choose your color

Author: admin

EMO 2023: Advancements in Tool Manufacturing Technologies

From September 18th to 23rd, the EMO trade exhibition is scheduled in Hannover. Here, the Biberach-headquartered sharpening expert, Vollmer, is all set to display its latest array of sharpening machines and services. In Hall 6 at Booth F32, the manufacturer will exhibit its range of automated grinding, eroding, and laser machines designed to process tools crafted from ultra-hard cutting materials like PCD, CBN, or carbide. Alongside the machines, Vollmer will also share insights into its maintenance and training services and digital solutions through V@dison. Additionally, products from Vollmer’s subsidiaries Loroch and ultraTEC Innovation will also be on display at the EMO booth.

Recognized globally as a paramount production technology trade show, EMO is emphasizing on the integration of products and services more than ever. This setting perfectly aligns with Vollmer’s objective of showcasing its machines, services, and digital solutions. As a comprehensive provider, Vollmer incorporates all production technologies to manufacture rotary tools along with circular and band saws, irrespective of the cutting material utilized.

Tool Manufacturing with Grinding, Eroding, and Laser Technologies

The primary product showcased by Vollmer at EMO will be the VHybrid 260 grinding and eroding machine, capable of grinding and eroding up to 100 cutting tools. The machine features multi-tier machining, facilitated by two vertically arranged spindles. The lower spindle is designed for both grinding and EDM. Thanks to a new V@dison booster solution, the VHybrid 260 can achieve surface quality up to 0.05µm Ra when eroding PCD tools. This digital application allows the integration of EDM as a comprehensive manufacturing process in tool production. The Vpulse EDM generator ensures that even the smallest micro tools, with diameters of 0.5mm or less, are manufactured with supreme precision, performance, and surface quality. The integrated ‘Laser Check’ measuring system guarantees high-precision machining and fully automatic closed-loop round machining, achieving tolerances of ±2µm.

Automated Solutions for All Sharpening Machines

Vollmer’s VGrind 360S tool grinding machine, which will also be on display at EMO, embodies the concept of multi-tier machining. The focus will be on machining CBN tools and how tool manufacturers can customize their production with the machine, irrespective of whether they manufacture special tools or mass-produce tools. With suitable automation solutions like the new HP 170 pallet magazine, the HPR 250 free-arm robot, or the HC4 chain magazine, the VGrind 360S is ideal for unmanned, round-the-clock machining. The HP 170 offers optional integration of optical detection of cooling channels. Moreover, up to eight grinding wheel packs, inclusive of the coolant supply, can be automatically changed.

The VLaser 370, another Vollmer machine to be showcased at EMO, can process ultra-hard materials directly at the pivot point, courtesy of patented kinematics that ensure fewer compensating movements for high-precision tool production. Besides these machines, Vollmer will also display the products and services of its subsidiaries Loroch and ultraTEC Innovation. Loroch specializes in machines for sharpening circular saw blades while ultraTEC Innovation provides ultrasonic deburring systems that allow contactless and resource-efficient deburring of metal or plastic components.

Vollmer’s Service and Digital Solutions

Vollmer concludes its EMO trade show presence with services for maintenance, repair, training, financing, and digitalization. These offerings include the digital initiative V@dison, which integrates the V@ boost solution ‘Performance Package for the VHybrid 260.’

Jürgen Hauger, Managing Director of the Vollmer Group, states, “The positioning of EMO as the world’s leading trade fair for production technologies aligns perfectly with our corporate philosophy since we provide global sharpening technologies for high-precision and automated tool manufacturing. We offer not just a specific process, but the exact process that customers need. Moreover, we supplement our machines with tailored services and digital solutions to optimally support tool manufacturers and sharpening services in automated and cost-efficient production.”

TIPS FOR CHOOSING THE PERFECT DRILL PRESS

While using a cordless drill may suffice for small DIY projects, there will come a time when you need the precision and accuracy of a drill press for tasks that require specific hole depths and distances. To ensure excellent results in your next project, it’s essential to select the right drill press with the necessary features. This buyer’s guide aims to assist you in finding the ideal drill press for your needs, whether you’re working with metal or wood.

Understanding Drill Presses: A drill press is similar to a handheld drill, featuring a drill chuck to hold various drill bits. However, the similarities end there, as drill presses are not operated by hand. Instead, the drill press consists of a motor, chuck assembly, speed control handle, and feed handle mounted on a sturdy support column and base. An adjustable worktable, often accompanied by a vise, moves along the column.

