Precision Manufacturing and When is it Important to Use?
Precision manufacturing is what happens when a design is developed that requires highly accurate components and is made into a workable part. There are many industries that have very precise tolerance that has to be exact. When it comes to parts for the aerospace industry, for example, this precision can save lives.
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Engineers will design a product or piece for a machine that has certain requirements. It is then up to the machining for manufacturing to get it to the right specifications. There is a lot of pressure to not only build these precise parts but to do it quickly and on budget as Mexico's growing electronics manufacturing industry clearly shows.
In this article, we will go over what this manufacturing process is like and when it is used.
CNC machines
A CNC machine is the best way to make precision parts. It lathes the surface of a piece of material like aluminum or other metal with precise dimensions and tolerance. The idea is that it subtracts material in a multidimensional way until it reaches the exact dimension to make something new. Some of the machines are exact up to a few microns.
The technology is what makes these machines as precise as they are. In the past, it required human labor to make the parts. The tolerance had to be manually measured which means that there could be some errors involved since the measurement devices couldn&#;t get that accurate.
These days, CNC machines use more technology. The use of software for control and monitoring has made huge progress with regard to precision manufacturing. The operator of the machine now is responsible solely for making sure the software is working and that the machine is not malfunctioning in any way. It is a far more automated process. For instance, one of the essential applications of these innovative machines is CNC punching.
It refers to the process of punching shapes into sheet metals through a programmable machine. This moves the sheet metal to accurately place it under the punching ram, allowing the precise replication of the target design.
CNC punching has several advantages, such as reduced waste, minimized costs, and faster production. This also means that manufacturing companies can produce as many parts as they want with fewer materials.
With these things in mind, there&#;s no question why CNC punching is in demand for businesses with fabrication needs. You can check out services offered by reliable companies like Alroys Sheet Metal, among others, to learn more.
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Accuracy and precision
There is the problem of getting diminishing returns when trying to get as accurate as possible. The irony is that accuracy and precision are not always the same thing. When dealing with accuracy, it involves being as close to the target value as possible on a piece. This is desirable, but the objective is to have the accuracy be the same from one piece to the next. That is precision.
To be profitable, it is important to have a certain tolerance. This is how much deviance is acceptable from the desired accuracy. The higher the tolerance, the more expensive it can be to make the product. It&#;s essentially a balancing act. However, when dealing with precision, it needs to be as accurate as possible for each piece when dealing with potential dangers.
Precision doesn&#;t necessarily only relate to CNC punching. For example, rotary jet mixers, a versatile and efficient tool in precision manufacturing, play a pivotal role in achieving accurate and consistent results. These industrial powder mixing equipment employ high-speed rotary motion to blend and homogenize liquids, ensuring a uniform composition that is critical in various manufacturing processes. By swiftly and thoroughly mixing different components or substances, rotary jet mixers enable precise control over chemical reactions and the production of high-quality products.
Benefits of precision machining
There are quite a few reasons to use precision manufacturing for a product. Not least of which is the accuracy. There is also greater reliability when using these processes. If the slightest error could result in a disaster, then it pays to have this kind of precision and reliability of the product itself.
A secondary benefit is that there is a fast turnaround from this type of manufacturing even with very high tolerances. The precise abilities of the machines don&#;t detract from getting the parts done quickly.
Precision machining is beneficial in more ways. For instance, it can help minimize the businesses&#; staffing needs since CNC machines can handle recurring tasks. It can also reduce the resources spent on raw materials because all parts are made with accuracy and precision.
Additionally, precision machining can ensure safe production. Instead of depending on human hands to manufacture precision parts, businesses can use CNC machines to keep the process as safe as possible. This cuts the rate of accidents and injuries in the workplace.
With these facts in mind, precision machining truly plays a crucial role in various industries, particularly those specializing in manufacturing and other related processes. Consider implementing it as part of your regular operations and see the results for yourself.
What Is Precision Manufacturing?
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Our guide to precision manufacturing will take you through what it is, how it works, and why it matters in any industry that strives to elevate quality, work quickly, and cut costs.
Precision Manufacturing: What Is It?
Precision manufacturing involves creating highly accurate and workable components from designs. It requires using tools like computer numerical control machines to remove areas from a piece of material until you have made a complete shape.
Accuracy is becoming more critical as parts become smaller. Precision engineering focuses on component design, while precision manufacturing is about the creation. CNC machines can cut pieces to precise specifications, small and accurate parts with tight tolerances &#; or little room for error.
Precision manufacturing has significant benefits in a world where users need accurate, high-quality products quickly and on budget. Manufacturers have evolved their processes over the years, and the addition of innovative technology that integrates machines with advanced computer programming allows them to respond rapidly to the evolving market.
The Core Principles of Precision Manufacturing
Precision manufacturing arose from the need to create components that work effectively and withstand the rigors of everyday life. The most notable difference between typical manufacturing and precision manufacturing is that the latter focuses on high tolerances. It produces components with greater accuracy, fewer defects, and high repeatability &#; the ability to perform repetitive tasks without deviation.
