What is CNC Machining?
Computer numerical control machining, known as CNC machining, is a process to control machine tools via computers in manufacturing industries. In simple words, CNC machining is the most accurate manufacturing technology, digitalization of production, or mechanism. In industries, while manufacturing tools and machines pre-programmed computer software detects all the movements. From grinders and CNC routers to mills and lathes, CNC machining controls a range of three-dimensional tasks on complex machines in a single 3D prompt. From the prompt to guiding the machine with levers, wheels, and buttons, all of this is done by live operators or software engineers. CNC machining is like working like a robot, as instructors program the task into 3D software in the form of a punch card, and CNC machining follows the instruction. From cutting to the complex edges to remove access waste from the device or machinery, CNC machining follows CNC programming and codes and flows the work without any error.
In computer numerical control machines (CNC), programs are typically input using punch cards. On the other hand, CNC machines utilize small keyboards to input programs directly into computers. These CNC programs are stored in the computer’s memory and can be written and edited by programmers. As a result, CNC systems provide significantly greater computational power. Additionally, CNC systems are highly adaptable, allowing for new instructions to be added to existing programs through updated code.
How is a CNC Machine Programmed?
Computer numerical control (CNC) machining is the basic choice of worldwide engineers due to its accuracy and efficiency in manufacturing technologies. CNC machining provides high-accuracy parts directly from a CAD file and can rotate tools around a variety of axes, usually 3 or 5 axes. From designing a CAD model and turning it into G-code, to programming with the G-code, and finally executing instructions, all are successfully transmitted by CNC machining in manufacturing industries.
Basically, engineers programmed CNC machining into three major steps.
Step 1:-
CNC Machine is to design the computer-aided design (CAD) software model of the specific part of machinery. CAD is basically the printed instructions given to the computer to process, as the operator cannot talk to the machine directly.
Step 2:-
is to turn the computer-generated design (CAD) file into a computer numerical control (CNC) program called G-Code. This will create the 2- and 3-dimensional models that understand how the final part will be created.
Step 3:-
to set up the CNC machine with the G-code program. Then the CNC machine operated in the correct manner, removed the access material, and created the final part according to the CAD software.
How does CNC Machining Works?
Imagine!! You have a skilled artisan with no margin for error, and just like that artisan, CNC machining has emerged integrated into the field of production. CNC machining is controlled on the basis of a special concept in which computer-aided design is used. First of all, this process starts with making the design of the product, which is made by giving instructions with the help of CAD. After this, all the instructions are set on a screen, and following these instructions, machine parts are made with the help of CNC machining. Usually, manufacturers follow these sets of instructions when designing the machining parts.
1. Designing the part of the product
The first step to follow while designing the machine part is to take a blueprint. for blueprints of machine parts, engineers and designers use computer-added design card software to create a detailed model of the part. This digital blueprint is the foundation of the entire process.
2. Programming the Machine
After designing the blueprint for machine parts, engineers converted it into a CNC program using computer-aided manufacturing software. CAM programs the machine. This program acts as a set of instructions to guide the machine as to how to move, what tools to use, and how much material to remove to get pinpoint accuracy.
3. Machining the part
After getting instructions via CAM, the CNC machine gets to work, following the program to the letter. It cuts, drills, and shapes the material with incredible precision machining process, creating the part exactly as designed.
4. Quality Control
At this stage, the final product is already manufactured, and after machining, a quality check must be done to meet customer satisfaction. For quality checks, machine parts undergo testing to get the required specifications. This step is crucial, as while undergoing testing, due to the temperature or the slightest deviation, the part’s performance can be affected and damage the machine parts.
The Four Stages of CNC Machining
Usually, computer numerical control and CNC machining work in four stages:
Stage 1: Creating the CAD Model
The first stage in CNC machining is creating the CAD model. In computer control, a 2D or 3D model of the design is needed in CAD software. Manufacturers have to hire expert designers to create complex CNC-machined component designs.
