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When it comes to crafting internal gears, the traditional gear hobbing method, commonly used for manufacturing spur gears, isn’t suitable due to the gear’s internal shape. Instead, internal gears are often produced using gear shaping, a process that involves employing a pinion cutter.
CNC turning provides numerous benefits in manufacturing processes. Firstly, it ensures precision machining with tight tolerances and accurate dimensions, leading to consistent quality in produced parts. Additionally, its automation capabilities enhance efficiency by enabling rapid and continuous machining, resulting in increased productivity and shorter lead times. CNC turning also offers versatility, allowing for the production of a wide range of parts, including complex geometries and threads. Moreover, its consistency ensures uniformity across manufactured components, reducing variability and scrap. Furthermore, CNC turning reduces labor costs by minimizing manual intervention and dependence on skilled operators. Lastly, its flexibility enables easy adaptation to design changes or production variations, enhancing overall manufacturing agility and responsiveness.
CNC lathes are usually 2-axis machines with a single spindle and may lack advanced production capabilities and protective enclosures. Conversely, CNC turning centers are more advanced iterations of CNC lathes, featuring up to 5 axes and expanded cutting versatility. These centers are equipped to handle higher production volumes and often come with added functionalities such as milling and drilling.
A CNC turning center is a type of machine tool used in manufacturing processes to perform CNC turning operations. It typically consists of a horizontal or vertical lathe with a computer numerical control (CNC) system integrated into it. This CNC system allows for precise control over the movement of the cutting tools and workpiece, enabling the production of various cylindrical components with high accuracy and efficiency.
CNC milling utilizes a computer numerical control (CNC) system to send digital instructions, precisely driving the milling machine mechanism for processing. This method can handle basic shapes not only like flats, grooves, gears, threads, and spline shafts but also perform complex manufacturing processes at multiple angles and orientations. With these features, the efficiency of CNC milling surpasses traditional lathe machining.
In the CNC milling process, a rotating tool cuts or carves away excess material from a stationary workpiece. Conversely, CNC turning is characterized by a rotating workpiece and is often used to produce cylindrical components.
5-axis CNC machining has five independent motion axes, allowing for flexible cutting and carving in multiple directions simultaneously. The five main motion axes include the X-axis, Y-axis, Z-axis, A-axis, and B-axis, representing different motion directions and rotation axes. The ability for multi-axis motion makes 5-axis machining particularly suitable for manufacturing complex-shaped parts and components, widely used in aerospace, automotive manufacturing, medical devices, and other fields.
During CNC milling, surplus material is removed from a fixed workpiece using a rotating tool. Conversely, CNC turning involves a rotating workpiece and is mainly used to produce cylindrical parts.
The main characteristic of CNC machining is the ability to store various cutting processing steps in digital form in the controller and execute different processing steps according to the predetermined program.
When CNC machining ultem, attention should be paid to controlling the machining temperature and selecting the appropriate tools. Ultem material is sensitive to heat, so it’s important to control the cutting speed and feed rate and choose the proper tools to ensure machining quality.
Ultem material has extremely high heat resistance (Can be used continuously at temperatures up to 170°C), excellent chemical resistance, corrosion resistance, and impact resistance. It also has good insulation and wear resistance.
Vapor polishing is a polishing technique specifically designed for transparent plastics like ultem and acrylics. It proves to be a superior option for applications requiring transparency, and it can effectively polish internal features such as threads and bores.
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