Posted on July. 10th, 2020, | By WayKen Rapid Manufacturing
Manufacturing has undergone drastic changes in the last 10 years. Massive mass production plants are giving way to smaller facilities that have less capacity for large volumes but are capable of delivering small batches, customized parts, and prototypes in a short span of time. These facilities are called CNC machine shops and CNC prototyping shops. Let us look at why they can be more useful than conventional manufacturing plants.
What is a CNC machine shop?
A CNC machine shop is a high profile manufacturing facility that will deliver your orders if you need metal, plastic, and other parts for different machine components. Depending on the capabilities of the CNC machine shop, they can concentrate on specific industries: automotive, aerospace, medical, and so on. Some shops have hired capable design and analysis engineers and can provide you with complete engineering design, verification, and production of your idea.
CNC machine shops tend to be at the cutting edge of manufacturing technology. The market is highly competitive and the shop that can deliver high-quality CNC parts faster will survive. Let us look at what kind of equipment you can find there and how it can be useful for you.
Contact Wayken’s CNC machine shop to learn more about our capabilities and get your project started today. ( Quick turn prototypes to full production runs )
What Can You Find in a CNC Machine Shop?
A fully functional machine shop usually includes many pieces of machine equipment with different sizes and purposes, as bellows:
A multi-milling machine is a machine tool that can conduct extensive machining operations. It usually doesn’t have any Computer Numerical Control (CNC) system and is operated manually by a machinist. The main advantage of such a tool is that with a capable machinist, you can simply give him the drawing and he will start machining right away. It’s a great option if you need a single simple metal part. You can get it within a couple of days.
Machine Center ( 3,4-5 and more axis CNC machine)
A Machine Center is a more complex version of the multi-purpose milling machine. You will need a 3D-model of your part to get it manufactured but the advantage is that a CNC Machine Center can manufacture almost any part you can imagine. They are quite precise too, and if you like the result, you can duplicate the first prototype easily by simply loading the same NC program again and again. CNC machine centers can have 3, 4, or 5 working axes. The more axes a CNC machining center has the more complex parts it can make.
But if your part is simple, it is better to go to a multi-milling machine because the machinist will need quite a while to prepare a good NC program.
A lathe is a kind of machine tool where the part revolves instead of the cutting tool. It is perfect for symmetric components and can work on them automatically if equipped with a CNC system.
A grinding machine uses high-quality grinding wheels made of small hard particles to shave off small layers of materials and form a very precise dimension with a great or mirror-like surface finish. Such operations are used for high-precision parts and it is recommended to use them only for tolerances IT 7 or higher. They are costly and take up a lot of time.
A drill press is the basic manufacturing machine tool. It is used to drill holes in any kind of part. It serves as a good complement for multi-milling machines and manual lathes forming a perfect combination to make parts swiftly.
Every CNC machine shop needs blank stocks. 90% of those are supplied in the form of long bars of different diameters. When an order is made, the bar is cut into single pieces and a part is machined from those. A bandsaw is used to cut those bars.
Micromachining is a machining process on a microscopic level. It allows you to create microscopic finishes on a part and create custom surface finish patterns.
EDM refers to electrical discharge machining - a process that relies on electric currents to vaporize particles from the surface of the part. This method is perfect for hardened aerospace parts and dies cavities. A tremendous advantage of the process is that the cutting force is close to zero so the part cannot be deformed during its processing.
Surface Finishing Tools
When the part is complete, you sometimes need to get additional properties. Such as mirror-like surface finish, color, glossiness, or smoothness. All of them require special treatment so a good CNC machine shop usually has at least a small set of painting equipment. Great machine shops offer polishing and anodizing services.
Coordinate Measuring Machine
In order to check the tolerances of the part and evaluate its properties, control equipment is necessary. Coordinate measuring machines are the best fit for the various orders a CNC machine shop gets. They are precise and can measure virtually any dimension.
A person moves the 3D scanner around the workpiece to capture its different parts and provide its 3D model. The process normally takes 3-4 minutes.
Different dimensions have been measured by using vernier caliper such as inner dimensions, outer dimensions, and depth of the workpiece by using their different jaws.
Micrometers and Pin Gauges
If the desired workpiece is needed to be highly precise, then a micrometer is used for measuring depth, length, and thickness. Pin gauges are used to measure and inspect the diameter of small holes in machine shops.
