Precision Machining

Precision Machining

A subtractive manufacturing technology to create intricate parts with expert engineering support, fast lead time and high precision.

Premium Parts can help you achieve exceptional and accurate results for your production needs through our precision machining process. CNC Precision machining is a process of manufacturing components and products with precision, quality, and consistency that has become increasingly important in applications such as aerospace and automotive, as well as medical technology. Our precision machining solution saves you additional costs and leaves minimal room for errors with high reliability and flexibility. We offer the optimum solution to maximize value without sacrificing dimensional accuracy and wasting extra material resources. Our commitment is to thoroughly analyze your project and production design and recommend the best course of action, from procedure to materials and budget.

What is Precision Machining?

Precision machining uses computer-controlled machine tools to make any part or product with tight tolerances and high complexity per its exact specification. This process involves sculpting raw materials into finished products by removing excess as instructed by the computer-aided design (CAD) or computer-aided manufacturing (CAM) blueprint. It is a subtractive technique that uses various CNC procedures, such as milling, turning, or multi-axis machining, such as 5-axis machining. Additionally, machine operators employ this method on various materials and during different production processes.

Before precision machining is used to create any product, it is essential to use CAD or CAM software to generate the product's blueprint. These systems create highly accurate 3D outlines that a precise machining procedure must follow to duplicate the product effectively.

While a qualified machinist must supervise the process, machines automatically complete most of the work. The design is created by computer-aided design (CAD) software, followed by computer-aided manufacturing (CAM) software translating it into manufacturing instructions for the machine. The final post-processor program encodes the instruction into data that the machine can understand. To begin the production process, the machinists then upload the instructions into the CNC machinery.

At Premium Parts, our expert machinists are well-trained to work with various equipment, materials and methods depending on the project's scope and raw materials. From automobile parts to aerospace and medical devices, we create high-quality and precise components for our clients from any technological industry.

Tight Tolerance for Precision Machining

Even though precision machining produces accurate results, it may not replicate the exact dimensions as directed by the CAD blueprint—this is the core reason why machinists use tolerances, also known as dimensional accuracy. Precision machining uses specialized techniques and cutting equipment to minimum tolerance to their minimum levels. As a result, the pieces are more accurate than the original drawings.

Different systems exist for measuring tolerance, such as:

Unilateral Tolerance

For such tolerance measurement, the deviation is allowed only in one direction. If a bearing's nominal shaft size is 20mm, a more oversized shaft will not fit. For this reason, machinists only permit a tiny amount of variation for such a shaft.

Compound Tolerance

This is the final tolerance determined by combining or subtracting the tolerances of the various dimensions that create a part.

Bilateral Tolerance

Dimensional variation is allowed in both directions. It is acceptable for the tolerance limit to be both above and below the size needed. It is commonly represented as a +/- value. Simply put, if a part has a measurement of 25 mm and a tolerance of +/- 0.05 mm, the value may range between 24.95 mm and 25.05 mm.

Limit Tolerance

Here, the tolerance value is set within a range. For instance, the dimension for a shaft is fixed to fall between 20 mm and 22 mm.

Understanding our Precision Machining process

Designing the graphic layout

Before any item can be produced, a graphical model must be created using computer-aided design (CAD) software. A designer can make 2D and 3D models of any part using CAD software. Designs often begin as hand-drawn sketches to understand the component's main features. Later, the Computer-Aided Design (CAD) designer uses these designs to develop the graphical layout precisely.

Programming

A CNC-compatible file format, such as STEP or IGES, is used to export the 2D vector or 3D solid plan created by computer-aided design (CAD) software for the manufactured product.

Next, the computer-aided manufacturing software (CAM) generates the digital programming code to operate the tools and make the custom-designed part. Computer Aided Manufacturing (CAM) uses two principal programming codes; G-code and M-code. The Geometric code, often known as the G-code, is more widely used. It instructs the machine when, where, and how to move, whereas the M-code controls its auxiliary functions.

Processing

This step involves placing the workpiece on the device and calibrating the machine tool. The workpiece material and final product design may vary depending on the machine tools used, as various precision machining tools are available for different uses. At this stage, it is important to properly secure all clamps and check if the machine's characteristics, such as the coolant levels, are acceptable.

Completion

Once the part is manufactured, it can be removed and sent for secondary procedures like grinding or polishing, depending on the requirement. However, precise machining usually eliminates the need for further processing completed goods.

While preserving the component's quality and accuracy, precision machining offers a good surface finish. This qualifies it for applications with strict quality requirements, such as those in the production of gadgets and aerospace, where it's crucial to maintain a clean surface finish.

