How to reduce the deformation of machining parts?

In machining process, the deformation of machining parts often happened ,and it’s difficult to solve. In order to take corresponding measures, let's study the reasons.

1.The material and structure of machining parts 

The degree of deformation is proportional to the complexity of shape , length ,width and wall thickness. And it’s also proportional to the rigidity and stability of the material. Therefore, when designing the parts, we should reduce the influence of these factors on the deformation. Then ,for some parts with large structure ,we should design a reasonable structure to reduce the deformation.

2. The clamping

First, we need to choose the right clamping point. Then, we should select proper clamping force at this position, and keep clamping point and the supporting point in line .So the clamping force will act on the supporting point. Importantly ,the clamping point should be close to the machined surface as far as possible, and select the position where the force is not easy to cause the deformation.

And we need to pay attention to the order of clamping force when there are several clamping forces on machining parts. First ,we should act the clamping force of machining parts and the supporting point, then act the clamping force of the cutting force.

Then, we should increase the contact area between the machining part and the fixture and use axial clamping force to enhance the rigidity of the machining part.

3. The processing

In the process of cutting, the machining part will produce elastic deformation due to the effect of cutting force. For similar deformation ,we can adopt harp cutting tool .On the one hand ,it can reduce the resistance between the tool and the machining part , on the other hand, it can improve the heat dissipation ability of the tool when cutting machining parts, thereby reducing the residual internal stress of the machining parts.

The heat generated by friction between cutting tool and machining part will also deform the machining part . Generally, we can adopt high speed machining to reduce deformation effectively.

In order to ensure the accuracy of machining parts, we should use a reasonable amount of cutting. And When machining thin-walled parts with high precision, generally, we will adopt symmetrical machining . Because it will balance the relative stress on both sides ,achieve a stable state and make the machining parts that after machining smooth.

What to consider during Copper Machining Process?

Copper is high purity, dense tissue material, with low oxygen content, Pore-free and excellent electric conductivity,suitable for precision machining, has good thermal conductivity.But the strength, the hardness is less.a large number of products are used to electric industry.

Since the material character,we should consider below point during precision machining process.

1. Soft material,easy to stick tool,the tool knife be used should be very sharp.

2. Small feeding with high speed.

3. For complex product,complete all dimensions include thread holes by 5 axis CNC machining to save clamp times,avoid scratch during several machining steps.

4. For some mark letter requirement,it's better marking by CNC machining,the appearance is not good if do it by laser marking.

5. Finish.generally do nickel plating for copper product to avoid surface oxidation,if without any surface treatment,it's better to put the copper machined part in vacuum plastic bag after cleaning process.

8 Top way to save money on precision machining

keep cost-effective design to reduce costs and save money on precision machining.

1.Material select

Select raw material with good machining performance,such as AL6061,Mild steel.
On the premise of ensuring the performance of the product,avoid expensive materials.

Size of material，try to use the material thickness (diameter) available on the market,especially for tube,if can find suitable size of tube for your product without machining inner surface,that would save more money.

2.Order Quantities

Order large quantities of same part to reduce unit price.For a small number of orders, if need to use CNC machine, the cost will go up more.Because each kind of product be done by CNC machining including programming,fixture making, machine commissioning, these labor costs be calculated in the unit price of the product.

3.Structural design of parts

Keep simple shape,the simpler the geometry of the parts surface,the better the machining process.Split up complex parts,especially for parts with deep pockets or multiple faces,may design and machining as separate simple parts,then weld or bolt together.

4.Internal corner

Use an in side corner radius 0.03" Min for tool diameter.

5.Relief groove

Gear,thread, keyway processing must have a relief groove,otherwise the tool will be damaged. Keyway, pin hole is arranged in the same direction,the height of the orifice should be the same plane,for one installation.

6.Hole depth

If can use thru hole,don't use blind holes.
Avoid deep holes (depth is 10 times larger than diameter.

7.Tolerance management

Limit tight tolerance,the lower the average manufacturing accuracy of the parts, the better the structure of the
product.According to the function of product requirement,assign tight tolerance to critical features,keep all other feature as standard tolerance +/- 0.005".

8.Surface roughness

When it comes to surface roughness specifications,use N6~N7 is easy to reach by turning or milling, up to N5,the surface would be done by grinding or polish,the cost would be increased 30%~40%。

5 Axis Milling Technology

5 Axis Milling Technology

Dec,28th.2017.

In order to better meet the needs of customers and process high quality complex machined parts,SYM brought in 2 sets of 5 Axis Milling Machines.

Brand: DMG MORI
Type: DMU95 MonoBlock

Whether for the classical 5-sided milling operation or 5- axis machines for the premium class of highly precise simultaneous machining, the availability of a wide series ranging from basic to high tech form the complete spectrum of an efficient milling technology.

DMG MORI opens the perfect way to make use of automatic 5- sided machining right and even challenging 5-axis simultaneous milling.This process not only ensures productive flexibility, but also high cutting performance and maximum precision coupled with high dynamics and excellent accessibility and ergonomics.

5 Axis milling technology, apart from the geometrical variety resulting from the 5- axis performance, task- optimized spindle alternatives guarantee perfect general conditions in all the areas of application of the CNC milling technology.

The range extends from materials that are difficult to cut, e.g. in the aerospace industry, to those which require highest accuracy and surface quality in the area of precision machining.

Any Precision Machining Needs,please contact us for instant RFQ.