Types of Drill Presses: There are two main types of drill presses: benchtop and floor models.

Benchtop Drill Press: As the name implies, the benchtop drill press is designed to fit conveniently on a workbench, making it suitable for smaller projects and compact workshops. These drill presses typically have an 8- to 12-inch swing, which is the distance from the center of the drill chuck to the edge of the support column, multiplied by two. They can drill holes up to 2 to 3-3/8 inches deep, making them ideal for garage setups.

Floor Drill Press: Floor drill presses, on the other hand, are standalone machines that are securely fastened to the shop floor. They offer more power for heavy-duty tasks and larger workpieces, usually featuring a 13- to 20-inch swing and the ability to drill holes 3 to 6 inches deep.

Common Uses for a Drill Press: While drilling holes is the primary function of a drill press, there are several other applications where it excels:

  1. Drilling holes to a specific depth using a depth stop.
  2. Drilling angled holes by tilting the head or table if the drill press has those features.
  3. Reaming precise-diameter holes.
  4. Creating threaded holes with a tap.
  5. Countersinking holes for flat-headed screws or deburring hole edges.
  6. Counterboring to accommodate socket head cap screws.
  7. Cutting square or rectangular holes in wood using a mortising bit.
  8. Sanding materials using a sanding drum that fits into the drill chuck.

Important Features to Consider: When choosing a drill press, there are several key features to look for:

  1. Sufficient Horsepower: Aim for a drill press with at least 1/2 horsepower unless you regularly drill large holes in tough metals. More power may be necessary for heavy-duty applications.
  2. Swing Size: Determine the swing size you require based on the distance from the center of the chuck to the column. Consider larger swings if you’ll be drilling holes more than six inches from the edge of your workpieces.
  3. Depth Stop: A depth stop is crucial for consistent drilling when multiple holes need to be drilled to the same depth.
  4. Stroke Distance: More stroke distance allows for working with longer drill bits and thicker materials, enhancing the versatility of the drill press.
  5. Digital Readout: A drill press with a digital readout displays the running speed and can provide precise depth measurements.
  6. Chuck Capacity: Ensure the drill chuck has a large enough capacity to accommodate the size of drill bits you intend to use.
  7. Adjustable Worktable: Look for a high-quality worktable that can be adjusted vertically and sometimes swiveled to accommodate various workpiece sizes and hole depths.
  8. Warranty: Check for a solid warranty to ensure the longevity of your drill press. Some manufacturers offer warranties that include additional features like laser guide alignment systems.

Common Drill Press Accessories: To enhance your drill press capabilities, consider these common accessories:

  1. Heavy-Duty Worktable: Especially useful for benchtop drill presses, a sturdy worktable provides a reliable surface for attaching your drill press.
  2. Drill Press Vise: A vise is essential for securely holding smaller parts during drilling.
  3. Mortising Chisels: These chisels are used for cutting square and other-shaped holes.
  4. LED Work Light: Built-in lights improve visibility and reduce shadows during drilling.
  5. Sanding Drums: Attachable sanding drums expand the drill press’s functionality to include sanding tasks.
  6. Laser Guide: A laser guide with crosshair lines on the workpiece helps achieve precise drilling accuracy.

Cost of Drill Presses: Drill press prices vary based on features and accessories. Smaller benchtop models can start as low as $40 to $50, while larger drill presses with advanced features can reach prices of $10,000 or more. Generally, the price reflects the quality and capabilities of the drill press.

Benefits of Owning a Drill Press: Investing in a drill press provides several advantages:

  1. Increased Control and Power: Drill presses offer greater control and power compared to handheld drills, resulting in faster and more accurate drilling.
  2. Versatility: With the ability to handle larger drill bits and work with harder materials, drill presses are more versatile for various applications.
  3. Durability: A quality drill press will outlast a handheld drill while consistently delivering high performance.

Conclusion: A drill press is a valuable tool that offers precise drilling and increased efficiency. It is an essential addition to any machine shop or workshop, whether you’re a professional or a hobbyist. By considering the necessary features and accessories, you can select the perfect drill press for your needs and ensure successful project outcomes.

Automated Support Removal & Finishing for Metal AM: Robots vs CNC

Metal additive manufacturing (AM) has brought about a revolutionary change in the manufacturing industry by enabling the production of intricate and complex parts in a faster and more cost-effective manner. However, post-processing these parts is crucial but can introduce time and financial constraints that offset the benefits of AM. One of the critical steps in post-processing metal AM parts is support removal, which poses a significant challenge. While supports are necessary for maintaining part fidelity during the manufacturing process, they must be removed to achieve the desired final product with the intended shape, features, and tolerances.