Types of Precision Machining equipment

Due to the wide application of the process, several different machines and equipment are used for precision machinery:

Materials

Precision machining can be operated on a wide range of production-grade materials. At Premium Parts, our precision machinery can manufacture simple and complex parts from plastics and metals. Here are some of the materials we work with:

Metals

  • Aluminum
  • Stainless steel
  • Mild Steel
  • Tool Steel
  • Brass
  • Copper
  • Titanium
  • Magnesium

Aluminum

Aluminum alloys have a good strength-to-weight ratio, high thermal and electrical conductivity, low density, and natural corrosion resistance. Can do Type II/ Type III anodizing.

Stainless steel

Stainless steel alloys have high strength, ductility, wear, and corrosion resistance. Easily welded, machined, and polished.

Mild steel

Mild steels are low-carbon metal alloys with good mechanical properties. They can be heat treated to achieve a higher hardness and a better mechanical performance.

Tool Steel

Tool steel can maintain high and red hardness at high temperatures and has good wear resistance and appropriate toughness.

Brass

Brass is an excellent conductive material, and it can be machined easily.

Copper

Excellent thermal and electrical conductivity. Widely used as busbar, wire connectors, and other electrical applications.

Titanium

Titanium alloy has high strength, good corrosion, and high-temperature resistance. Widely used for aerospace and biomedical.

Magnesium

Magnesium has low density (1.8g/cm3), high strength, large elastic modulus, good heat dissipation, shock absorption, and greater impact load capacity.

Plastics

  • POM (Derlin/Acetal)
  • Nylon
  • ABS
  • PEEK
  • PTFE
  • PC
  • PEI
  • PVC
  • PMMA (Acrylic)
  • PET
  • PP
  • FR4

POM (Derlin/Acetal)

POM has excellent fatigue resistance, creep resistance, self-lubrication, and machining properties and can work for a long time at a temperature of -40° C -100° C.

Nylon

Nylon has superior comprehensive properties, including mechanical strength, stiffness, toughness, mechanical shock absorption, wear resistance, and good electrical insulation and chemical resistance. Use for manufacturing mechanical structure parts and maintainable parts, can work in temperatures -40-105 ° C.

ABS

ABS sheet has excellent impact resistance, heat resistance, low-temperature resistance, chemical resistance, and electrical properties. It also has the characteristics of easy processing, product size stability, good surface gloss, easy painting, and coloring.

PEEK

PEEK has excellent comprehensive properties and resistance to energy radiation irradiation and has excellent dielectric properties before the use temperature of 260 ° C. It can meet the requirements of food contact materials in the EU and the United States and has good biological compatibility.

PTFE

PTFE is basically corrosion resistant to all chemical substances except some fluorides and alkaline metal liquids, and the temperature range is very wide – 180 -260° C.

PC

PC has excellent comprehensive performance and environmental protection and is a plastic building material widely used in the world nowadays, with strong light transmission and impact resistance.

PEI

PEI has good mechanical properties and heat resistance, strong creep resistance, excellent dimensional stability, the best torsional strength plastic, and continuous work in high-temperature water and steam is also very stable. Withstand temperature up to 170℃. Meet the requirements of biocompatibility and food-grade material.

PVC

PVC has good chemical stability, corrosion resistance, self-extinguishing, excellent flame-retardant effect, and can replace some highly used stainless steel and other corrosion resistance synthetic materials.

PMMA (Acrylic)

PMMA has excellent transparency, weather resistance, good processing performance, suitable for mechanical processing and easy hot forming, good aging resistance, good chemical resistance, and good sound insulation effect.

PET

PET has good mechanical properties, stiffness, and physiological inertness and can be used for food contact materials, with a temperature of -40-110, and better mechanical properties and temperature resistance after fiber filling.

PP

PP has superior chemical, heat, and impact resistance and is non-toxic and tasteless. It is one of the most environmentally friendly engineering plastics and a food-grade material. The operating temperature is -20-90℃.

FR4

FR4 has high mechanical and dielectric properties, good heat and moisture resistance, and good machinability.

Applications of Precision Machining

Due to its many applications, cost-effectiveness, and quick turnaround times, precision machining is consistently expanding in the manufacturing industry. The following industries use the precise machining process:

Automobile Industry

Precision machining creates intricate gears for engine modules, axles, nuts, and other automotive-related items. This manufacturing process can accurately create parts for motorcycles, two-wheelers, vehicles, trucks, ships, and many more.

Medical Industry

As medicine evolves rapidly, so does the need for new equipment. Creating geometrical complex and error-free medical devices is possible through precision machining. These include implants, MRI machines, secure enclosures, orthotic devices, research tools, etc.

Aerospace Industry

Aerospace vehicles require highly reliable devices, from commercial airplanes to space shuttles. Even a minor error can result in serious harm to various aviation vehicles. Precision machinery can work on the most complex material and develop parts such as landing gear ports, bushings, manifolds, airfoils, etc.

Defense Industry

The defense industry holds similar requirements as the aerospace industry. It demands the most rigid materials and high-precision machining. The applications are numerous and diverse, ranging from complete missile systems to new weapon prototypes.

