Computer numerical control (CNC) machining is a versatile and precise technique that allows manufacturers to rapidly and cost-effectively create parts and components for various applications. However, effective CNC machining entails using the appropriate methods and selecting the right materials. In addition, material selection is essential in any manufacturing process, making it a challenging task for engineers and manufacturers.
At ProCam Services LLC, we can create prototypes or mass-manufacture complex precision machined parts with extremely tight tolerances. We also offer CNC machining, milling, turning, and routing services to our customers in various industries.
The CNC Machining Process
CNC machining is a computerized manufacturing method in which software and codes facilitate processing equipment’s flow and motion, such as milling machines, grinders, and lathes. It is also ideal for producing intricate details in medium to high-volume production runs. Moreover, this process begins with a block of material (referred to as a blank) and utilizes high-performance tools to start the carving process and create the finished part quickly.
CNC machines are powered by a computerized system that streamlines, controls, and limits the movement of an automated machine. Computers are typically mounted in the devices in large manufacturing sites, but they are attached externally for small businesses. Furthermore, the precise motions of the software controls are determined by the type of CNC machine used.
Benefits of CNC Machining
The CNC machining process enables manufacturers to optimize previously manual production methods, resulting in increased productivity and fewer human errors. The following are some of its most significant benefits:
Improved Precision and Minimal Defects
Since codes and software programs regulate the entire process, the machines deliver greater precision with little to no flaws. CNC machining also eliminates the risk of human errors in the manufacturing process because all devices function autonomously and with very little manual intervention.
Faster Production
Manufacturers and operators can utilize CNC machines at their fastest speeds to meet the needs of their customers, particularly in large production. These devices can also run continuously for 24 hours a day, seven days a week, with no breaks or compromises.
Reduced Waste
CNC machines run software programs through optimization techniques to determine the most efficient way to produce parts with the least amount of waste. Besides that, it efficiently uses raw materials as it comprises repeatable applications that use fixed tools along specified routines.
Enhanced Workers’ Safety
CNC machining restricts human involvement to a supervisory role in which they can constantly monitor the software system operation. It also assists humans in performing precautionary or reactionary maintenance to prevent breakdowns, reducing the need for manual interference and making the environment safer.
Guide To CNC Machining Materials
One important feature of this technique is the ability to create finished parts from diverse raw materials. This advantage enables engineers and manufacturers to choose from a vast selection of materials for their machining requirements.
Metals and plastics comprise the majority of CNC-machined components. These two material groups are extremely strong, rigid, and long-lasting. Here is a list of the common CNC machining materials:
Metals
Metals appropriate for CNC machining have unique mechanical properties such as strength, flexibility, and hardness. The following are the commonly used metals that are widely available in the market:
Steel
Steels are malleable and have high corrosion resistance and excellent fatigue, tensile, and yield strength. They are also resistant to abrasion and wear and have superior thermal and electrical conductivity. Here are some steel types and grades:
- 303: This grade contains sulfur, making it one of the easiest stainless steel. It cannot be hardened by heat treatment, but it is widely used in consumer electronics, nuts and bolts, fasteners, aircraft connectors, and bushings.
- 304: This standard stainless steel is corrosion-resistant, weldable, and machinable, and it is reasonably priced. It is suitable for food processing, cookware, automotive components, and architectural applications.
- 1045: This medium carbon steel alloy has excellent strength, toughness, weldability, and machinability. It is ideal for high-wear applications like axles, light gears, and wrought connecting rods.
- 1018: This grade is ideal for carburized parts due to its exceptional weldability and machinability, as well as its moderate strength and flexibility. It is typically used in tie rods, spindles, and machinery parts.
- 8620: This alloy reacts well to nitriding hardening and has excellent wear resistance. It is used in piston pins, fasteners, camshafts, gears, and chains, among other things.
- 8630: This alloy has good hardenability and heat treatment resistance. It is used in crankshafts, forged connectors, and block valves.
