoke in the cutting area must be monitored, the operator must wear an impact-resistant mask and flame-retardant clothing, and the emergency brake button must be triggered immediately in the event of a spindle overload alarm.

Maintenance of equipment after shutdown​
Closed-loop cleaning of metal debris in cutting fluid tank and testing of pH value (8.5-9.2), using ultrasonic cleaning machine to remove micron-sized oil film residue on the taper surface of tool shank. Perform monthly ball screw backlash compensation (C3 grade precision screw compensation ≤ 0.015mm), prejudge spindle bearing life through vibration spectrum analysis, and lubricating grease filling volume is accurate to ±0.5ml.

Machining Accident Case Study​

Accident Case I​
An auto parts factory CNC lathe spindle overheating fire: the operator violated the shutdown of coolant for stainless steel continuous turning, cutting temperature exceeded 900 ℃ lead to fuel mist. After the accident, it was mandatory to install a thermal imaging monitoring system and implant a cutting thermodynamic model in the PLC to realize temperature-speed linkage control.

Accident case II​
Gantry milling machine protection door interlock failure to disability: equipment transformation shielding safety grating signals, iron filings splash through the 5mm acrylic baffle. Rectification program upgraded to IP67 protection level of pressure-sensing floor mats and dual circuit grating, trigger response time ≤ 0.3 seconds.

Machining Development Trends and Challenges​

Development trend of machining technology​

• Digital twin drive: real-time mapping of machine tool status to the cloud, machining error prediction accuracy of 99.2%
• Composite machining revolution: integrated turning, milling, boring and grinding equipment reduces the number of clamping times and shortens impeller machining cycle time by 60%
• Green Manufacturing: Hydrogen Cutting Technology Replaces Emulsions, Reduces Carbon Footprint by 451 TP3T

Challenges facing the machining industry​

• High-skilled talent fault: five-axis programming technician shortage of 37%, need to AR remote guidance system to fill the gap
• Bottleneck of superhard material processing: Silicon carbide mirror processing tool life of only 15 minutes, urgent need for plasma-assisted cutting technology breakthroughs
• Data security risk: CNC system vulnerability leads to G-code tampering, blockchain encrypted transmission required

Prospects for the development of machining technology​
Quantum measurement technology advances dimensional inspection accuracy to the nanometer level, and AI self-evolutionary algorithms increase the efficiency of dynamic optimization of cutting parameters by 300%. By 2030, brain-computer interface-based gesture control of machine tools and zero-emission dry machining centers will become standard in high-end manufacturing, and the microfactory model will reconfigure the aerospace supply chain.