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Precision
CNCMachiningRepeatability
and
Tight
Tolerancesfor
Complex
Part
Geometries2What
ItDoes:What
are
some
common
11uses
for
CNC
Swiss
machining?Drilling
11Threading
(OD
&
ID)
12Slotting
13Boring
14Reaming
14Polygonmachining
15Broaching
15Deburring
16How
It’s
Used:
What
are
some
applications
18for
precision
CNC
Swiss
machining?General
industry
applications
18Benefits
in
medical
device
applications
18Conclusion:
Why
precision
CNC
machining?
21Introduction:
3What
is
precision
CNC
machining?The
role
of
“CNC”
in
precision
machining
3Materials
that
are
machined
4Some
advantages
of
precision
CNC
machining
4How
It’s
Done:
What
processes
and
equipment
5are
commonly
used
in
precisionmachining?Milling
vs.
turning
5Manual
vs.
CNC
machining
6CNC
mills
6CNC
lathes
8Unique
advantages
of
CNC
Swiss-style
machining
10TABLE
OF
CONTENTStable
of
contentsTHE
ROLE
OF
“CNC”
IN
PRECISIONMACHININGUsing
codedprogramminginstructions,
precision
CNCmachining
allows
a
workpiece
to
be
cut
and
shaped
tospecifications
without
manual
interventionbya
machineoperator.Taking
a
computer
aided
design
(CAD)
model
providedbyacustomer,
an
expert
machinist
uses
computer
aidedmanufacturingsoftware
(CAM)
to
create
the
instructions
formachining
the
part.
Basedon
the
CAD
model,
the
softwaredetermines
what
tool
paths
areneeded
and
generatestheprogramming
codethat
tells
the
machine:What
the
correct
RPMs
and
feed
rates
areWhen
and
where
to
move
the
tool
and/or
workpieceHow
deep
to
cutWhen
to
apply
coolantAny
other
factors
related
tospeed,
feed
rate,
andcoordinationA
CNC
controller
then
uses
the
programming
code
to
control,automate,
and
monitor
the
movements
of
the
machine.IntroductIon:
What
Is
precIsIon
cnc
machInIng?3Introduction:What
isprecision
CNC
machining?For
design
engineers,
R&D
teams,
and
manufacturers
thatdepend
on
part
sourcing,
precision
CNC
machining
allows
forthe
creation
of
complex
parts
without
additional
processing.In
fact,
precision
CNC
machining
often
makesit
possible
forfinished
parts
to
be
made
on
asingle
machine.Themachining
process
removes
material
and
uses
a
widerange
of
cutting
tools
to
create
the
final,
and
often
highlycomplex,
design
of
a
part.
The
level
of
precision
is
enhancedthrough
the
use
of
computer
numerical
control
(CNC),
whichis
used
to
automate
the
control
of
the
machining
tools.Today,
CNC
is
a
built-in
feature
of
a
wide
range
of
equipment,from
lathes,
mills,
and
routers
to
wire
EDM
(electricaldischarge
machining),laser,and
plasma
cutting
machines.
Inaddition
to
automating
the
machining
process
and
enhancingprecision,
CNC
eliminates
manual
tasksand
frees
machiniststo
oversee
multiple
machines
running
at
the
same
time.In
addition,
once
a
tool
path
has
been
designed
and
amachine
is
programmed,
it
can
run
a
part
any
number
of
times.