In addition, precision manufacturing applies lean principles, implementing efficiency, and waste management throughout the manufacturing process. Producing precision parts results in excess material, as the process requires removing pieces until only the final product remains. CNC machines reduce human error and, therefore, unnecessary waste. Precision manufacturers are always looking for ways to decrease scrap further, allowing the customer to benefit from cost savings on bulk orders.
Continuous improvement is another core principle of precision manufacturing, and constant technology advancements regularly enhance the process. Many precision manufacturers adopt a culture of continual improvement and commit to looking for methods to make the process faster, cheaper and more reliable.
Methods of Precision Machining
Precision machining is a high-velocity process used in precision manufacturing. It relies on machine tools controlled by computer software for producing components.
CNC machining starts with engineers or designers who use computer-aided design software. They translate their designs onto a computer-aided manufacturing file, instructing the CNC machines about the tools and processes. CNC machining is a broad term that can include milling, drilling, boring, tapping and turning.
Depending on the application and requirements, several precision machining methods are available.
- CNC milling:Rotary cutters remove material from a workpiece in this subtractive process. Users can change the tool, direction, pressure, cutting speed, and angle to create different components.
- Multi-axis CNC machining:Many CNC machining tools have multi-axis capabilities, which means they can perform several processes simultaneously. This innovation saves time in machine setup and component creation.
- Swiss machining:This type of CNC machine creates parts by bringing stock to the tool, while typical CNC machines do it the opposite way. They are highly accurate and often run unattended for prolonged periods, reducing labor costs.
- CNC turning:In this method, the workpiece rotates on a central axis, while a single-point cutting tool moves linearly to remove material.
- Precision grinding:Precision grinders perform one of the final steps in the manufacturing process. Abrasive grinders create a flat surface on components with a smooth finish and produce close-tolerance finishes by removing any excess material.
- Electrical discharge machining:This precision machining method uses sparks to shape metals. It brings the tool and the workpiece close together to create an electrical arc. This process raises the electrode&#;s temperature and melts the metal. Often, EDM is an ideal choice for hard metals, which can be challenging to shape with other CNC machines.
- CNC laser machining:As the name suggests, this method uses a high-frequency laser beam to engrave or slice workpieces. While EDM only works on metal components that conduct electricity, laser machining is suitable for metals and non-metals.
Precision Manufacturing Industries and Applications
Precision manufacturing is essential for many industries and applications due to its tight tolerances, repeatability, and capacity. It has many applications in tooling and creating finished products, but some of the most common include the following.
- Prototyping: Many industries require accurate reproductions of a design. Precision manufacturing is ideal for creating detailed and precise prototypes of many designs.
- Automotive: Automotive applications require intricate components for engines, chassis, and more. Precision manufacturing makes many of these parts.
- Medical: Technology has changed the face of the medical industry, and advanced machines can even perform surgeries. Medical components require micro-level detail, made possible by precision manufacturing.
- Aerospace: Aerospace applications need the most advanced and reliable equipment and machining tools, suitable for rugged and durable materials. Precision manufacturing can create the quality of components required for aerospace performance and safety.
- Defense: Similar to the aerospace industry, defense requires components that maintain reliability in even the most challenging conditions. Precision manufacturing has applications across the defense industry, from developing prototypes to full-scale pieces.
- Electronics: Precision manufacturing enables the miniaturization of complex electrical components used in many consumer electronics applications, such as computers and cell phones.
The Future of Precision Manufacturing
Precision manufacturing continues to aim to enhance the accuracy, quality, speed, and cost of creating intricate parts. Technology has already changed the face of manufacturing, and we can look forward to more exciting innovations in the future. The Industrial Internet of Things could result in real-time monitoring of operating conditions by embedding sensors. Adding multiple axes to CNC machines will make them more flexible, increase accuracy, and boost manufacturing speeds.
In addition, sustainability continues to be a primary concern across industries due to the consumer demand for renewable resources and carbon footprint reductions. Precision manufacturing processes must evolve to reduce carbon emissions and leverage renewable sources to align with this global need.
In short, the future is bright for precision manufacturing. It has always been a flexible and innovative process, and this trend is likely to continue.
Stay Ahead of the Curve With Setco
Precision manufacturing relies on quality tools to achieve accurate and reliable components. Setco has been in business since , and we specialize in rebuilding, manufacturing, and repairing spindles, milling heads, and other components to provide reliable and efficient precision parts across industries. At Setco, we pride ourselves on helping you achieve the speed, quality, and flexibility you need to stay ahead of the curve in a competitive field.
Our expertise, experience, and global resources make us the world&#;s largest independent spindle rebuilder. We have the tools, knowledge, and state-of-the-art equipment to deliver precision parts fast, on budget and to your specifications. Learn more about our precision parts manufacturing and sourcing capabilities, or contact us today to learn more.
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