STUDER & SON CUSTOM MACHINING’s Post

#Manufacturing Since the development of the mechanical machining industry, CNC numerical control machining is a good machining method, but its machining cost is also an important factor being considered. Factors such as materials, design, surface treatment, quantity, and turnover time will all affect the cost of CNC machining parts. The following factors will affect the price of CNC parts:   1- Processing time: The more complex and larger the product design, the longer the processing time. The longer the processing time of the parts, the higher the cost. Processing time is usually the main influencing factor for CNC machining of parts.   2- Material: The prices of different raw materials often vary. Even materials with similar performance can have vastly different prices.   3- Tolerance: Stricter tolerance requirements will make it more difficult to process, and the scrap rate will also increase, which will lead to higher CNC processing costs.   4- Quantity: The programming time required to produce 1 piece and 1000 pieces is the same, so if there are more quantities in the same batch, the total cost will be shared, thereby reducing the cost of individual products.   5- Surface treatment: If surface treatments such as coating, smoothing, anodizing, black oxidation are required, and even some workpieces require local electroplating, local anodizing, dual color prototype oxidation, or oxidation in one area, electroplating in another area will increase processing steps and costs.   6- Delivery time: A short delivery time means that the supplier needs to coordinate more workers to arrange this batch of orders first, and has to delay machining other orders. This is also a small factor in the additional cost, abbreviated as "expedited machining fee".

❓ What is Wire Electrical Discharge Machining ❓ Wire Electrical Discharge Machining (WEDM) is a high-precision machining technology that utilizes the principle of galvanic erosion, and is commonly used for cutting hard metal materials or materials that are difficult to machine by conventional mechanical methods. The technology uses a fine metal wire (usually copper or molybdenum) as an electrode to remove the workpiece material by pulsed discharge to cut along a predetermined trajectory. It is widely used in mold making, aerospace, and electronic component processing. The basic principle of EDM wire cutting is to use the working fluid (usually deionized water or other insulating fluids) as the medium to melt and vaporize the workpiece material by triggering a local high temperature through the discharge spark between the electrode wire and the workpiece. This machining method is suitable for materials with high hardness and good electrical conductivity, such as cemented carbide, hardened steel and titanium alloy. ### Main features 1. **High-precision machining**: EDM wire cutting can achieve extremely high machining precision, usually up to the micron level, and is suitable for the manufacture of complex shapes and fine structures. 2. **Non-contact processing**: There is no direct contact between the electrode wire and the workpiece during processing, which reduces the possibility of mechanical stress and deformation, and is particularly suitable for processing thin-walled and fine structural parts. 3. **Wide adaptability**: capable of processing a variety of materials that are difficult to process by traditional methods, especially high hardness, heat-resistant materials. 4. **High degree of automation**: Modern EDM wire-cutting machines are usually equipped with numerical control systems, enabling high automation and precise trajectory control. ### Areas of application - **Mold Manufacturing**: Especially for the processing of stamping molds and plastic molds, EDM wire cutting can effectively improve the life and precision of molds. - **Aerospace**: for processing complex engine parts, turbine blades and other parts with high performance requirements. - **Electronic industry**: for the manufacture of precision circuit boards, integrated circuits molds and so on. The development of EDM wire cutting technology has improved the overall processing capability of the manufacturing industry, especially in the processing of high-precision parts with irreplaceable advantages.

🔴 What are the characteristics of machined parts？ 🔴 1. High precision: machining is capable of achieving high machining accuracy, and the accuracy can usually be controlled at the micron level. Through CNC machine tools, lathes, milling machines and other machining equipment, complex geometric shapes and high-precision dimensions can be achieved, which is particularly important in parts requiring strict tolerances. 2. Good surface quality: The surfaces of machined parts are usually very smooth and can achieve high surface roughness standards. This is especially critical for parts that require smooth contact surfaces, such as bearings, slides and other parts. 3. Material adaptability: machining can be used for a variety of materials, including metals (such as steel, aluminum, copper), alloys, plastics and even some composite materials. The characteristics of different materials determine the applicable processing methods, machining diversity to meet the needs of different materials. 4. Complex shapes: Through the use of CNC equipment and multi-axis machine tools, machining can accomplish complex geometric shapes, such as curved surfaces, grooves, threads and so on. This allows machined parts to meet a variety of complex design requirements. 5. High production efficiency: machining has a high production efficiency in mass production, especially with the use of automated CNC equipment, it can quickly complete the production of a large number of parts, increase production and reduce costs. 6. good processing stability: machining equipment usually has good stability, to ensure consistency of processing quality, for the need to maintain high precision mass production, this consistency is very important. 7. Good machinability: the design of machined parts is usually considered the convenience of the machining process, part geometry, clamping, tool paths, etc. have been optimized in order to reduce the difficulty of machining and production costs. 8. Wide range of applications: machined parts are used in a variety of fields such as automotive, aerospace, medical, industrial manufacturing, etc., involving almost all mechanical equipment and key components of precision instruments. 💛 💚 💙 If need quotation for our machining service, please contact me.

🔧 At DEKA Surface Technologies, we specialize in high-precision CNC machining of challenging materials such as Inconel, Duplex, and Superduplex. These materials are renowned for their strength and resistance to corrosion, making them ideal for demanding applications but also exceptionally difficult to machine. Not every CNC machining company can handle these materials due to the specialized knowledge and equipment required. 💡 Our extensive experience and expertise enable us to machine these hard metals with exceptional precision, achieving tolerances as tight as 5 microns. Machining Inconel, Duplex, and Superduplex requires more than just advanced machinery; it demands meticulous attention to detail and an in-depth understanding of the materials' properties. Here are some key factors: Tooling: We use specialized cutting tools made from carbide or ceramic that can withstand the high temperatures and pressures involved. Cutting Parameters: Adjustments to the RPM, feed rates, and depth of cut are critical. For example, lower RPMs and higher feed rates help reduce work hardening in these tough alloys. Coolants: Using high-pressure coolant systems is essential to dissipate heat, prevent tool wear, and maintain dimensional accuracy. Machine Adjustments: Precise control of cutting forces and speeds is necessary to avoid deformation and ensure the integrity of the parts. 🔍 Quality is our top priority. Our fully equipped quality control department includes state-of-the-art measurement instruments like Coordinate Measuring Machines (CMMs), form tracers, and surface roughness testers, ensuring every part we produce is flawless. 📸 The photo below showcases some of the small, high-precision parts we've manufactured from Inconel, Duplex, and Superduplex. Each piece represents our commitment to excellence and precision in every detail.

The Advantages of Aluminum Material in CNC While there is a multitude of aluminum alloys with various characteristic properties, there are also some fundamental features that apply to all aluminum alloys. Machinability Aluminum can be rapidly shaped, manufactured, and processed under various treatment processes. It can be easily cut by machine tools due to its soft and easily machinable texture, making it cost-effective and requiring less force compared to processing steel. These characteristics are significant advantages for both machinists and customers ordering parts. Additionally, the excellent machinability of aluminum means it is less prone to deformation during the machining process. Given its ability to enable CNC machines to achieve higher tolerance, and the precision is also enhanced. Strength-to-Weight Ratio Aluminum has a density of approximately one-third that of steel, making it relatively lighter in mass. Despite its lightweight nature, aluminum exhibits high strength. The combination of strength and weight is referred to as the material's strength-to-weight ratio. The high strength-to-weight ratio of aluminum makes it suitable for manufacturing many components needed in industries such as automotive and aerospace. Corrosion Resistance Aluminum demonstrates resistance to scratching and corrosion in typical marine and atmospheric environments. This characteristic can be further enhanced through anodization. It's worth noting that the corrosion resistance varies among different grades of aluminum, with the general-purpose CNC machining grade often exhibiting the highest resistance. Low-Temperature Performance Many materials lose some of their desirable properties below 0℃. For instance, carbon steel and rubber can become brittle in low-temperature conditions. In contrast, aluminum maintains its softness, ductility, and strength even at extremely low temperatures.

🔧 At DEKA Surface Technologies, we specialize in high-precision CNC machining of challenging materials such as Inconel, Duplex, and Superduplex. These materials are renowned for their strength and resistance to corrosion, making them ideal for demanding applications but also exceptionally difficult to machine. Not every CNC machining company can handle these materials due to the specialized knowledge and equipment required. 💡 Our extensive experience and expertise enable us to machine these hard metals with exceptional precision, achieving tolerances as tight as 5 microns. Machining Inconel, Duplex, and Superduplex requires more than just advanced machinery; it demands meticulous attention to detail and an in-depth understanding of the materials' properties. Here are some key factors: Tooling: We use specialized cutting tools made from carbide or ceramic that can withstand the high temperatures and pressures involved. Cutting Parameters: Adjustments to the RPM, feed rates, and depth of cut are critical. For example, lower RPMs and higher feed rates help reduce work hardening in these tough alloys. Coolants: Using high-pressure coolant systems is essential to dissipate heat, prevent tool wear, and maintain dimensional accuracy. Machine Adjustments: Precise control of cutting forces and speeds is necessary to avoid deformation and ensure the integrity of the parts. 🔍 Quality is our top priority. Our fully equipped quality control department includes state-of-the-art measurement instruments like Coordinate Measuring Machines (CMMs), form tracers, and surface roughness testers, ensuring every part we produce is flawless. 📸 The photo below showcases some of the small, high-precision parts we've manufactured from Inconel, Duplex, and Superduplex. Each piece represents our commitment to excellence and precision in every detail.

