Machining Process for Short-Axis Components with Less Scrap
Machining is the process of cutting and shaping materials, such as metal and plastic, to create a desired shape and accuracy. Using a variety of tools, including CNC machines and lathes, machining can be used to create almost any part, from simple screws to highly intricate components. When machining short-axis components, however, it is important to choose the right processes and tools to ensure a quality, cost-effective output with less scrap.
The first step in machining short-axis components is selecting the right cutting tools and processes to achieve the desired tolerances. Carbide end mills, for example, are ideal for cutting intricate components with high accuracy, while parting tools and drills can be used for drilling and countersinking features. The selection of the most suitable cutting tools is important as it will ensure that the components are machined to the correct tolerances and with minimal scrap produced.
Once the suitable cutting tools have been selected, it is important to consider the machining strategy. For short-axis components, the ideal strategy is to firstly machine as much of the material as possible in one operation, to reduce scrap. For example, in a CNC milling process, rather than milling the features one at a time in separate operations, it is best to use an end mill to machine, countersink and drill features in the same operation. This reduces the number of rounds of machining, which will reduce scrap and improve accuracy.
For components requiring high levels of accuracy, it is best to focus on maximising the accuracy of the machining set-up and tooling. For example, ensuring that tooling is sharp and in good condition, as well as using a suitable depth of cut and feed rate for the machining process, will help to reduce variability of the machined components. Additionally, using higher speed and lower cutting forces will also result in a smoother surface finish, which is desirable for most components.
Finally, the amount of scrap produced in the machining process can be significantly reduced by the use of palletised set-ups. By setting up multiple components on a pallet, it is possible to use a single tool to machine all of the components on the pallet. This allows for higher consistency of machining operations, resulting in less scrap as each component is machined with the same tool settings.
In conclusion, machining short-axis components requires selecting the right cutting tools and processes, selecting a suitable machining strategy, focusing on accuracy and maximising the use of palletised set-ups. When done correctly, this will ensure a cost-effective output with less scrap produced, making the process more efficient and cost-effective for many manufacturing applications.