Stage 2: Converting a CAD Model to a CNC File
CNC machines only understand their specific code language, as a CAD model must be converted into G-code. Sometimes CAD software requires CAM software, while sometimes it can directly save files as G-code. The complete G-code process can be done with the help of free tools when there is a lack of CAM software.
Stage 3: Configuring the CNC Machine
Before processing, a CNC machine needs proper setup to perform. The workpiece and CNC machining tools must be positioned correctly and adjusted properly for better performance.
Stage 4: Machining Operation Execution
Once the machine is configured, the CNC program is executed through the display panel. The CNC machine parts will operate until the program ends unless stopped by the operator or due to an error or power disruption.
What are G-code and M-code in CNC?
G-code and M-code are essential commands used by a CNC machine to operate. Each serves a unique purpose.
G-code
G-code basically stands for geometry code. As G stands for geometry, that is the set of instructions given to the CNC machine to move. G-code controls the movement along the X, Y, and Z axes. In CNC machining tools, each number indicates the position of the X, Y, and Z axes. Whether there are some more G-codes available in software that can be used to adjust spindle speed or turn the spindle on and off.
M-code
M-codes refer to given miscellaneous commands while cutting or edging the tools for CNC machining. M0-code is the function that can handle the non-cutting actions of the CNC machine. These include starting or stopping programs, controlling coolant flow, or managing the behavior of CNC machining tools.
Which Common Support Software for CNC Machining is Needed?
Common support software refers to the tools that work together to streamline the CNC machining process, from design to final production.
CAD (Computer-Aided Design) Software
Various tools of computer-aided design are used to create detailed 2D or 3D models of the parts. Examples contains:
- AutoCAD
- SolidWorks
- Fusion 360
CAM (Computer-Aided Manufacturing) Software
Computer-aided manufacturing software is needed to convert the CAD blue-print design into G-code to program further instructions. Some various examples of CAM softwares
are
- Mastercam
- Fusion 360
- SolidCAM
Simulation Software
In CNC machining, simulation software works to understand and validate the whole process before processing, reducing the chance of future errors. These programs are:
- VERICUT
- Simul CNC
Post-Processing Software
In CNC-machined components, this is the software used to optimize the G-code to ensure it is compatible with specific CNC machines. This software works with programs
like:
- PostHASTE
- GibbsCAM
CNC Control Software
To interpret G-code and control the CNC machine’s movements during machining, the common CNC control support software works like the backbone of CNC machining. Some common programs using this software are:
- Mach3/Mach4
- LinuxCNC
Key Features of CNC Machining
Work finishing:
with the use of CNC machining, each and every cut, turn, and drill during production is executed with pinpoint accuracy and efficiency.
Automation for Efficiency:
Digitalization of Machines Results in fast production and a lower error percentage with just a few manual interventions to control machinery.
Versatile Applications:
the creation of complex parts of machinery can be typical and risky with human labours, but CNC machining assures accuracy and efficiency to create complex parts that require intricate designs and tight tolerances. With its versatile range, it is ideal for the aerospace and automotive industries too.
Cost-effective:
with the one-time installation of CNC machining, manufacturers not only increase work accuracy and efficiency but also decrease labour costs. It directly affects the price reduction of products.
Various Types of CNC Machines
CNC machining is always designed according to the complexity and nature of the material. Hence, it is not possible to invent them so that the same size fits for all processes. Till now, these types of CNC machining are available on the market.
CNC milling machines
● CNC milling machines can be used as rotating cutting tools to remove material from a workpiece.
● Ideal for complex shapes and multiple features.
CNC Lathes
● This type of CNC machining is used to create cylindrical parts.
● Ideal for making shafts, pulleys, and other round components.
CNC Plasma Cutters
● Used for high-velocity jets of ionized gas
● Ideal for cutting large sheets of metal quickly and accurately.
CNC Laser Cutters
● These machines use a focused laser beam to cut materials.
● Ideal for cutting intricate designs.
CNC routers
● Used as a milling machine
● Ideal for cutting delicate materials like wood, plastic, and foam.
