In the realm of CNC Machining, not all materials are created equal.
Some materials - like aluminum and steel - present routine challenges that most machine shops are equipped to handle. However, other materials - like tungsten - raise the bar. As a matter of fact, Machining Tungsten can overwhelm even the most experienced machinists with its complexity.
This blog post delves into a fascinating case study in which our team at P4Swiss/Lindel CNC Machining rose to the challenge. Essentially, we engineered a successful strategy to manufacture a particularly demanding tungsten part that many other machine shops refused to even consider.
The Challenge: Machining Tungsten Material
Tungsten is known for its high melting point, hardness and density. For this reason, it is notoriously difficult to machine.
When a customer approached us with the need to manufacture a part that is made of this formidable material, we understood the gravity of the challenge.
A majority of our competitors had declined the project, due to the difficulties that are associated with machining tungsten material. But, in spite of that, we at our facility view these challenges as opportunities to showcase our skills and capabilities.
Developing a Strategic Approach for Machining Tungsten
The initial steps in tackling this project involved detailed planning and strategy formulation. Recognizing the complexities of machining tungsten, we considered various methods to approach the task.
Initially, we planned to use an EDM (Electrical Discharge Machining) sinker to create the necessary cavity in the part.
EDM sinkers are oftentimes used for hard metals like tungsten, as they do not require direct contact with the material. Therefore, avoiding many common machining challenges.
However, after further analysis and testing, we discovered that we could achieve the desired results more efficiently using the 5-axis CNC machining method. This approach not only simplified the process, but also kept all operations in-house. Overall, this was crucial for maintaining control over the quality and timelines of the project.
What Is 5-Axis CNC Machining?
5-axis CNC machines offer a specialized and advanced manufacturing process that has the ability to fabricate complex parts and components.
CNC refers to a Computer Numerically Controlled operation. In other words, the manufacturing process is completely controlled by computer programs that precisely guide the cutting tools and the cutting technique of the machine.
The cutting tool can move in five different directions on a 5-axis CNC machine.
- The x-axis is a horizontal movement from left to right
- The y-axis is a horizontal movement from front to back
- The z-axis is a vertical movement that moves up and down
- The a-axis rotates around the x-axis
- The b-axis rotates around the y-axis
5-axis CNC machining is commonly used in various industries, where the production of highly detailed and intricate components are required. For instance:
- defense/military CNC machining
- aerospace CNC machining
- medical CNC machining
- precision engineering
Refining the Process of Machining Tungsten
To determine the most effective approach, we developed two different CNC program versions. After careful evaluation and testing, we selected the program that offered the best chance of success. The chosen strategy certainly included several intricate steps:
1) Material Preparation: The first step involved squaring up the tungsten block to prepare it for precise machining.
2) Cavity Removal: Using the 5-axis CNC machine, we meticulously removed material from the cavity. This step required precision to ensure that the integrity of the surrounding material was not compromised.
3) Machining the Groove: The next challenge was machining a groove on the inside of the short wall of the part. Given the wall's minimal thickness—only 0.025 inches—this was particularly challenging. It not only required precision, but also an innovative approach to tooling and speed adjustments.
Overcoming the Biggest Challenge
The most significant challenge in this project was maintaining the integrity of the extremely thin wall during the machining process. The risk of breaking such a thin piece of hard material was high. As a result, it required every ounce of our team’s expertise and careful handling.
The precision in CNC programming and the execution of machining operations were critical to ensuring the part was made to specifications without any material failure.
The Outcome: Success and Customer Satisfaction
Upon completion of the CNC machining process, the tungsten part underwent thorough inspection and testing to make sure it met all quality and design specifications.
Our ability to keep all operations in-house contributed greatly to the successful outcome. Not to mention, it ultimately allowed for tighter quality control and quicker adjustments during the process.
The customer was extremely satisfied with the outcome. Not only did we deliver a part that many other machine shops had refused, but also provided an innovative approach that reduced the need for additional outsourcing and potential complications.
Why Choose P4Swiss/Lindel CNC Machining for Your Manufacturing Needs?
![[360° imagery - white background] cnc machining tungsten material](https://precisioncncmachining.com/wp-content/uploads/2024/07/360°-imagery-white-background-cnc-machining-tungsten-material.gif "[360° imagery - white background] cnc machining tungsten material")
This project is a testament to our commitment to excellence and innovation in CNC machining.
By choosing to tackle a project that others had turned away, we demonstrated our capability to handle even the most challenging materials and specifications.
For anyone looking for a CNC shop that goes beyond the norm, pushing the boundaries of what's possible in CNC manufacturing, we stand ready to deliver. Whether it’s tungsten or any other challenging material, our team is equipped with the knowledge, technology and drive to transform complex problems into precision-engineered solutions.
If you have any questions or would like to submit your own custom CNC request for quote (RFQ), please do not hesitate to contact Tony Torrez at tony@p4swisslindel.com, call us at 520.792.3160 or click the “Request A Custom CNC Quote Today” button below.
