Introduction to CNC Machining and Cost Considerations(fastener types Page)
- source:FANYA CNC Machining
How CNC Machining Works
CNC machining starts with a digital 3D model of the desired part created with CAD (Computer-Aided Design) software. The CAD file is converted into CNC code containing coordinates, speeds, feed rates, and instructions for operating the machine. The CNC code guides the machining center, which can include mills, lathes, routers, grinders, lasers, waterjets, EDM (electrical discharge machining), and other programmable equipment. By following the programmed instructions, the CNC machine can automatically change tools, position workpieces, and carry out machining operations to transform raw material into finished parts. This enables fast, consistent production of intricate components shaped with a high degree of precision.
Common CNC Machining Processes
- Milling: CNC mills use rotating cutting tools to selectively remove material and produce prismatic parts with complex geometries. Mills can create flat surfaces, angled holes, slots, pockets, contours, and 3D shapes. They are versatile for manufacturing prototypes, production runs, and custom parts in metals, plastics, woods, foams, and waxes.
- Turning: CNC lathes rotate the workpiece while non-rotating cutting tools remove material. Precision turning operations include facing, boring, drilling, grooving, parting, threading, and forming various diameters, shoulders, and contours. Lathes are ideal for machining rotational parts like shafts, discs, sleeves, and more.
- Drilling: CNC machining centers can accurately drill holes of all sizes and depths at multiple angles in one setup. Holes can be spot drilled, through drilled, counterbored, countersunk, and more. Precise hole patterns and grids are easily produced.
- Other processes: CNC routers cut patterns and shapes into flat material like wood, plastic, and aluminum. EDM machining erodes conductive materials without contact for intricate cavities and cores. Laser and waterjet cutters direct high-energy beams for cutting sheet materials.
Key CNC Machining Cost Drivers
When estimating costs for CNC machined parts, there are several key factors to consider:
Part Size and Complexity
In general, larger and more complex parts that require more programming, setup, and machining time will be more expensive. Intricate parts with delicate features, tight tolerances, and difficult-to-machine materials increase costs. Simple, small parts can usually be produced faster and cheaper.
Machining Operations Required
The types of machining operations, number of steps, tool changes, and overall production route impact costs. Parts requiring extensive milling, drilling, turning, or specialty operations take more programmer and machinist time and increase cycle lengths. Simpler parts with minimal operations are more economical.
Machine Size and Type
Larger CNC machines with higher horsepower allow faster metal removal rates, accommodate bigger parts, and have a higher hourly rate. Using the right machine for the required work also affects hourly rates. Complex 5-axis or multi-tasking machines often have higher rates than standard 3-axis mills and lathes.
Fixturing and securing parts properly takes time and affects cycle times. Minimal setups using basic vise workholding or simple jig/fixture systems help lower costs compared to parts needing elaborate locating strategies and custom workholding solutions.
Parts requiring many specialized cutters, large/small diameter tools, and extensive tooling inventories lead to higher tooling costs. Simpler parts machined with standard end mills, drills, and insert tooling have lower tooling costs.
Batch Size and Volume
CNC machining costs are higher for one-off prototyping and low volume work compared to large production batches due to fixture amortization across parts and economies of scale. Per part costs decrease significantly with higher quantities due to spreading fixed costs over production volume.
Easy-to-machine metals like aluminum and mild steels are more economical than harder alloys, stainless steels, titanium, and exotics. Plastics range from cheap ABS and nylons to higher-cost PEEK and PTFE. EDM machining costs also depend on the workpiece material.
CNC manufacturing costs vary regionally based on labor rates, facility overhead, logistics, and market demand. In general, higher local wages and living costs increase machining rates. Outsourcing to markets with lower wages may reduce costs but introduces supply chain risks.
Quality and Tolerances
Tighter tolerances, better surface finishes, chamfers, edge deburring, cleanliness standards, quality procedures, inspection, and documentation add to production costs. Relaxed specs and quality expectations can decrease costs.
Additional considerations like quick-turnaround, design changes, special packaging/handling, certifications (ISO, FDA, aerospace, etc.), and other customer requirements influence cost as well.
How to Reduce CNC Machining Costs
Here are some tips on how to design parts and approach CNC machining to increase efficiency and reduce overall manufacturing costs:
- Use standard material sizes or nest multiple parts in raw material to minimize waste
- Design parts for 2.5 or 3-axis machining when possible, rather than expensive multi-axis
- Avoid complex curves and surfaces in favor of straight lines and simple radii
- Design uniform wall thicknesses and avoid thin, fragile features
- Minimize specialty tools by using standard cutters where possible
- Specify generous corner radii and chamfers to streamline programming
- Allow for conventional workholding methods like vise clamping or fixture plates
- Adjust tolerances to the least precision necessary for function
- Consider alternative processes like laser or waterjet for cut shapes
- Produce similar parts on same machine for sequencing and scheduling efficiency
- Review design and process with manufacturer for cost-reduction ideas
- Consider production volumes and life cycle when seeking quotes
- Use quotation bidding processes to compare machine shops on cost
- Build prototype or test run before committing to full production
By following design-for-manufacturability guidelines and working closely with manufacturing engineers and machine shops, effective CNC solutions can be developed to meet project goals while controlling costs.
In closing, CNC machining is an extremely useful manufacturing method for producing custom parts with accuracy, repeatability, and complex geometries. However, CNC costs can vary substantially based on technical aspects like part size, complexity, tolerances, materials, and production volumes. In addition, operational factors like machine shop location, capabilities, and capacity utilization affect pricing. By understanding these cost drivers and working with an experienced manufacturer, buyers can effectively source high quality CNC machined components while managing their budget and lead times. With attention to design principles and clear project requirements, CNC machining provides a flexible solution for prototypes, custom manufacturing, and production parts. CNC Milling CNC Machining