Our CNC Macining Services

CNC Processes We Are Offering

• CNC Milling

  Compared with CNC turning, CNC milling, especially 5 axis milling can be used to create complex 3D shapes or to apply a machined surface or features to parts made both plastics and metals. The advantage of multi-axis milling machines makes CNC milling process versatile, as well as accurate and repeatable, for creating many different types of part features of complex geometries. Example include holes, curves, slots, angled shapes, and channels. Milling is also ideal for making tooling for pressure die casting and plastic injection molding.

  CNC MILLING GUIDELINES
• CNC Turning/Lathing

  CNC lathes allow us to get high-speed turning of both plastics and metals from bar or block material. The turning process allows the production of complex external and internal geometries, including generating all kinds of threads. For any round shaped components, for example, shafts, worms, spheres, CNC turning is a more efficient method compared with CNC milling.

  CNC LATHING GUIDELINES
• Electrical Discharge Machining (EDM)

  Electrical discharge machining (EDM) is an essential manufacturing process used primarily on tool steels for plastic injection molding or pressure die casting. EDM uses a conductive graphite or copper electrode submerged in a dielectric bath of water or oil. When a high voltage current is applied to the electrode it sparks against the tool wall, etching away at the surface to produce deep holes, ribs, undercuts and surface textures that are difficult to machine conventionally. When done properly, EDM can produce excellent surface finishes with tight tolerances, virtually eliminating the need for secondary polishing.

  ELECTRICAL DISCHARGE MACHINING (EDM) GUIDELINES
• 5 Aixs CNC Machining

  Multi-axis CNC machining centers come in three variations: 5-axis indexed CNC milling, continuous 5-axis CNC milling and mill-turning centers with live tooling.

  
  

  These systems are essentially milling machines or lathes enhanced with additional degrees of freedom. For example, 5-axis CNC milling centers allow the rotation of the machine bed or the toolhead (or both) in addition to the three linear axes of movement.

  
  

  The advanced capabilities of these machines come at an increased cost. They require both specialized machinery and also operators with expert knowledge. For highly complex or topology optimized metal parts, 3D printing is usually a more suitable option though.

  5-AXIS CNC MACHINING GUIDELINES

Advantages of CNC Machining

• 01

  Variety of Production-grade Materials

  CNC prototype machining can use a variety of production-grade plastic and metal materials, which allows engineers to use the same (or similar) materials as the final part to make prototypes to test the product's performance, function, and manufacturing cost.

• 02

  Consistently Surface Finishing

  Prototype machining provides a consistently smooth surface finish with a typical machined surface roughness of Ra 1.6μm and super-finish machined surfaces up to Ra 0.2μm. additional costs.

• 03

  Highly Accurate Parts With Tight Tolerances

  CNC machining can create parts with greater dimensional accuracy than most other common manufacturing technologies. During the final finishing machining steps, material can be removed from the workpiece very accurately, achieving very tight tolerances.

• 04

  One-off Custom Parts & Prototypes

  In contrast to formative technologies (Injection Molding), CNC machining does not need any special tooling. So, the on-demand production of custom one-off parts and prototypes is economically viable. This is especially relevant for one-off custom metal parts and prototypes, where CNC is the most cost-competitive solution.

CNC Machining Tolerances

Precision Machining Tolerance

Why Choose CNC Machining Service From IDEAL?

How IDEAL Improve the Precision of CNC Machining?

• Machine Calibration and Workshop Environment Maintenance

  We Ensure that CNC machines are regularly calibrated according to manufacturer specifications. Keep machines well-maintained, checking for wear and tear on components such as spindles, linear guides, and ball screws.

  
  

  Also IDEAL do best to maintain a stable temperature in the workshop to minimize thermal expansion of the machine and materials.

  Cutting Parameters Optimization and Programming Techniques

  Optimize feed rates and spindle speeds for the material and tool to achieve the best balance between speed and accuracy, and adjust the depth of cut to minimize tool deflection and chatter.

  
  

  Use optimized toolpath strategies, such as adaptive machining, to minimize tool load and improve finish, and utilize software to simulate CNC operations to identify potential issues before actual machining.

• Tool Selection, Management

  Use high-quality cutting tools designed for the specific material and application, regularly inspect and replace worn or damaged tools to prevent inaccuracies, and select appropriate tool dimensions for the task to reduce vibration and improve cutting stability.

  Fixture and Workpiece Stability

  Use fixtures to securely hold the workpiece, minimizing movement during machining, and ensure that workpieces are properly aligned and set up before starting a job.

  Operator Training and Quality Control in Processing

  IDEAL Invest in comprehensive training for operators to ensure they understand machine capabilities and best practices.

  
  

  We Perform in-process inspections and final checks using precise measuring tools such as coordinate measuring machines (CMM), and keep track of measurements and tolerances to identify patterns and areas for improvement.

Our Maxime Size Range of Your Machine Ability

Overview of CNC Machining Post-Processing Solutions

• Deburring and Edge Finishing

  • Manual Deburring: Using handheld tools such as files, deburring knives, or sandpapers to remove burrs and sharp edges.

  • Mechanical Deburring: Using machines like vibratory finishers or tumblers to smooth edges.

  • Chemical Deburring: Employing chemical solutions to dissolve burrs and improve surface smoothness.

  • Cleaning: Remove oils, dust, and other contaminants from the machined part.

• Sanding, Grinding and Polishing

  • Polishing: Applying a buffing wheel or polishing machine to further chieve a high-gloss finish and enhance the aesthetic appeal of the part.

  • Grinding: Utilizing surface grinders or cylindrical grinders to achieve tight tolerances or specific surface roughness requirements.

  • Sandblasting: Propelling abrasive particles against the surface to achieve a matte or textured finish.

• Anodizing, Plating and Passivation

  • Anodizing: An electrochemical process that converts the metal surface into a durable oxide layer.

  • Plating: Applying a thin layer of metal (e.g., nickel, chrome) through electroplating or other methods.

  • Passivation: Treating stainless steel parts with an acid solution to enhance corrosion resistance by forming a passive oxide layer.

  
  

  

• Heat Treatment

  • Annealing: Heating and then cooling the material slowly to relieve internal stresses.

  • Hardening: Heating and quenching to increase hardness and wear resistance.

  • Tempering: Reheating after hardening to reduce brittleness and enhance toughness.

  
  

  

• Coating & Laser Marking

  • Powder Coating: Applying a dry powder that is then cured under heat to form a hard finish.

  • Liquid Coating: Using paint or specialized coatings for added protection.

  • Laser Marking and Engraving: Adding permanent markings, logos, or identification codes using laser technology.

• Assembly & Sub-assembly

  • Mechanical Assemby: Using fasteners, screws, or other hardware to join parts.

  • Welding or Adhesive Bonding: Permanently joining parts through welding or applying adhesives.

  • Sub-assembly: Integrating machined parts with additional components to create sub-assemblies or final products. Testing and verifying functionality and fitment of assembled parts.

• Quality Control & Packaging

  • Dimensional Inspection: Using tools like calipers, micrometers, or coordinate measuring machines (CMM) to verify dimensions.

  • Surface Finish Testing: Checking for surface roughness and finish quality.

  • Visual Inspection: Checking for surface defects, scratches, or irregularities.

  • Non-Destructive Testing (NDT): Employing techniques like X-ray, ultrasound, or dye penetrant testing to detect hidden defects or flaws.

  • Packaging and Labeling: Packaging machined parts securely to prevent damage during shipping and handling. Labeling parts with identification tags, barcodes, or instructions for assembly.