Machining generally describes a manufacturing process in which a worker uses sharp cutting tools to remove excess material from a part in order to create a desirable new shape. Castings, forgings, extrusions, bar stock and even raw materials can all provide substrates for the process of machining.
Typically, machining constitutes a secondary operation. It usually involves cutting away and discarding a portion of the material. The process of machining rarely proves economical when it involves removing more than 40% of the weight of the part. In that case, the manufacturer should rely upon other manufacturing techniques, such as forging or casting.
The final shape of the part conforms to dimensions specified by the manufacturer. Companies employ machining to add features to or refine an existing metal component. Machinists may also smooth the surface of a part to achieve a finer finish. Nowadays, machining allows for the production of metal parts within high tolerance levels.
Manufacturing facilities frequently apply machining to add desired features to metal components. The features may include holes, slots, flattened surfaces, pockets or even complex exterior markings.
In today's modern world, many industries utilize precisely machined parts. Companies furnishing semiconductor, aerospace, automotive and fiber optics products all depend upon machining for the creation of certain components.
Machining as a process is generally cost-effective, however the duration of the process varies significantly. Machining by well-equipped manufacturers usually offers the advantage of low setup and tooling costs. However, when the process of machining requires a long period of time to complete per part, it can add significant costs to overall production expenses.
For this reason, many manufacturers limit the use of machining involving an extensive time commitment to the creation of a limited number of detailed prototypes. Products with short machining times frequently permit cost-effective high volume production runs. In the case of some smaller parts easily and rapidly fabricated from bar stock, machining provides a highly cost-effective solution.
Our company employs three main types of traditional machining operations in order to remove excess material from metal parts. The operations include turning, drilling, and milling. During these processes, machinists utilize sharp cutting tools to mechanically cut away small chips of material from the initial segment.
Each operation differs slightly from the others:
Turning refers to the operation in which a machinist moves metal against the cutting tool by carefully rotating the workpiece on a lathe machine. A lathe helps to shape metal by means of a rotating drive which turns the metal component at desired angles. Turning will generate cylindrical-shaped parts that display various specified internal or external features. Typically, turning operations encompass boring, facing, grooving, thread cutting and the cut-off process, also known as parting.
Drilling is used to create holes on a workpiece, or refine the size of existing holes. A machinist usually performs this step by using a cylindrical, rotating tool drill bit. The bit penetrates the stationary metal part in order to create a hole. The machinist relies upon a drill press to perform rapid precision drilling.
A third widely performed machinist operation, milling involves passing a metal part in front of a cylindrical rotating tool with multiple cutting edges called a milling cutter. A machinist uses a milling machine to effectively remove any excess parts of the material.
In addition to these three main machining operations, our company also provides secondary operations in order to produce parts meeting manufacturer specification. The secondary operations may include shaping, planing, boring, broaching, or sawing.
Categorization of machining processes
In general, all machining processes can be divided into two distinct machining categories: conventional and non-conventional. The processes differ with regards to the tools used for removing excess material.
Conventional machining represents a mechanical process. Machinists use a sharp tool to cut away excess material from a part. The process can be further divided into three sub-categories:
1) Single point cutting: This process refers to using a cutting tool with a single sharp edge that turns, planes and shapes the part.
2) Multi-point cutting: Multi-point cutting involves a cutting tool with two or more cutting edges to mill, drill, broach or saw the part.
3) Abrasive machining: During the process of abrasive machining, a machinist uses small abrasive particles to hone, grind, lap or polish the part. The process may also include ultrasonic and abrasive jet machining.
Non-conventional machining processes encompass two sub-categories: chemical machining and thermal machining.
Chemical machining: This process involves using baths of temperature-regulated etching chemicals. The chemicals remove material from the part, thus creating a metal component of a specified shape. Chemical machining can be a regular or an electrochemical process.
Thermal machining: This process employs a source of thermal energy, such as a laser or an industrial torch, to direct intense heat towards a metal part in order to remove excess material. Types of thermal machining include torch cutting, electrical discharge machining and high energy beam machining.
Why Customers Choose Our Machining Services
At Bunty LLC, we are able to provide a variety of machining services and processes in order to manufacture a wide range of custom metal parts that match particular customer specifications. Our company employs highly experienced and knowledgeable machinists who possess the resources required to furnish various machining services. Our experts are able to manage complex machining tasks.
The company maintains versatile equipment capable of performing well under manufacturing conditions and tailored to zero defects. Our machinery enables us to complete assignments for customers efficiently and accurately. Therefore, the in-house machining capabilities of Bunty LLC can save our customers both time and money.
We provide just-in-time delivery so that our customers may avoid unnecessary inventory storage costs. We offer reasonable prices and exceptional customer service for all our clients.