This
provides
a
high
level
of
precision
andrepeatability,
which
in
turn
makes
the
process
highlycosteffective
and
scalable.MATERIALS
THAT
ARE
MACHINEDSome
metals
thatarecommonly
machined
includealuminum,
brass,bronze,copper,steel,
titanium,
and
zinc.In
addition,
wood,
foam,
fiberglass,
and
plastics
such
aspolypropylenecanalso
be
machined.In
fact,
just
about
any
material
can
be
used
with
precision
CNC
machining
—
of
course,
depending
on
the
application
and
its
requirements.SOME
ADVANTAGES
OF
PRECISIONCNC
MACHININGFormany
of
the
small
parts
and
components
that
are
usedina
wide
rangeof
manufactured
products,
precision
CNCmachining
is
often
the
fabrication
method
of
choice.IntroductIon:
What
Is
precIsIon
cnc
machInIng?4As
is
true
of
virtually
all
cutting
and
machining
methods,different
materialsbehavedifferently,
and
the
size
and
shape
of
a
component
also
have
a
big
impact
on
the
process.However,
in
general
theprocess
of
precision
CNC
machiningoffers
advantagesover
other
machining
methods.That
isbecauseCNC
machining
is
capable
of
delivering:A
high
degree
of
part
complexityTight
tolerances,typically
ranging
from
±0.0002”
(±0.00508mm)
to
±0.0005”
(±0.0127
mm)Exceptionally
smooth
surfacefinishes,
including
customfinishesRepeatability,
even
at
high
volumesWhile
askilled
machinist
can
useamanual
lathe
to
make
aquality
part
in
quantities
of
10or
100,
what
happens
when
youneed
1,000
parts?
10,000
parts?100,000
or
a
million
parts?With
precision
CNC
machining,
you
can
get
the
scalability
andspeedneeded
for
this
type
of
high-volume
production.
Inaddition,
the
high
repeatability
of
precision
CNC
machininggives
you
parts
that
are
all
thesamefrom
start
to
finish,
nomatter
how
many
parts
you
are
producing.Get
some
machinists’
tips
on
how
tokeep
the
productionof
small,
complex
parts
cost-effective
in
our
blog
Top5
Challenges
in
CNC
Machining
Services
Explained.In
the
next
section,
we’ll
take
a
look
at
some
of
the
equipmentand
the
processes
that
are
most
frequently
usedin
precisionCNC
machining.Therearesome
very
specialized
methods
of
CNC
machining,
including
wire
EDM
(electrical
discharge
machining),additive
machining,
and
3D
laser
printing.
For
example,
wire
EDM
uses
conductive
materials
—
typically
metals
—
andelectrical
discharges
to
erodea
workpiece
into
intricate
shapes.However,
herewe
will
focus
on
the
milling
and
turning
processes
—
two
subtractive
methods
that
arewidely
available
andfrequently
used
for
precision
CNC
machining.hoW
It’s
done:What
processes
and
equIpment
are
commonly
used
In
precIsIon
machInIng?5How
It’s
Done:
What
processes
and
equipmentare
commonly
used
in
precision
machining?MILLING
VS.
TURNINGMilling
is
amachining
processthat
usesa
rotating,
cylindrical
cutting
tool
to
remove
material
and
create
shapes.Milling
equipment,
known
as
amill
or
amachining
center,accomplishes
auniverse
of
complex
part
geometries
on
someof
the
largest
objects
machined
metal.An
important
characteristic
of
milling
is
that
the
workpieceremains
stationary
while
the
cutting
tool
spins.
In
otherwords,
on
a
mill,
the
rotating
cutting
tool
moves
around
theworkpiece,
which
remains
fixed
in
place
onabed.Turning
is
the
process
of
cutting
or
shaping
a
workpieceon
equipment
called
a
lathe.
Typically,
the
lathe
spins
theworkpiece
ona
vertical
or
horizontal
axis
whilea
fixed
cuttingtool
(which
may
or
may
not
be
spinning)
movesalong
theprogrammed
axis.The
tool
cannot
physicallygo
around
the
part.
The
materialrotates,
allowing
the
tool
to
perform
the
programmedoperations.
(There
is
asubset
of
lathes
in
which
the
tools
spinaround
a
spool-fed
wire,
however,
that
is
not
covered
here.)In
turning,
unlike
milling,
the
workpiece
spins.Thepart
stockturns
on
the
lathe’s
spindle
and
the
cutting
tool
is
broughtinto
contact
with
the
workpiece.MANUAL
VS.
CNC
MACHININGWhile
both
mills
and
lathes
are
available
in
manual
models,CNC
machines
are
more
appropriate
for
purposes
of
smallparts
manufacturing
—
offering
scalability
and
repeatabilityfor
applications
requiring
high
volume
production
of
tighttolerance
parts.In
addition
to
offering
simple
2-axismachines
in
which
thetool
moves
in
the
X
and
Z
axes,
precision
CNC
equipmentinclude
multi-axis
models
in
which
the
workpiece
can
alsomove.