Although manual support removal is still prevalent in many metal AM applications, this article explores the transition to automated support removal (and finishing) solutions and examines the advantages and disadvantages of using Computer Numerical Control (CNC) systems compared to the versatility and reliability of robots.

TO SUPPORT OR NOT TO SUPPORT? THAT IS THE QUESTION

There is an ongoing debate that the support removal challenge in AM will eventually be resolved through support-free printing. This ultimate goal would allow for complete design freedom and optimized resource efficiency, where raw materials and energy are solely utilized for the final part rather than supports.

Unfortunately, the AM industry has not reached that point yet. While designs are being optimized to minimize the need for supports, they remain a necessity for the foreseeable future. Reducing the material and energy used for supports is generally beneficial, but it can also compromise design freedom and impact the functionality of the end-use part. For instance, parts requiring filled cavities or overhangs may face challenges in achieving lightweight designs. Generative designs may also face unnecessary constraints to accommodate reduced supports.

Moreover, a focus on support reduction can affect process efficiency. For example, building long parts may require specific orientations, occupying more space on the build plate. Stacked builds may become impractical due to interconnected support structures.

In summary, while efforts should always be made to minimize supports, they currently remain essential for most complex AM applications.

MANUAL POST-PROCESSING

Surprisingly, manual support removal remains the preferred method for the majority of AM users today. Skilled technicians employ various traditional hand tools, including Dremels, to remove supports. This method has been tried and tested, requiring problem-solving skills and creativity. It is well-suited for high-mix, low-volume production environments.

However, manual support removal is time-consuming, labor-intensive, and messy, often involving toxic dust that necessitates personal protective equipment (PPE) or shielded environments. There are common issues such as the risk of powder ignition and explosion, as well as repetitive strain injuries. Additionally, manual removal lacks accuracy and repeatability, as quality control problems arise due to variations between individuals and shifts. Furthermore, scaling up manual support removal becomes challenging when the demand for AM parts significantly increases.

AUTOMATION, AUTOMATION, AUTOMATION

Some progress has been made in automating the post-processing of metal AM parts. One common approach involves the use of CNC milling machines, a proven technology widely used in various manufacturing applications, including hybrid AM. CNC machines offer undeniable accuracy and repeatability. However, just because a solution is common and successful in certain areas does not always make it the best choice.

CNC can be effective when dealing with parts that require tight tolerances and when flatness, circularity, concentricity, or dimensions need to be within a few microns. It is also suitable for support removal in large batch builds with simple geometries that can be easily fixtured in a few orientations. Furthermore, CNC can be a good fit for prints where a CNC EDM (Electrical Discharge Machining) takes care of most supports during platform removal.

However, CNC machines are not well-suited for thin-walled components, space-saving stacked builds, lattice structures, or breakaway supports. CNC programmers also struggle with generatively-designed organic shapes with compound curves.

This highlights the argument against using CNC for support removal in the AM ecosystem.

One of the key advantages of AM is the design flexibility that enables users to iterate, customize, and upgrade components from one batch to the next. Companies utilizing AM for production purposes rarely invest in rigid industrial automation as any design iteration would require new CNC trajectories and come at a high cost. The design flexibility of AM should extend throughout the entire manufacturing process chain.

This issue is similarly encountered in tooling and fixturing. High-precision fixtures suitable for rigid industrial automation do not make sense unless committing to a long-term design.

Additionally, batch-to-batch variability poses a challenge. Even with perfect fixtures and tool paths, relying solely on a perfectly predictable support surface directly from the printer may not be ideal. AM supports are designed to deflect, ensuring that AM parts remain stable. The thin connections between supports and components minimize surface witnesses and facilitate the easy removal of scaffolding. Material composition may even vary between batches, resulting in different behaviors and appearances of supports.

ROBOTS TO THE RESCUE

Automation in AM requires adaptability, especially for support and witness removal. This challenge has been addressed through sophisticated software and artificial intelligence systems that generate tool paths and robot motions without the need for an entire systems-engineering team. This allows for quick iteration and automation of small batches.

Instead of high-precision fixtures, 3D scanning can be utilized to locate parts. This means that plastic fixtures can be quickly produced using desktop FDM printers without concerns about accuracy or design changes. Force sensors can be employed to sense the surface and adjust the machining process accordingly, spending more time on high spots until the final shape is achieved or achieving a consistent finish through polishing.

