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Machining Process Ranking

As a result of the technological breakthroughs made on machining methods in the industry, many alternatives have been created in the production processes and choosing the most efficient manufacturing method among these alternatives has gained great importance. While manufacturing methods that can meet the needs can be determined at the design stage, designing considering the limitations created by manufacturing can be considered as the other side of the coin. In addition, while choosing the process, factors such as unit cost, manufacturability of the material, annual production capacity, and the ability to meet the requirements of the design are taken into account. Therefore, choosing the right method can be vital for new enterprises and businesses in the growth process. In our first article on process selection, we will discuss the features we will consider when choosing the turning process, as well as design and production capabilities. In our next articles, milling will come. Turning Turning is called the turning process to bring the workpiece to the desired geometry (giving the desired shape) by removing the chips during the relative (relative) movement of the fixed cutting tools, which is in the form of advancing and passing, while the workpiece rotates on the axis of the chuck (the moving part to which the workpiece is connected on the lathe). -Production- Turning can be applied to all metals, some plastics and ceramics, mostly free machining. It is suitable for both identical (serial) production of many parts and one-off production with universal and CNC. A wide range of options are available in cutting tool geometry. Production speed is up to 1000 pieces / hour depending on the conditions. Efficient use of the material is rare because the amount of chip varies depending on the nature of the process, but chip recycling is also possible. Tool and equipment costs are medium-high for CNC turning. Labor costs are low-medium for CNC turning. -Design- It can work in conjunction with CAD / CAM software in terms of design and production. Processing time should be minimized with CAM software and different connection methods. Cylindrical-symmetrical geometries, shafts, power transmission components, engine parts, screws and connecting elements are suitable for production by turning. Different operations can be performed sequentially on the same bench. To increase tool life, possible edges should be designed and machined in chamfer / radius and corners in radius geometry. For ease of installation in the advanced stage of the design, the chamfer should be broken after the guide and thread. Considering the material diameters determined during the design, the working range for CNC turning is generally in the range of ø0.5mm-ø60mm. Large scale machines can also handle diameters over 2 meters. -Quality- The workability of the material; affects properties such as surface roughness, coating quality, tool life and cutting forces. The cutting tool, coolant, feed, cutting depth and cutting speed are determined according to the material to be processed. The surface roughness obtained is almost perfect. In addition to removing heat, the coolant also facilitates cutting by removing chips. The cutting tools used should be checked regularly for wear during operation. In our second article on the selection of the right method in machining, we will discuss the features, design and production capabilities of the milling process. You can check out our first article about turning here. Milling The process in which the workpiece is fixed to the bench table and chip is removed by the rotational movement of the tool is defined as milling. -Production- The milling process can be applied to easily workable metals, some plastics and ceramics. Cutting tool options are quite high. It can reach a production speed of 100 pieces / hour. Different machining operations can be performed on the same part in CNC milling. Leaves high amount of sawdust and chip recycling is possible. Depending on the use of automation, the costs of the milling process are medium to high. Machining time is low for CNC milling. Labor costs are medium-high for CNC milling. -Design- It can work in conjunction with CAD software. By observing the simulations prepared with CAM software, possible errors can be determined in advance. Tool paths can be created with desired tolerances and transition properties. Since there may be different design requirements in one piece; By organizing the process sequence, surfaces to be processed in one go and surfaces to be processed more than once can be determined. At this stage, the correct use of CAM software significantly affects the efficiency of the milling. Parts of any standard or non-standard geometry can be machined. Due to the constraints of the cutting tool and the workpiece, some complex geometries are not suitable for milling production. Specially designed apparatus and some components 

production can be carried out faster and easier, for example gear production, etc.
Depending on the fixability to the bench table, workpieces with an area of up to 1.5m2 can generally be processed. Work pieces up to 5m in length can also be processed on larger looms.
-Quality-

Domain of material workability; It covers properties such as surface roughness, tool life, and cutting forces.
Adequate fixation of the cutting tool, workpiece and machine is very important to prevent deviations during machining.
Cutting tool, coolant / lubricant, feed and cutting speed; must be chosen according to the material to be processed.
Coolant dissipates heat and also allows chips to be removed from the cutting environment.
The surface roughness obtained is in the range of 0.2-25 μm Ra.

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