High-precision gear machining is an important technology in the mechanical manufacturing industry, and its machining accuracy directly determines the transmission performance and service life of gears. However, in the actual machining process, high-precision gear machining faces numerous technical challenges. First, the non-uniformity of materials and internal stress have a significant impact on machining accuracy. Even with high-quality materials, there may be subtle organizational differences and residual stresses inside, which can cause gear deformation or dimensional deviation during the machining process, making it difficult to achieve the precision required by the design. Second, the stability of machining equipment and processes is crucial for high-precision gear machining. The precision and stability of CNC machines, cutting tools, and fixtures directly determine the quality of gear machining. The rational selection of process parameters and optimization of process routes are also key factors in ensuring high-precision machining. However, the adjustment of these equipment and process parameters often involves complex physical and mathematical models, requiring rich experience and professional knowledge. In addition, the impact of thermal deformation and cutting forces on high-precision gear machining cannot be ignored. During the machining process, changes in cutting forces and temperatures can cause thermal deformation of the gears, thereby affecting their precision. Therefore, how to effectively control cutting forces and temperatures, and reduce the impact of thermal deformation on machining accuracy, are important issues that need to be addressed in high-precision gear machining. In response to these technical challenges, a series of solutions can be adopted. For example, by optimizing material selection and pre-treatment processes to reduce the non-uniformity and stress within materials; by improving the precision and stability of machining equipment and processes to ensure the stability and reliability of the machining process; by reasonably adjusting cutting parameters and using coolants to effectively control cutting forces and temperatures, and reduce the impact of thermal deformation on machining accuracy. #Gear Customization #Gear machining

EDM, also known as Electric Discharge Machining, is a process used in manufacturing, especially in the mold-making industry, to remove metal from a workpiece using electrical discharges (sparks). EDM is a non-traditional machining process that utilizes electrical discharges generated between an electrode (usually made of copper or graphite) and the workpiece, which are submerged in a dielectric fluid such as oil. When a high-voltage pulse is applied between the electrode and the workpiece, the fluid ionizes and creates a path for an electrical discharge. This discharge results in localized melting and vaporization of the workpiece material, which is then flushed away by the dielectric fluid. In mold manufacturing, EDM finds extensive application due to its ability to machine complex shapes and hard materials that are difficult to cut using conventional machining methods. For instance, EDM can be used to create intricate cavities, textures, and undercuts in molds made from materials like hardened steel or carbide. The process is also capable of achieving very high levels of accuracy and surface finish. EDM operations are broadly classified into two types: wire EDM and sinker EDM. Wire EDM uses a thin, continuously fed wire electrode to cut the workpiece, while sinker EDM utilizes a solid electrode that is gradually eroded away during the machining process. Both techniques are widely used in mold making, depending on the specific requirements of the mold design and material. By leveraging the precision and flexibility of EDM, mold manufacturers can produce complex and high-quality molds that are essential for the production of various parts and components in industries like automotive, aerospace, and consumer electronics.

🚀 Unlock the Secrets of CNC Machining Success! 🔑 Mastering material selection is crucial in achieving precision and performance in CNC machined components. 🎯 Choosing suitable materials can make all the difference in your projects! To become a pro at picking the perfect materials, consider factors like: ⇉ Stress load and temperature requirements 🌡️ ⇉ Desired precision and tolerances 📏 ⇉ Compatibility with your specific application 🤝 Our team at CH-Tech has compiled a comprehensive guide packed with expert tips and advice on navigating the world of CNC materials. 🌍 https://lnkd.in/gxrZRiVb From metals to plastics to composites, we've got you covered! Don't let material selection stress you out. 😌 Arm yourself with knowledge and elevate your CNC game today! 📈 Drop a comment below with your biggest CNC material challenge, and let's conquer it together! 💪 #CNCMachining #MaterialSelection #ManufacturingMastery #CNCTips #PrecisionManufacturing #EngineeringExcellence #MachiningMaterials #ProductionPerfection

The role of different metals in CNC machining is as follows: Aluminum alloy: It has good thermal conductivity and electrical conductivity, low density, and small cutting resistance of tools during processing, which can adopt high-speed machining and obtain a better surface finish. It is often used in aerospace, automotive industry, etc. Steel: It has high strength and wear resistance, and is suitable for manufacturing engineering applications with high requirements such as mechanical parts and automotive parts. Copper: It has good electrical conductivity and thermal conductivity, and is suitable for electrical connectors and electronic products. Plastics: Common ones include ABS, PC, PMMA, etc. ABS has good impact resistance and moldability, and is often used in the manufacture of home appliance housings and automotive parts; PC has high transparency and excellent high-temperature resistance performance, and is suitable for the manufacture of optical elements and high-temperature tolerance parts; PMMA has high transparency and good weather resistance, and is often used in lamps and decorations. Alloys: Alloy materials combine the advantages of metals and non-metals, and have high strength and good corrosion resistance. Common alloy materials include aluminum alloys, nickel-based alloys, cobalt-based alloys, etc. Aluminum alloys have good machining performance and high strength, and are widely used in aerospace and automotive manufacturing; nickel-based alloys have excellent high-temperature performance and corrosion resistance, and are often used in aero-engine parts and chemical equipment; cobalt-based alloys have good mechanical performance and wear resistance, and are suitable for the manufacture of aerospace and medical equipment.