One significant advantage is that robots can employ various tools for support removal and finishing. If the suitable tools for the materials or types of supports used are already known, these exact tools can be attached to a robot, providing greater confidence in the automation process. Adding a new custom tool to a robot is similar to adding a new type of endmill to a CNC machine and does not require costly involvement from a system integrator.

Rivelin Robotics, a specialist in metal AM post-processing, already offers products that demonstrate these capabilities. The company specializes in developing and installing robots designed specifically for a wide range of AM post-processing applications. Rivelin Robotics’ advanced robotic solutions excel in reliable and accurate support removal.

Compared to traditional CNC machines, Rivelin Robotics’ robots offer several advantages such as improved speed, accuracy, and repeatability for support removal and finishing processes. They are highly flexible and can be easily adapted to different applications and processes.

Safety is a significant focus in the design of Rivelin Robotics’ robots, featuring protective casings and safety features that reduce the risk of accidents and injuries. Moreover, their power and coolant requirements are significantly lower than those of CNC machines, leading to increased resource efficiency, energy efficiency, and waste reduction.

In summary, robots are emerging as a superior solution compared to CNC machines for automating support removal from metal AM parts due to their speed, efficiency, flexibility, accuracy, repeatability, safety, cost-effectiveness, and sustainability. Integrating robots into the process not only improves the quality of the finished product but also ensures a safer, more sustainable, and cost-effective end-to-end manufacturing process.

Wireless IO-Link Technology Revolutionizes Packaging Equipment

Rotzinger, a leading provider of automated cosmetic and packaging equipment, has successfully integrated CoreTigo’s state-of-the-art wireless IO-Link technology into their packaging machines. This innovative solution enables dynamic changeovers, minimizes cable infrastructure, and significantly reduces downtime.

Driven by a customer request for a food packaging machine that could handle high throughput and accommodate various products, Rotzinger recognized the need for advanced technology. They turned to CoreTigo, a renowned supplier of industrial communications, to explore their wireless IO-Link technology, which promised to deliver the required I/O capabilities without the hassle of bulky cables and enable rapid tooling changeovers.

IO-Link Technology Unleashed IO-Link represents a cutting-edge industrial protocol that leverages Ethernet/IP or ProfiNet to transmit status or control information from discrete inputs, discrete outputs, or IO-Link devices. A key advantage of IO-Link is its ability to enable devices to transmit diagnostic data and accept configurations via industrial protocols.

The Power of IO-Link Wireless CoreTigo’s impressive portfolio includes a range of wireless IO-Link devices meticulously designed for industrial applications. These wireless products encompass control and monitoring systems, as well as sensors and actuators. Among their offerings, the TigoMaster product line stands out by providing wireless IO-Link master functionality, which can be seamlessly integrated into virtually any industrial device. Additionally, the TigoHub i4, a multiport I/O hub, wirelessly connects to IO-Link masters and supports up to four IO-Link devices.

Moreover, CoreTigo offers IO-Link bridges, clever devices that can transform traditional wired IO-Link devices into wireless counterparts. Equipped with an internal antenna and two M12 connectors, these bridges enable wireless IO-Link technology to connect wirelessly with the device.

Like conventional IO-Link masters and hubs, the Tigo product line offers great flexibility as it can be combined and configured in various ways to enhance overall I/O capability.

Flexible Packaging Equipment Revolutionized Flexibility is a crucial aspect of automated equipment, as manufacturers constantly strive to make their machines as adaptable as possible. Interchangeable tooling is one method employed to increase flexibility, but the time required for equipment changeovers often results in lost production time.

To tackle this challenge, Rotzinger has successfully implemented wireless IO-Link technology in their packaging machines. By utilizing grippers mounted on a servo-driven conveyor, the need for cables is eliminated. CoreTigo’s TigoBridge actuators enable wireless control, allowing the machine to package single or double product packages without any equipment downtime. The shuttles can be easily batched into their respective configurations, ensuring seamless production.

Retrofitting Equipment for Enhanced Performance As an alternative to purchasing new equipment, retrofitting existing machinery is gaining popularity, particularly when integrating data collection into established production lines. However, older equipment often lacks the necessary signals or sensors to gather machine efficiency data effectively. By leveraging wireless IO-Link technology, the impact on existing equipment is reduced, eliminating the need for signal cables or complex interfacing with the existing PLC.

Enter the TigoGateway, an IO-Link master capable of utilizing popular IIoT protocols for edge computing applications. Employing wireless IO-Link technology empowers machine builders to expand and upgrade existing equipment or facilitate the integration of flexible machinery with reduced changeover requirements.

