Complex geometries and demanding tolerances are desired and sought after by the manufacturing industry. As a result, Precision CNC Machining is widely used by manufacturers today. This production process is essential in the manufacturing sector.
Precision CNC machining, solely, relies on computerized machine tools. In other words, computer numerically controlled cutting tools will perform an automated manufacturing procedure. The computerized machine tools are going to precisely remove material with high repeatability and accuracy.
Our highly skilled team of machinists, here at P4Swiss | Lindel CNC Machining, had the opportunity to fabricate extremely intricate CNC machined parts that, ultimately, required great detail - an offset cam shaft. The offset cam shaft that we manufactured is going to be used in robotics - particularly for a robot part or a device - at Boardwalk Robotics, Inc. The cam shaft contains a metal rod that has offset lobes attached. Simply put, a cam shaft’s function is going to turn a reciprocal motion into a rotational motion. Not only that, but it can additionally be operated from the rotational end, where the reciprocal motion is the desired result.
A Swiss style lathe was unable to successfully manufacture this offset cam shaft. However, a Swiss CNC Machine and a 5-axis CNC Mill Machine were both necessary to complete the precise features of this machined part.
What Is Swiss CNC Machining?
Swiss CNC Machining can, also, be referred to as Swiss screw machining or Swiss turning. This fabrication process is utilized to machine small and intricate components that have tight tolerances.
A Swiss CNC machine consists of two main parts - a sliding headstock and a guide bushing. A sliding headstock will have cutting tools that are securely mounted to it. The cutting tools will operate along the surface of the stock material. They are going to repeatedly move in and out, accurately cutting the material into the shape that is desired. The guide bushing is what will support the stock material, as it is passing through. A guide bushing will specifically reduce vibrations during the production operation, which will, in turn, increase the accuracy and improve the surface finish of the machined part.
Advantages of Swiss Screw Machining:
- Reduced cycle times
- Increased production efficiency
- Better accuracy and precision
- High repeatability and consistency
- Improved surface finish
Swiss CNC machines have the ability to manufacture numerous intricate features on a workpiece simultaneously - even if it has a small diameter - because of the precise tool positioning, vibration damping techniques and high rigidity.
The Swiss CNC Machining Process:
01) Bar Feeding
The stock material is going to be loaded into the machinery, while also being securely supported by the guide bushing.
Moving along the edge of the material is the sliding headstock, which will utilize cutting tools to accurately form the material into the specific shape that is desired. A guide bushing is going to hold the stock material in place.
Additional computer numerically controlled cutting tools will be mounted on the sliding headstock, in order to precisely manufacture a more intricate feature on the stock material. For instance, machining a complex opening like slots or holes.
04) Parting Off
Once the entire production operation is complete, the remaining stock material from the project is going to be cut off, disconnecting the machined part from the excess material that is left.
The final product is, essentially, ejected out of the machinery. Then, the machined part is processed or assembled, if need be.
What Is 5-Axis CNC Mill Machining?
The 5-axis CNC mill is a milling machine that can simultaneously move the cutting tool along five separate axes. Precise and complex components can be successfully manufactured with the 5-axis CNC mill machinery.
The more traditional mill machines are, generally, restricted to only three axes of motion, which includes X, Y and Z. When it comes to a 5-axis CNC mill, two additional axes of motion are added to the cutting tool technique - A and B. This is going to allow a workpiece to be machined on from a variety of sides and angles.
A and B axes of motion on the 5-axis CNC milling machine will distinctively control the rotation of the cutting tool, particularly around the X and Y axes. The X, Y and Z axes, on the other hand, are going to control the linear movement of the cutting tool down those three axes. With these additional motions that have been incorporated into the milling process, versatility and greater flexibility are provided, making certain that a more intricate feature or shape can be effectively produced in just one individual setup.
The 5-Axis CNC Milling Process:
01) Programming the Design
A 3D model of the part is created in the CAD software. Then, the CAM software will generate the toolpath of the cutting tools. This is the programmed instructions that the CNC machine will follow, so that the desired shape can be efficiently produced.
The specific workpiece is to be securely attached to the milling machine’s table. The cutting tool will, then, be mounted to the machine’s spindle. The machine will also be calibrated, to ensure accuracy.
A large cutting tool will be cutting off the excess material from the workpiece. The cutting tool is going to machine along three axes (X, Y and Z). Whereas, the workpiece is going to rotate around the two axes that have been added (A and B).
A small cutting tool will be performing the finishing cutting operations. This includes the smoothing and polishing processes on the surface of the workpiece. The cutting tool will follow the same 5-axis motion cutting instructions.
05) Inspection & Quality Control
Utilizing precision measuring tools, the machined part is carefully inspected. As a result, each part is guaranteed to properly meet the necessary requirements and specifications. If needed, modifications or adjustments can be made, prior to the approval of the machined part.
High Quality Precision CNC Machining
P4Swiss / Lindel CNC Machining can offer you an all around improved experience on your CNC manufacturing project. We are dedicated to providing highly qualified CNC parts. The components that we fabricate are used in various products, for a variety of applications. Precision CNC machining is, especially, ideal for a wide range of industries. Our machine shop particularly specializes in and offers: