In the vast field of precision manufacturing, selecting the right processing technology plays a crucial role in product accuracy, cost, and production efficiency. This article provides an in-depth comparison of ten mainstream precision machining processes to help you make the most appropriate decisions based on your needs.
1. Turning
Technical Principle: Achieve the machining of cylindrical surfaces, threads, and other rotating parts through the cooperation of workpiece rotation and tool feeding.
Precision Range: IT6-IT8, surface roughness Ra 0.8-3.2μm.
Advantages:
– Highly efficient for processing axisymmetric parts.
– Capable of full-process operations from roughing to semi-finishing.
Limitations:
– Limited ability to process complex curved surfaces.
– Prone to deformation when machining thin-walled parts.
Typical Applications: Automotive engine crankshafts, inner rings of bearings, etc.
2. Milling
Technical Principle: Use rotating milling cutters to machine workpieces into planes, grooves, or complex curved surfaces.
Precision Range: IT7-IT9, surface roughness Ra 0.4-1.6μm.
Advantages:
– 5-axis can machine complex-shaped parts such as impellers and blades.
– Suitable for integrated processing of multiple
Limitations:
– Relatively low efficiency in deep cavity machining.
– Tool wear affects the consistency of machining accuracy.
Typical Applications: Aluminum alloy frames of aircraft wings, mold cores, etc.
3. Grinding
Technical Principle: Achieve ultra-high surface quality by removing material through the high-speed rotation of grinding wheels.
Precision Range: IT5-IT7, surface roughness Ra 0.1-0.8μm.
Advantages:
– Capable of mirror-finish surface treatment.
– Can machine hard-to-cut materials such as quenched steel.
Limitations:
– Low processing efficiency and material removal rate.
– High investment cost in equipment.
Typical Applications: Hydraulic valve cores, raceways of rolling bearings, etc.
4. Electrical Discharge Machining (EDM)
Technical Principle: Remove material through the electrical erosion effect caused by pulsed discharges between the electrode and the workpiece.
Precision Range: ±0.01mm, surface roughness Ra 0.4-1.6μm.
Advantages:
– Suitable for processing complex cavities in conductive materials.
– No cutting force during processing, suitable for thin-walled parts.
Limitations:
– Slow processing speed (approximately 0.1-10mm³/min).
– Electrode wear affects machining accuracy.
Typical Applications: Complex cores of injection molds, cooling holes of turbine blades, etc.
5. Wire Electrical Discharge Machining (WEDM)
Technical Principle: Use a moving metal wire as an electrode for discharge cutting.
Precision Range: ±0.005mm, surface roughness Ra 0.8-2.5μm.
Advantages:
– Can machine ultra-narrow slits as narrow as 0.03mm.
– Suitable for high-hardness materials such as carbide.
Limitations:
– Only applicable to 2D contour machining.
– Limited workpiece thickness (usually <300mm).
Typical Applications: Cutting edges of stamping dies, micro-parts, etc.
6. Laser Machining
Technical Principle: Focus laser beams to melt or vaporize materials in an instant.
Precision Range: ±0.02mm, surface roughness Ra 1.6-3.2μm.
Advantages:
– Non-contact processing with no mechanical stress.
– Suitable for machining micro-holes as small as 0.01mm.
Limitations:
– Thermal affected zone on the machined surface.
– High maintenance cost of equipment.
Typical Applications: Micro-holes in electronic components, cutting of aerospace titanium alloys, etc.
7. 3D Printing (Additive Manufacturing)
Technical Principle: Build 3D entities by layer-by-layer material deposition.
Precision Range: ±0.1mm, surface roughness Ra 5-20μm.
Advantages:
– Can create complex structures that are difficult to manufacture with traditional processes.
– High material utilization rate (>90%).
Limitations:
– High surface roughness requiring post-processing.
– Long forming time for large-sized workpieces.
Typical Applications: Customized medical devices, fuel nozzles of aircraft engines, etc.
8. Ultrasonic Machining
Technical Principle: Break materials using high-frequency vibrations of the tool head.
Precision Range: ±0.02mm, surface roughness Ra 0.4-1.6μm.
Advantages:
– Suitable for brittle materials such as glass and ceramics.
– No thermal deformation during processing.
Limitations:
– Low processing efficiency (approximately 0.1-1cm³/min).
– High noise during equipment operation.
Typical Applications: Lenses of optical glass, cutting of semiconductor silicon wafers, etc.
9. Nanomachining Technology
Technical Principle: Achieve ultra-precision machining based on atomic or molecular manipulation.
Precision Range: Nanometer level, surface roughness Ra <0.1μm.
Advantages:
– Can achieve atomic-level surface flatness.
– Used in the manufacturing of quantum devices.
Limitations:
– Extremely high equipment cost (>USD 1 million).
– Limited machining size.
Typical Applications: Hard disk heads, MEMS sensors, etc.
10. Waterjet Cutting
Technical Principle: Impact materials with high-pressure water jets (containing abrasives).
Precision Range: ±0.1mm, surface roughness Ra 1.6-6.3μm.
Advantages:
– No thermal affected zone, suitable for heat-sensitive materials.
– Can cut any complex shape.
Limitations:
– Low cutting efficiency for hard materials.
– Need to replace nozzles regularly.
Typical Applications: Cutting of composite materials, architectural decorative panels, etc.
Technology Selection Decision Tree
| Demand Dimension | Recommended Technologies |
|---|---|
| Ultra-high precision (μm level) | Grinding, Wire EDM, Nanomachining |
| Complex Surfaces | 5-Axis Milling, 3D Printing |
| High Hardness Materials | EDM, Laser, Waterjet |
| Infinitesimal Feature | Laser, wire cutting, ultrasonic |
| Rapid Prototyping | 3D Printing, CNC Milling |
If you need professional processing solutions based on specific workpiece parameters, please Contact Our Technical Team.
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