This
is
in
contrast
toa
lathe
where
the
workpiece
islimited
to
spinning
and
the
tools
willmovetocreate
thedesired
geometry.These
multi-axis
configurations
allow
for
the
production
of
more
complex
geometries
in
asingle
operation,
withoutrequiring
additional
work
by
the
machine
operator.
Thisnot
only
makesit
easier
to
produce
complex
parts,
but
alsoreducesor
eliminates
thechanceof
operator
error.In
addition,
the
use
of
high-pressurecoolant
with
precisionCNC
machining
ensures
that
chips
do
not
get
into
theworks,
even
when
utilizing
amachine
with
a
verticallyoriented
spindle.hoW
It’s
done:What
processes
and
equIpment
are
commonly
used
In
precIsIon
machInIng?6CNC
MILLSDifferent
milling
machines
vary
in
their
sizes,
axisconfigurations,
feed
rates,
cuttingspeed,
the
milling
feeddirection,
and
other
characteristics.However,
in
general,
CNC
mills
all
utilize
a
rotating
spindle
tocut
away
unwanted
material.
They
are
used
to
cut
hard
metalssuch
as
steel
and
titanium
but
can
also
beusedwith
materialssuch
as
plastic
and
aluminum.CNC
mills
are
built
for
repeatability
and
can
be
used
foreverything
from
prototyping
to
high
volume
production.High-end
precision
CNC
mills
are
often
used
for
tight
tolerancework
such
as
milling
fine
dies
and
molds.While
CNC
milling
can
deliver
quick
turnaround,
as-milledfinishing
creates
parts
with
visible
toolmarks.It
mayalso
produce
parts
with
some
sharp
edges
and
burrs,
soadditional
processes
may
be
required
if
edges
and
burrs
areunacceptableforthose
features.Of
course,
deburring
tools
programmed
into
thesequencewill
deburr,
althoughusually
achieving
90%
of
the
finishedrequirement
at
most,
leaving
some
features
for
finalhand
finishing.As
for
surface
finish,
there
are
tools
that
will
produce
not
onlyan
acceptable
surface
finish,
but
alsoa
mirror-like
finish
onportions
of
the
work
product.TYPES
OF
CNC
MILLSThe
two
basic
types
of
milling
machines
are
known
as
vertical
machiningcenters
and
horizontal
machiningcenters,
wherethe
primary
difference
is
in
the
orientation
of
the
machine
spindle.A
vertical
machining
center
is
a
mill
in
which
the
spindle
axis
is
aligned
ina
Z-axis
direction.
These
vertical
machines
can
befurther
divided
into
two
types:Bed
mills,
in
which
the
spindle
moves
parallel
to
its
own
axis
while
the
table
moves
perpendicular
to
the
axis
of
the
spindleTurret
mills,
in
which
the
spindle
is
stationary
and
the
table
is
moved
so
that
it
is
always
perpendicular
and
parallel
to
theaxis
of
spindle
during
the
cutting
operationInahorizontal
machining
center,
the
mill’s
spindle
axis
is
aligned
inaY-axis
direction.
The
horizontal
structuremeansthesemills
tend
to
take
up
more
space
on
the
machine
shop
floor;
they
are
also
generally
heavier
in
weight
and
more
powerful
thanvertical
machines.A
horizontal
mill
is
oftenusedwhena
better
surface
finish
is
required;
that’s
because
the
orientation
of
the
spindlemeansthecutting
chips
naturally
fall
away
and
are
easily
removed.
(As
an
added
benefit,
efficient
chip
removal
helps
to
increase
tool
life.)In
general,
vertical
machining
centers
are
more
prevalent
becausethey
can
be
as
powerful
as
horizontal
machining
centers
andcan
handle
very
small
parts.
