4 Steps for Every Quality Machining Process

The advances in CNC machining, new composites, computer-aided design, and even newer computer feedback improve quality and speed and reduce waste. These are all important factors in a competitive global economy, but there are steps for every quality machining process that rely on client service and intelligent design. We review some basic steps here that apply to manual and CNC operations for the best outcome every time.

Systems

A machine process, whether manual or computerized, can only be as good as the design input. Following a process for design and manufacture of every part is essential in a quality machine shop. While CNC machining is a technical business, people do come first. Your shop needs to follow a process for every project, especially as you grow, so new machinists and software designers will offer the same level of quality. That begins with customer service. Assessing client needs with your equipment capabilities should be the first step in any project. Once a contract is established, each project needs to move through design and approval, modeling, tool selection, and the final machining process. Hiring and training quality staff, like machinists covered in this previous blog, is key to your system performance.

• Technical Drawings

The technical drawings collaboratively created and approved between client and design engineers have a critical role before machining begins. Drawings must include a variety of views, precise measurements, and angles to be sure all criteria are inputted properly in the final execution. While the initial design concept comes from the client, a quality engineer may be able to find cost-cutting design suggestions or improve the final product with their expertise.

While CAD systems easily prepare drawings for a trained operator, a good technical designer will still have the ability to draw a part manually, exhibiting their skills as an engineer. New AI (artificial intelligence) can take the input of a design and produce a quote in minutes, but this still lacks the experience an engineer can communicate to the client for best results.

Detailed drawings include tolerances, threads, finish notes, and should include cross-sectional and 3D views, where needed, to help in the next phase of production. No work should proceed without client approval on the technical drawings.

• Modeling

While 3D CAD designs can be easily produced from 2D technical drawing input, it is highly recommended a technical drawing file accompany a 3D CAD file for accuracy. The 3D CAD file can be used for modeling, itself, or a prototype may need to be run.

In manual machining, a prototype is often a needed step beyond a 2D drawing, but many applications still require prototypes to satisfy both client and manufacturer for a range of quality and finish observations. Prototypes can be milled from different composites than the final product to expedite time and cost, for example, wood or aluminum. And other prototype options like 3D plastic printing and injection molding are also available. The complexity or application of product design will dictate if a prototype is needed for modeling in each project.

• Choosing the Right Tools

The volume of the production run, the complexity of the part, and the degree of precision affect the machine and tool choice when you’re ready to start production. Starting with the machine, itself, a manual shop can work just about any piece with a lathe and a mill. In a CNC machine shop, there are often a variety of machines to choose from. Newer multi-axis machines can often process the entire production in one run.

The technical drawings are often made with the machine in mind, but in a busy shop, the machine availability may dictate the production choice. Tools are specifically chosen based on the finish and the workpiece material. Machinists must be well-versed with the strength of composite material to guide their choices in tools and holders.

• Machining

The skill of the machinist now comes into play with quality control and safety. Automated machining will begin production for a hands-free operation. The machinist needs to check for quality with various tests and measurements. Tool wear and maintenance are an important function in a CNC machine shop to be sure tolerances are met for high-quality production.

Having a standard system of operation for every quality machining process ensures easy training for new staff, quality production, and satisfied customers. Even with the onset of more technology, you can still see how the human factor affects the production process.

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