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.

You must to know material specification for tube machined project

Case Study: It is very important to know material specification for tube machined project.

We get a order of tube machined parts from a Canadian customer in October,big diameter with 65" long,C1020 material, OD 8" x 0.75" wall, it's difficult to buy this inch tube in China,unless make mold specially,but the MOQ is 10T.

The offer we provided to customer is based on OD8 x0.78" with out machining inner diameter.When we book the raw material HRS tube,we found the surface of inner diameter is very rough,with rusty black skin,it is not possible to used for precision machining parts if the inner diameter without machining.

We have difficulty now,it is easy to machining OD ,but we don't have a bility to machining ID for so long tube.Due to complete this project for customer,we began to search the tube with smooth inner surface.It is called grinding tube,rough OD and smooth ID.Material cost twice as much as HRS tube.The inner diameter is bigger 0.08" than HRS tube.After confirmation of the dimensions changing with customer,we start working on it.

We found a new problem in the process,since the thickness of grind tube is uneven,the difference is about 0.078",so there is somewhere of outer diameter not processed,if increase the tool feed,the smaller diameter will be obtained and the wall thickness will be thinner than the tolerance requirement of the drawing.Communicate with customer again,we get instruction is that make sure the dimensions and ignore the appearance.

In Turning Process

One month, we finally finished this project, although no profit, but we completed the order.In business, honesty is more valuable than money.Through this project, we have deeply realized that the earlier quotation work needs to be more detailed,especially for tube machined parts,we should know more details of raw material,such as the tube specification,surface roughness of tube,dimensions tolerance.

If the customer can consider the existing specifications of the market materials in the design,Design reasonable size according to the application demand of the product,Will reduce material cost and processing cost.

How to reduce the distortion of Delrin machined parts during processing?

POM/ Delrin. Thermoplastic crystalline polymer,it is known as 'super steel',with high mechanical strength and rigidity,strong impact resistance,used for widely temperature range (-40℃~120℃).

At present,the Delrin as lower cost of plastic,It is replacing some of the markets that have traditionally been dominated by metals.For examples,alternative zinc alloy, brass, aluminum and steel parts.Has been widely used in electronic electrical, mechanical, instrument,daily light industry, automobile, building materials, agriculture and other fields.

But it's not easy to process.The delrin machined parts is easy to deform during processing. SYM precision team always machining the delrin machined parts slowly,and comply below steps.

1. Annealing the raw material first.

2. Cutting standard material with more machining allowance (10mm~20mm).

3. Try to process more steps,take a long time (12~ 24hours)to let the delrin part cool down during every steps.

4. use as little force as possible to hold it during machining,or use glue instead of clamps to fix the product during process.

5. Use high speed steel tool instead alloy steel tool,because the high speed steel tool is very sharp,the heat produced is small during the cutting process.

6. Keep small cutting output during the process.


Even we did all above,there still exist small distortion for Delrin machined parts for its character,so if the dimensions within 0.05mm(0.002") tolerance of your machined parts,please consider other material,Aluminium Alloy or Steel.

7 kinds of clamping method of turning eccentric parts

In mechanical transmission, the rotary motion into reciprocating linear motion or linear motion into rotary motion, usually with an eccentric shaft or crankshaft to complete.Eccentric shaft that is parallel to the axis of the parts between the cylindrical outer and without overlap. The method of turning eccentric parts,according to different quantity,shape and precision of the machined parts.

Turning + Grinding Parts

There are 7 kinds of clamping method of turning eccentric parts.

1. With four-jaw chuck turning 

This method is suitable for processing eccentricity smaller, less precision, shorter and smaller quantity of eccentric parts.

2.With three-jaw self centering chuck turning

This method is suitable for mass production,shorter and smaller eccentricity,less precise eccentric parts. Spacer should be added in a claw of three-jaw self-centering chuck.

3.With double chuck turning

This method is suitable for processing short length,eccentricity is small,a large quantity of eccentric parts. Should adjust the eccentricity before processing.

4. With faceplate turning 

This method is suitable for the shorter length,the larger eccentricity,less precise eccentric parts.Before machining eccentric hole,the firs processing is turning out diameter and two ends surface,and then machining the eccentric hole.

5.With eccentric chuck turning

This method is suitable for processing short axis,the disc,tube with high precision eccentric parts.

6.With two top turning eccentric parts

This method is suitable for processing longer eccentric parts,before machining the parts,should draw the center point and eccentric point on both sides of the parts,and then turning.