In
addition,
verticalcentershave
a
smaller
footprint
than
horizontal
machining
centers.MULTI-AXIS
CNC
MILLSPrecision
CNC
mill
centersare
available
with
multiple
axes.
A3-axis
mill
utilizes
the
X,
Y,
and
Z
axes
for
a
wide
variety
ofwork.
With
a4-axis
mill,
the
machine
can
rotate
on
avertical
and
horizontal
axis
and
move
the
workpiece
to
allow
for
morecontinuous
machining.A
5-axis
mill
has
three
traditional
axes
and
two
additional
rotary
axes,
enabling
the
workpiece
to
be
rotated
as
the
spindle
headmoves
around
it.This
enablesfivesides
of
a
workpiece
to
be
machined
without
removing
the
workpiece
and
resetting
themachine.Learnmoreabout
precision
CNC
milling
here.hoW
It’s
done:What
processes
and
equIpment
are
commonly
used
In
precIsIon
machInIng?7CNC
LATHESA
lathe
—
also
called
a
turning
center
—
has
one
or
more
spindles,
and
X
and
Z
axes.Themachine
is
used
to
rotate
aworkpiece
on
its
axis
to
perform
various
cutting
and
shaping
operations,
applyingawide
range
of
tools
to
the
workpiece.CNC
lathes,
which
are
also
called
live
action
tooling
lathes,
are
ideal
for
creating
symmetrical
cylindrical
or
spherical
parts.Like
CNC
mills,
CNC
lathes
can
handle
smaller
operations
such
prototyping
but
can
also
be
set
up
for
high
repeatability,supporting
high
volume
production.CNC
lathes
can
also
be
set
up
for
relatively
hands-free
production,
whichmakes
them
widelyused
in
the
automotive,electronics,
aerospace,
robotics,
and
medical
device
industries.There
is
hands-free
production
—
and
then
there
is
fully
automated
“lights
out”
production.
Learn
about
the
challenges
in
our
blogBarriers
to
Lights
Out
Operation
in
Precision
Machining.HOW
A
CNC
LATHE
WORKSWith
a
CNC
lathe,
a
blank
bar
of
stock
material
is
loaded
into
the
chuck
of
the
lathe’s
spindle.
This
chuck
holds
the
workpiece
inplace
while
the
spindle
rotates.
When
the
spindlereaches
the
required
speed,
a
stationary
cutting
tool
is
brought
into
contactwith
the
workpiece
to
remove
material
and
achieve
the
correct
geometry.A
CNC
lathe
can
perform
anumber
of
operations,suchas
drilling,
threading,
boring,
reaming,
facing,
and
taper
turning.Different
operations
require
tool
changes
andcanincreasecost
and
setup
time.When
all
of
the
required
machining
operations
are
completed,
the
part
is
cut
from
the
stock
for
further
processing,
if
needed.The
CNC
lathe
is
then
ready
to
repeat
the
operation,
with
little
or
no
additional
setup
time
usually
required
in
between.CNC
lathes
can
also
accommodate
avariety
of
automatic
bar
feeders,
which
reduce
the
amount
of
manual
raw
materialhandling
and
provideadvantages
suchas
the
following:hoW
It’s
done:What
processes
and
equIpment
are
commonly
used
In
precIsIon
machInIng?8Reduce
the
time
and
effort
required
of
themachine
operatorSupport
the
barstock
toreducevibrations
that
cannegativelyaffect
precisionAllow
the
machine
tool
to
operate
at
optimumspindle
speedsMinimize
changeover
timesReduce
material
wasteTYPES
OF
CNC
LATHESThere
are
anumber
of
different
types
of
lathes,
but
the
most
common
are
2-axis
CNC
lathes
and
Swiss-style
automatic
lathes.Most
CNC
Swiss
lathes
useone
or
two
main
spindles
plus
one
or
two
back
(or
secondary)
spindles,
with
rotary
transferresponsible
for
the
former.
The
main
spindle
performs
the
primary
machining
operation,
with
the
help
ofa
guide
bushing.In
addition,
some
Swiss-style
lathescomeequipped
withasecondtool
head
that
operates
asa
CNC
mill.With
aCNC
Swiss-style
automatic
lathe,
the
stock
material
is
fed
throughasliding
head
spindle
intoaguide
bushing.