Why do businesses require Precision Machined parts?

One of the main benefits of precision machining is the capacity to produce machined parts with high accuracy. Overall, simple machining procedures can be performed by a trained machinist, manually operating the machine's arm onto the workpiece to create cuts. A computer-controlled system is considerably favored to reproduce a design as minor details and strict tolerances are much more challenging to manufacture manually. There are many different reasons why companies might need precision machining parts and some of them are described below:

Aesthetic appeal

For aesthetic or other visible aspects, where imperfection or defects would not be acceptable, precision is essential. Evident flaws might reduce the product's visual appeal or provide safety risks. While some items may require standard machining for internal parts, precision machining is vital for outward-facing or surface elements (with accidentally sharp edges, for example).

Assembly

When pieces need to fit together into a larger assembly, the tight tolerances provided by precision machining are essential. These parts might become worthless if the dimensions differ too far from the design and fail to join. Even if an assembly is technically successful, the end-user or consumer will want to avoid unwanted gaps or overhangs where components should be flat.

Added benefit

The ability to sell high-quality components with precise tolerances for a higher price is a clear motivation for precision machining. A high-value product, like a stereo system or smartphone, can only demand its high retail price if each of its parts is made to a high standard, regardless of whether the precision results in any practical benefit.

Advantages of using Precision Machining

Many industry leaders are already utilizing this technology for the following specific benefits:

High accuracy

To ensure high accuracy of the finished product, precision machining processes create tight tolerance during the production process. Each component must interwork with the other to function perfectly in later phases.

Speed and efficiency

High-speed computer-operated precision machinery produces items faster than traditional manual methods. There is also no need for additional processes as the parts have high precision and close tolerance finishes. This reduces production time, making the operation more productive and efficient.

Low wastage of materials

It has a lower error rate, reduces wastage of materials, helps lower raw material cost and improves repeatability.

High consistency

After the design is finalized using CAD software, there is no alteration done to the plan. As a result, the parts can be mass-produced with high accuracy and consistent quality and output. Each item is programmed into the machine using the same code by the CAD application, producing uniform, high-volume, and precisely manufactured components and products.

Low production cost

Once the first design is approved, the machine can quickly repeat the cutting operation. Production does not require manual labor to operate as it does not follow a fixed schedule of shifts. Furthermore, there are no additional labor costs. After the initial samples are accepted, the machine may finish the operation with minimal human supervision.

Easier prototype testing

Its fast and accurate machining helps produce high-quality prototypes of your product quicker and identical to end-use parts. This can help businesses test their product prototype and the design's functionality.

Safety

A CNC machine replaces manual labor with computer numerical control systems, removing the risk of human error and accidents from cutting operations.

In today's world, Precision machining has revolutionized the way of standard parts manufacturing. It has eliminated errors, reduced labor costs, achieved desired part quality and reduced cycle times in the manufacturing process. Precision machining is here to stay and its applications will only improve with time. It is no longer a supplementary manufacturing technique that improves quality but a necessity for industries requiring complex components to function together and create customized parts.

At Premium Parts, we provide the best representation of your CAD drawings and will deliver the best results for your precision machining needs. With our extensive range of engineering knowledge and expertise, we guarantee exceptional production capabilities. With our 3, 4, and 5-axis CNC machines and various auxiliary equipment, we can produce your CNC ideas for one-off custom prototypes or high-volume production parts to their exact specifications.

Why choose Premium Parts

Strong competency

Our operations follow a consistent process that provides minimal risk, inspecting raw materials before manufacturing, and the ability to produce high-quality prototypes and end parts uniformly.

No limit on the quantity required

Precision machining services at Premium Parts are accessible to all customers without limitations or minimum order quantities. From one-piece to mass volumes, we can produce components in different amounts as per our client's requirements.

Expert internal resources

We provide a comprehensive array of services at our manufacturing facilities, so our clients will avoid the hassle of outsourcing production or finishing services during prototype and product development cycles.

Rapid delivery

Our efficient quality control, supply chain, and delivery logistics make it possible to deliver your products in the least amount of time.

FAQs

What makes precision machining different from non-precision machining?

Precision machining’s focus on tight tolerances makes it different from non-precision machining due to its emphasis on tight tolerances. It guarantees to create pa with higher consistency, fewer defects, and greater accuracy.

Where else is precision machining used?

In today’s world, precision machining is required by many industries to manufacture parts and tools ranging from decorative wall hangings to an airplane and medical devices. Some products produced through precision machinery include publishing equipment, surfboards, hardware elements, cooking utensils and musical instruments.

What is the minimum level of tolerance achieved through Precision Machining?

Precision machines are perfect for applications with strict tolerance requirements since they can meet tolerances as small as 0.004 mm.

Can I provide the raw material myself?

Yes. However, to ensure the material can be machined, we will first identify and analyze it thoroughly.

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