In a CNC shop, the machines perform different production tasks, either manually by CNC machinist or equipped with CNC technology.
In addition to machinery, the manufacturer usually stores raw materials in a machine shop that can be used for machining parts. However, for manufacturers with small size CNC shops, their materials may be stored elsewhere, such as in a warehouse.
There is a specialized area containing computers equipped with CAD software in the machine shop where machinist can design parts in digital ways.
Choosing the Right Machine Shop for One-Stop Post Finishing
When you have an urgent project, it is wise to choose a CNC machine shop that can offer one-stop services. It is because a complete machine shop not only provides fully CNC machining service but also various post-processing options. In this way, you can get perfect prototypes or parts at one time without visiting different suppliers.
Following are the post finishing techniques:
- Hand Finishing and Form fit function: A common aspect of hand finishing is adding inserts or functional assemblies. For example, when an item requires screws or bolts in the assembly process, adding metal threaded inserts can make the threads more durable.
- Sanding and Polishing: In this process, the product defects such as burr, machine line, and adhesive mark from the surface of the part were removed by efficient hand sanding and polishing which may take hours.
- Painting and Printing: Clean paint represents the quality of the product. Painting and printing are done in a strictly controlled environment which may be done by spray guns or airbrushes.
- UV Coating: It is used to protect the material from scratches and ultraviolet radiation.
- Laser Etching: Etching refers to the process of material removal and in a machine shop etching is done on a specific area for printing brand name logo or custom message before moving to mass production.
Quality Control and Inspection In a CNC Machine Shop
A good CNC machine shop usually can carry out the complete quality control inspection throughout the entire production process in order to produce high-quality prototypes and parts.
There are detailed inspection steps that are used for the quality control process of the product being produced by the CNC machine shop.
Inspection by machine operator: The operators usually perform various inspections on the parts while they are still on the machine or immediately after they are removed from the machine.
Customer Communication: Effective customer communication as an essential element of delivering customer satisfaction.
Verification of Purchased Products: All purchased products are subjected to a visual inspection by the receiving quality control inspector.
Inspection via in-process Probing: Process Probing refers to use the automated probe to check the tolerances of the part in a part program.
Inspection in the Quality control department: After the parts come off the machine and leave the hands of the operators, the quality control department performs additional inspection steps based on the statistical process control system.
At Wayken, we give you 100% promise to carefully monitor each project from start to finish to meet all customers' exact specifications.
CNC Machinists Can Ensure High-quality Machined Components
Another vital element that ensures the work of a CNC machine shop is its staff. If the machine tools are the heart of the shop, machinists are its brains. A capable machinist can take a drawing and turn it into a part without any previous preparation. He can set up the machine tool and the cutters and do everything himself. A good CNC machinist will create complex programs for the CNC machine centers and provide the shop with complex and high-quality part orders.
A professional machinist and craftsman should have skills as follows:
- Problem Solving Skills: CNC machinists should be highly professional and know how to fix any error, how to increase efficiency, and why machines are not at peak performance.
- Technical knowledge: Machines controlled by computers will need operators who understand CAD/CAM technology.
- Attentive: A little negligence can lead to a serious accident, so the machinist should have his full attention while working on the machine.
- Math Skills: For understanding complex instructions the CNC machinist should have good math skills, and make sure items are designed and built correctly.
- Stamina: The machinist should have good stamina in order to perform under strict working conditions.
At Wayken's machine shop, our team of CNC machinists carefully carries out every step of the machining process with state-of-the-art technology such as EDM, 5-Axis Machining and Micromachining, etc
How to Ensure Machine Shop's Safety
A machine shop is dangerous working in place. That’s why a lot of safety rules are imposed. Workers have to wear casks and special attire, special goggles to prevent chips from reaching their eyes. They have to undergo special courses in machining safety and adhere to the current rules.
However, some production anomalies frequently happen, how to manage, or fix them in the right way? Here are five steps to manage production anomalies prototype Shops for you.
How to Optimize Your CNC Machine Shop
Here are some tips for optimizing your CNC machine shop and help you to make the right choice.
Are you still looking for a respected, trusted CNC machine shop? WayKen as a prototype manufacturer can provide advanced manufacturing and prototyping solutions for global customers.