Thisallows
the
tool
to
cut
the
material
closer
to
the
point
where
the
material
is
supported,
making
the
Swiss
machine
especiallybeneficial
for
long,
slender
turned
parts
and
for
micromachining.Multi-axis
CNC
turning
centersand
Swiss-style
lathescan
accomplish
multiple
machining
operations
using
a
single
machine.Thismakes
them
a
cost-effective
option
for
complex
geometries
that
would
otherwise
require
multiple
machines
or
toolchanges
using
equipment
such
asatraditional
CNC
mill.Learn
about
5-
and
7-axis
Swiss
machining
capabilities
here.hoW
It’s
done:What
processes
and
equIpment
are
commonly
used
In
precIsIon
machInIng?9UNIQUE
ADVANTAGES
OF
CNCSWISS-STYLE
MACHININGOlder
style
lathes
werecam-driven,
making
them
relativelyprimitive.
Today’s
Swiss-style
lathe
with
CNCis
leaps
andbounds
better,
in
both
accuracy
and
efficiency.On
a
regular
chucker
lathe,
the
part
sticks
out
and
is
pushedaway
—
that
is,
deflected
—
as
you
start
removing
material.But
on
a
CNCSwiss
machine,
the
material
moves
and
thetools
are
stationary,
so
there
is
farlessdeflection.In
addition,
a
Swisslathe
has
both
a
collet
and
a
guidebushing,
to
further
reduce
deflection
and
machine
the
partsmore
precisely.
All
the
action
is
at
the
edge
of
the
guidebushing;
the
correct
length
of
material
is
fed
out,
machined,and
parted
off,
then
another
length
of
material
is
fed.hoW
It’s
done:What
processes
and
equIpment
are
commonly
used
In
precIsIon
machInIng?10So,
with
little
or
no
deflection
in
its
machining
process,
theCNC
Swiss-style
screw
machine
providesgreateraccuracy,precision,
and
consistency.
Learn
more
about
the
advantagesof
eliminating
deflection
in
our
blog
DeflectionandPrecision
in
CNC
Swiss
Machining.In
addition,
compared
with
other
precision
CNC
machiningmethods,
CNC
Swiss-style
machining:Reduces
part
handling
and
laborStreamlines
setupAccelerates
cycle
timesAllows
parts
to
be
finished
in
a
single
operationEliminates
the
risk
of
operator
errorIn
the
next
section,
we’ll
examine
some
of
the
tools
andtechniques
used
with
precision
CNC
Swiss
machining.The
Swiss
screw
machine
has,
quite
literally,
been
around
for
centuries
and
shows
no
sign
of
stopping.
You
can
read
about
theevolution
of
the
modern
Swiss
lathe
in
our
blog
The
Swiss
Machine
in
Today’s
Machine
Shop.The
modern
precision
machine
shop
leverages
CNC
Swiss-style
machining
with
a
wide
rangeof
tools
to
create
parts
with
aninterestingarrayoffeaturesand
functions,
described
below.DRILLINGWhat
It
does:
What
are
some
common
uses
for
cnc
sWIss
machInIng?11What
It
Does:
What
are
some
commonuses
for
CNC
Swiss
machining?Drilling
is
a
process
that
is
often
used
in
precision
machiningto
remove
material
before
performing
finishing
operationssuch
as
threading,
tapping,
boring,reaming,or
broaching.For
Swiss-style
machining,
almost
any
drill
can
be
attached
to
a
screw
machine
tool
holder,
within
the
size
limitations
of
the
machine.
The
drill
is
then
used
to
remove
material
and
createfeatures
such
as
through
holes,
cross
holes,
and
blind
holes
ofvarious
sizes.The
world
of
drills
issovast,
you
could
write
a
book
on
it,
andthe
availability
of
drills
hasexploded.