CNC Machine Type | Primary Function | Ideal For |
CNC milling machine | Cutting complex shapes | Metal and plastic parts |
CNC Lathe | Creating cylindrical parts | Shafts, pulleys |
CNC Plasma Cutter | Cutting large metal sheets | Metal fabrication |
CNC laser cutter | Precision cutting and engraving | Intricate designs |
CNC Router | Cutting softer materials | Wood, plastic, and foam |
Application of CNC Machining
Industry | Applications |
Aerospace | Engine components, structural elements |
Automotive | Engine blocks, transmission parts |
Medical | Surgical instruments, implants |
electronics | Connectors, housings |
Industrial Manufacturing | Gears, bearings, and custom tools |
Benefits of CNC Machining
CNC machining is not just the digitalization of manufacturing units; it is the backbone or lifeblood of modern manufacturing. These are some of the useful and demanding benefits of using CNC machining.
Tolerance power
Highest tolerance power with exact specifications and can achieve the minority of accuracy at 0.001 inches too.
Consistency and accuracy
Ideal for producing identical parts every time, free from manual human error, and providing more consistency.
Efficiency
With higher rates of efficiency, CNC machining can lead to faster production cycles.
Flexibility
Can be programmed to create a wide variety of parts, making them versatile tools for any industry.
Cost-Effective
One-time investment for industries for large-scale production, as human labour can be more expensive and time-consuming. although CNC machinery results in a reduction in labor costs, increased production speed makes it a cost-effective solution in the long run.
Materials Compatible with CNC Machining Tools
When it comes to materials used in CNC machining, there’s no shortage of raw materials in manufacturing industries. Basically, various types of hard materials are used in making CNC machining tools. Some of the most common materials used in CNC-machined components are metals, alloys, plastic, and wood. Common tolerances for machining metals or plastics are around ± 0.125 mm, or 125 microns. Features with a tighter tolerance down to ± 0.050 mm can be manufactured. and even tolerances of ± 0.025 mm are feasible. That’s about a quarter the width of a human hair. Let’s discuss some common materials used as CNC-machined components.
1. Alloys
In the CNC machining process, alloy materials like stainless steel, carbon steel, and brass are used to make various CNC machining parts.
- Stainless steel: with its physical qualities of hardness, stainless steel is the purest and most popular variety of steel, always used for shaping in CNC machining.
- Carbon steel: with its properties of being cheaper and stronger than steel, carbon steel has a wide scope to shape CNC machining components with high accuracy.
- Brass: a soft and corrosion-resistant material available in various varieties with varying proportions of zinc and copper, is used as a perfect material to be CNC machined.
2. Metals
Metal is commonly a hard material, and that is why it is most probably used in CNC machining. Manually machining metal can be slow and less productive, That’s why CNC machines offer a faster and more accurate way to produce CNC-machined components. Various metals used in CNC machining are:
- Aluminum: aluminum has a high strength-to-weight ratio and is ideal for creating lightweight CNC machine parts that still require good strength.
- Magnesium: Magnesium is 33% lighter than aluminum and perfect for CNC-machined components in electronics, such as laptops and mobile bodies; these components need less weight.
Titanium: Titanium is extremely tough and is used to create high-grade CNC machining parts for aerospace, military, and other demanding applications.