Aluminum
Aluminum is one of the best materials for CNC machining. It is highly malleable and ductile, reasonably priced, and three to four times faster than other metals to machine. Although it is too vulnerable to be used commercially in its pure form, it is frequently combined with other metals like copper, lithium, silicon, and zinc to improve its properties. The following are the three common alloys used in aluminum machining:
- Cast Aluminum: This alloy is inexpensive, lightweight, flexible, and long-lasting, and it operates well at high temperatures. In addition, it is widely used in the automotive industry for engine parts, housing, car chassis, and structural components.
- Aluminum Lithium: This alloy is mainly used in aerospace industries because of its lightweight property, making it ideal for wing structures, fuselages, and fan blades. Furthermore, it is significantly more expensive than cast aluminum alloys.
- Wrought Aluminum: This alloy has excellent mechanical properties and structural integrity, particularly when compared to cast aluminum alloys. It is also less difficult to machine and produces better surface finishes.
Titanium
Despite its higher cost than other materials, titanium is commonly used to manufacture products for the most stringent aerospace, military, and industrial applications. Moreover, this material is biocompatible and suitable for use in the manufacture of medical devices.
Brass
Brass — a copper-zinc alloy — is a very soft metal that can be machined without lubrication. It is also workable at room temperature, making it ideal for CNC applications requiring little strength.
Other Metals
Other metals for CNC machining that are less common than the mentioned ones include magnesium, zinc, bronze, and copper.
Plastics
Plastics are among the most preferred manufacturing materials due to their versatility and associated benefits. As a result, there are multiple machinable plastics to choose from, each with its properties and capabilities. Here are a few examples:
ABS
Also known as acrylonitrile butadiene styrene, ABS is a tough, impact-resistant material that can withstand chemicals and electric current. It is widely used in automotive parts and machine tools and is a popular material for rapid prototyping.
Nylon
Nylon is a flexible, low-friction plastic commonly used as a metal substitute in CNC-machined parts. Additionally, it is used in electrical insulation, medical devices, circuit board mounting hardware, and engine compartment components in vehicles.
PMMA
Also called acrylic, PMMA is a clear, rigid plastic used to replace glass or make other optics. It is resistant to scratches and is utilized in screens, light pipelines, lenses, enclosures, and food storage.
HDPE
HDPE stands for high-density polyethylene. It has good chemical resistance, electrical insulation, and a smooth surface. It also has a low friction coefficient and a high resistance to low-temperature impact. Furthermore, it is inexpensive and long-lasting, making it suitable for CNC-machined plastic parts.
PEEK
PEEK, also known as polyether ether ketone, is a high-strength, stable plastic that manufacturers can use in place of metal. It is an excellent material for lightweight fixtures but is more applicable in advanced medical, aerospace, and electronic components.
Other Plastics
Other plastic materials for CNC machining include polycarbonate, Delrin, PTFE, and UHMW.
Other Considerations for Material Selection
Alongside differentiating the CNC materials, it is also essential to consider the following factors when selecting the best material for a specific application:
Nature of Application
Consider how the part will be used, as it will significantly impact material selection. For example, incorrect plastic material or metal grade may adversely affect the part’s performance.
Budget
Before making final decisions, consider the budget because costs frequently influence material selection. For example, some materials are more expensive than others but produce higher-quality results, whereas less expensive materials are not always the best choice.
Manufacturer’s Capabilities
It is critical to select a manufacturer who provides a wide range of machining services and is knowledgeable about raw material sourcing. It is also advised to choose a company with certifications demonstrating its commitment to producing high-quality parts and components.
At ProCam Services LLC, we produce parts and components with quality as our top priority. We exercise caution at every stage of each work to continuously improve and maintain our quality standards.
Partner With ProCam Services LLC for Exceptional Machining Needs!
ProCam Services LLC can machine various materials, including aluminum, stainless steel, and plastic. Our full-service machine facility, cutting-edge equipment, and proven expertise guarantee that we will complete the job for you.
To collaborate with ProCam Services LLC, contact us, and we will provide you with a quick quote!