Today,
there
are
drills
ofremarkably
small
diameters
—
as
small
as
0.002”
(50
micronsor
0.051
mm).Of
course,
the
length
and
diameter
ratios
apply,so
there
are
limitations
to
how
deep
you
can
drill
withultra-small
diameter
drills.Drills
come
in
a
range
of
sizes
and
with
different
types
offlutes.
Here
at
Metal
Cutting
Corporation,
most
of
the
drillswe
use
for
precision
CNC
machining
are
standard,
fractional,decimal,
wire,
and
letter
sizes.Certain
drills
areusedfor
specific
processes.
For
instance,a
#7drill
is
used
to
make
a
hole
to
tap
a
quarter-twenty
threadinside
a
part.Flutes
are
grooves
that
can
vary
in
size,
shape,and
thenumber
on
the
bit.
The
purpose
of
a
drill’s
flutes
is
to
ease
theexit
of
the
chips
as
the
material
is
being
cut.The
exception
isaspadedrill,
which
doesn’t
have
flutes
because
it
isusedforshallow
hole
drilling.Drills
are
typically
made
of
hardened
steel
or
carbides,
somewithabrasive
features.
The
point
of
a
drill
is
typically
angledbetween
118°
and
135°
(sometimes
145°),
depending
on
thematerial
being
machined,
witha
118°
being
the
standardangle.
It
isused
on
all
drills
for
all
materials,
usually
followinga
spot
drill
orcenter
drill
application.THREADING
(OD
&
ID)Forthe
purposes
of
precision
CNC
Swiss
machining,
athread
is
a
symmetrical
radial
feature
that
varies
in
its
pitch.
The
pitch,
orangle,
determines
the
depth
of
the
thread.In
the
machining
of
small
parts,a
threadingprocessisused
to
create
precision
threads
on
the
outside
diameter
(OD)
or
insidediameter
(ID)
of
the
part.
There
are
four
methods
for
producing
OD
threads:Singlepoint
threading
usesatool
that
is
ground
to
the
specific
angle
needed
for
the
thread
you
want
to
create;
at
MetalCutting,
typically
we
thread
at
60°
inclusive.
The
single
point
tool
is
fed
along
the
Z
axis
until
the
desired
depth
is
met.Thread
rolling
involves
feeding
the
material
between
(usually,
three)
die
rolls,
where
the
threads
are
formed
rather
thancut
into
the
correct
shapeand
depth.
Quicker,
more
efficient,
and
more
accurate
than
the
single
point
method,
threadrolling
can
also
create
threads
all
the
way
to
the
shoulder
of
the
part
(such
as
up
to
the
headof
a
screw).Threadwhirling,
which
was
invented
for
surgical
bone
screws,
is
complicated
and
expensive.
However,
with
the
propertools
and
inserts,
it
can
be
used
to
make
virtually
any
type
of
thread
an
engineer
can
design
for
medical
and
otherproprietary
uses.
With
the
tool
spinning
at
a
set
RPM
and
the
material
also
rotating,
the
threads
come
out
with
no
burrs.Die
threading
makes
threads
using
adie
made
of
high-speed
steel
or
carbide
and
having
the
pitch
and
diameter
of
thethread
you
want
to
make.
Generally,
the
die
is
fed
over
a
rotating
diameter,
usually
along
the
Z
axis.
Alternatively,
a
die
maybe
inserted
into
the
holder
and
used
to
form
threads
rather
than
cut
them.In
Metal
Cutting’s
world
of
very
small
diameter
parts,
ID
threading
presents
adifferent
kind
of
variable.
That’sbecause
weusually
don’t
have
the
luxury
ofaperpendicular
tool,
due
to
the
extremely
small
IDs
we
are
requested
to
tap.However,
in
general
precision
CNC
Swiss
machining
uses
one
of
two
methodsusedto
produce
ID
threads:
singlepointthreading
and
tapping.
ForID
threads,
single
point
threading
is
accomplished
in
basically
thesameway
as
described
abovefor
OD
threading,
except
in
this
instance
on
the
ID
of
the
part.What
It
does:
What
are
some
common
uses
for
cnc
sWIss
machInIng?12Tapping
creates
threads
using
a
tool
called
a
tap,
which
has
a
specific
pitch
and
diam
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