3. Plastic
- CNC machines can also shape plastic parts. Common plastics used in CNC machining include:
Ultra High Performance Plastic
- PEEK (Polyether Ether Ketone)
- PFSA (Perfluorosulfonic Acid)
- PI (Polyimide)
- TPI (Thermoplastic Polyimide)
- PAI (Polyamide-Imide)
- HTS (High-Throughput Screening)
High Performance Plastic
- PPSU (Polyphenylsulfone)
- PEI (Polyetherimide)
- PESU (Polyethersulfone)
- PSU (Polysulfone)
- PARA (Polyarylamide)
- PPS (Polyphenylene Sulfide)
- PPA (Polyphthalamide)
- LCP (Liquid Crystal Polymer)
- HPN (Hyperform Polypropylene)
- PTFE (Teflon)
Technical Plastics
- PC (Polycarbonate)
- ABS (Acrylonitrile Butadiene Styrene)
- MABS (Methacrylate Acrylonitrile Butadiene Styrene)
- ASA (Acrylonitrile Styrene Acrylate)
- PMMA (Polymethyl Methacrylate)
- PVC (Polyvinyl Chloride)
- PBT (Polybutylene Terephthalate)
- PET (Polyethylene Terephthalate)
- POM (Polyoxymethylene)
- PA 6 (Polyamide)
- PA 6.6/PPE (Polyamide/ Polyphenylene Ether)
- PA 12 (Polyamide)
- TPE (Thermoplastic Elastomer)
- TPU (Thermoplastic Polyurethane)
Standard Plastics
- PS (Polystyrene)
- PVC (Polyvinyl Chloride)
- PP (Polypropylene)
- HDPE (High Density Polyethylene)
- LDPE (Low Density Polyethylene)
- Nylon (C6H11NO)n
- Delrin (Acetal)
- UHMW (Ultra-High-Molecular-Weight Polyethylene)
The Bright Future of CNC Machining Parts
In manufacturing industries, more demands require more supply. But with the help of human labour, manufacturers are unable to fulfill market demand. To solve this imbalance, CNC machining stands as a vital tool in industries. CNC machining allows for more accuracy in automotive manufacturing. Industries earn fruitful results with the help of CNC machining in the production area, as it results in consistent and high-quality parts. With the help of CNC machining, manufacturers can expand their production as it tirelessly turns raw materials into the finest product without any error and offers finishing like traditional craftsmen.
Increased automation
Digitalization and development of high-scale CNC machining materials
Sustainable Manufacturing and Development
Complex and intricate CNC machine parts.
Customization at Scale
Petron Thermoplast is the Best Choice for your CNC Manufacturing Needs
In the world of manufacturing, technology like CNC machining has emerged as a game changer and the backbone of industrialization. When the question of choices stands in front of you, what should you choose, or what is the best choice? Petron Thermoplast stands out in the market as a prominent supplier of CNC machining parts. We, with the experience of 10 years in CNC machined components, have perfection and expertise with our highly educated engineers and staff. We are standing in the market with dedication and goodwill to provide higher-quality services and customer satisfaction. We understand the value of words and customer service, which makes us the most demanding company in CNC machining tools. We value your company’s requirements and demand, which motivates us to produce specially designed custom machining parts and components to fulfill your company’s needs. So, if you need the best for your company, always choose Petron Thermoplast for your company’s bright future.
Parts of CNC Machine that makes by Petron Thermoplast
Petron Thermoplast, being involved in high-performance thermoplastics and manufactures various CNC machine parts, particularly those that require precision, high strength, chemical resistance, and thermal stability. Some common CNC machine parts that could be made by Petron Thermoplast include:
1. CNC Spindle Components
Parts like bearing cages or spindle insulators made from PEEK can handle high temperatures and mechanical stress.
2. Guide Bushes and Bearings
PEEK bushings or bearings provide low friction, high load-bearing capacity, and can operate in harsh environments without needing lubrication.
3. Wear Plates
Made from high-performance thermoplastics like PEEK, wear plates resist abrasion and can withstand high temperatures in CNC operations.
4. Insulation Parts
Electrical insulation components made from PEEK offer high dielectric strength and resist high temperatures.
5. Sealing and Gasket Components
PEEK seals and gaskets can handle high pressure, chemicals, and temperatures, making them ideal for CNC systems operating in extreme conditions.
6. Component Mounts and Housings
Thermoplastic housings or mounts for CNC machine parts, which require lightweight but strong materials, may be made from PEEK or other engineered plastics.
Conclusion
By applying the process of CNC machining, manufacturers can increase the efficiency, accuracy, and quality of producing complex machine parts. With the establishment of CNC machining in aerospace, automotive, or any other industry, manufacturers can win the rat race of modern industrialization.