7. With special fixture turning eccentric parts

This method is suitable for high-precision machining, and larger quantities of eccentric parts. Before processing should be processed from the corresponding eccentric shaft or eccentric according to the eccentricity of the part, and then clamping the part on eccentric shaft for turning.

Please Contact Us for Insistent Offer of your machining needs.

What is grinding process?

Precision Grinding Machining Parts

Grinding process is also known as grinding machining.

Grinding is machining the surface of metal parts by grinding wheel,oil stone and abrasive.The machine tool that uses grinding wheel is usually called grinding machine,the machine tool that uses oil stone and abrasive is called precise grinding machine.

The grinding wheel is a cutting tool with a lot of small and extremely hard abrasive particles.From its cutting action,each of the fine grinding granules on the surface of grinding wheel, the effect is equal to a subtle blade.grinding machining just like countless subtle blade cut at the same time.

In grinding process,blunt the edges of the grinding grain,since the effect of cutting force,It often breaks or falls off to reveal a new sharp sharpen,This kind of
The phenomenon is called self -sharpness of grinding wheel.

The abrasive grinding process produces a lot of heat,So we need to cool down with a lot of flowing cooling water.

The range of grinding is very wide,almost any surface can be machined with grinding,such as inner and outer cylinder,Internal and external cone,kinds of plane,the screw thread,gear, spline, forming surface.Further more,it is hard to process hard materials such as hardened steel and hard alloy.

SYM Grinding Team

Due to the multiple blade and self-sharpness of  grinding wheel, high cutting speed and The grinding machine has high precision,the precision and surface finish of metal parts are high after grinding,The average grinding precision reaches grade 1-2, the roughness can meet Ra0.4-Ra0.8, for precise grinding parts,the surface roughness can meet Ra0.05.

At present, the grinding process is generally used as the finishing process of parts surface.However, it can also be used for rough processing of preprocessing and cleaning works.

3 point you must to know for design complex CNC Machined Parts

Complex parts are the most common processing products in CNC machining.In the process of processing complex parts,Its processing route will be covered.
Including selection processing methods, division of processing stage, division process, processing sequence arrangement and determination of the processing route and so on.

complex CNC machined parts

1.Determination of parts blank

According to the parts process design, the selection of the blank is to determine the type of the blank, the manufacturing method and the size of the blank after determining the residual amount.

The material is steel. According to technical requirements,The parts are required to be deburred,that is to ask for the appearance of clean and beautiful.According to the structural shape of the parts overall dimensions,can select forging.

It is necessary to select the steel that has been processed, because it has a high hardness and is suitable for cutting.

2.Determination of locating datum of complex parts

When selecting coarse benchmarks for processing, the key consideration is how to ensure that there is sufficient allowance for each machining surface.Make the size and the position of machined surface and unmachined surface meet to prints.Therefore, the rough datum selects the blank plane.According to the processing of the concave, the machining requirements of the hole,select the base plate to location datum.

SYM CNC Machining Shop

3.Machine selection

Different types of parts should be machined on different CNC machines,by different CNC machining process, and machine tools should be selected according to the design of the parts.

1) The CNC lathe is suitable for machining complex shaft parts and the mold inner cavity formed by the rotating complex curve.

2) CNC vertical machining center are suitable for processing box, box cover, flat CAM, shape complex plane or the internal and external cavity of the mould.

3) The CNC horizontal machining center is suitable for processing all kinds of complicated box parts, pump body, body, shell and so on.Multi - coordinate horizontal machining center can also be used to process various complex curves, surfaces, impeller, mould and so on.

Precision machining shop

Shengyuan precision machining was founded in 1997.We specializes in manufacturing precisionCNC machining parts, manual machined parts,stamping parts, bending parts, tube welding and sheet metal fabrication.  precision machined parts

 

cnc milling team

• More than 5000 M^2 factory occupies 
• Over 370 employees
• 22 sets of CNC miller
• 25 sets of CNC lathe 
• 25 sets of manual grinding machine
• 25 sets of manual milling machine
• 5 sets of slow wire cutting machine
• 4 sets of  EDM and so on.

Quality control, we have established a whole set of management system, ISO9001-2000 certification was obtained in 2005, TS-16949 certification in 2010. 

There are 38 QA inspectors including IQC, IPQC,FQC,OQC. Strictly control all links from incoming materials inspection, In process quality control, Warehouse-inspection to Outgoing quality control. 

Inspection equipments including CMM, X-Y table, Height gauge, Projector and so on.

Key customers
GE Energy, Emerson,Kyocera,TDK, 

QA Inspection Room

Hitachi,Kone.

All our products are widely used in hardware, plastics, electronics, medical equipment, optical communication, cars and many machinery industry areas.