What types of CNC machines will be in high demand in smart factories? Will software or hardware dominate?

The landscape of manufacturing has evolved significantly from the days of basic cutting tools. Nowadays, customers expect top-notch tools made from high-quality materials, with minimal margin for error. The focus has shifted towards achieving an end-to-end process that encompasses everything from sourcing the best materials to delivering an exceptional customer experience. This transformation heavily relies on interconnected machines and devices. As the expectations for cutting tools continue to evolve, the types of CNC machines employed can make or break a company’s position in the competitive toolmaking industry.

In the future, smart factories will require both software and hardware solutions. You might have come across everyday objects like toasters that can detect when we’re running out of bread or devices that anticipate our need for servicing before we even realize it. These are the exciting applications of the Internet of Things (IoT). However, the advantages of IoT are not limited to these consumer-oriented examples; they can significantly benefit manufacturing facilities as well. IoT enables factories to predict when a machine requires servicing, monitor its performance, and detect low stock levels. In fact, factories can even integrate IoT-connected devices like a USB-connected sandwich press in the lunchroom, bringing convenience to the workplace.

This is where software plays a crucial role. Smart factories seeking the benefits of IoT must prioritize connectivity. Machines must have access to software that connects them to an internal network, enabling seamless interaction across the entire system. In some cases, it may even be beneficial to connect these machines to larger networks that leverage customer and supplier information, resulting in streamlined processes.

Software also brings other impactful benefits. For instance, our latest product introduced advanced features to cutting tools, allowing for more intricate cutting tool geometries. Different industries have varying requirements; for example, aerospace and power generation utilize both hard and soft materials, necessitating different cutter geometries for machining. Through software, we have incorporated new geometries to manufacture specialized cutters tailored to these specific processes.

Moreover, having the right software is crucial for enabling different types of CNC machines to communicate with one another. In the past, machines utilizing different protocols or from different manufacturers often struggled to interact with internal systems within the factory. By implementing software on these machines, they can transmit data to a central location, where it can be distributed in a format understandable by every machine and person involved.

Interestingly, a significant portion of the machines currently in use (approximately 95%) are ten years old or less. This presents an advantage to your factory as these machines can often be upgraded with the latest software and compatible accessories for automation. Retrofits offer an opportunity to avoid wholesale machine replacements. Instead, updating machines one by one allows for uninterrupted factory operations with minimal downtime and cost, ensuring a seamless customer engagement experience.

Functionality in CNC machines is constantly improving and expanding. While CNC machines are not akin to phones that can fit in your pocket or fold up, they continue to evolve. Machines of the same size as those installed fifteen years ago now offer enhanced capabilities. For instance, CNC milling machines have progressed from four-axis to six-axis and have incorporated spiralling into their repertoire. As machines improve, so do their cutting processes and productivity, delivering faster, more precise, and easier-to-monitor operations.

It’s important to approach the transition one step at a time. Upgrade or replace machines strategically to achieve quick wins and swiftly enhance your factory’s capabilities in a cost-effective manner.

Closed-loop manufacturing is on the horizon, whether you embrace it or not. When upgrading or replacing your CNC machines, it’s essential to consider the business advantages you aim to achieve. In the realm of smart factories, competition revolves not only around range and precision but also specialization, customer experience, and time to market. CNC machines that facilitate build-to-order processes enable reduced

10 Ways the Manufacturing Industry will Change in 2023

The manufacturing industry is constantly evolving, driven by advancements in technology, market demands, and shifting consumer preferences. As we look ahead to 2023, it becomes evident that this sector will undergo significant transformations. In this article, we will explore ten key ways in which the manufacturing industry is poised to change in the coming year.

  1. Increased Adoption of Automation:

Automation has been revolutionizing the manufacturing industry, and its impact will continue to grow in 2023. With advancements in robotics, artificial intelligence, and machine learning, manufacturers will increasingly implement automated systems to streamline operations, enhance productivity, and reduce costs.

  1. Growth of the Industrial Internet of Things (IIoT):

The Industrial Internet of Things (IIoT) will play a pivotal role in transforming the manufacturing landscape. In 2023, we can expect a surge in connected devices, sensors, and data analytics, enabling manufacturers to gather real-time insights, optimize production processes, and improve overall efficiency.

  1. Embracing Sustainable Practices:

Sustainability will take center stage in the manufacturing industry in 2023. With growing environmental concerns, manufacturers will prioritize eco-friendly practices, such as energy-efficient technologies, waste reduction, and responsible sourcing, to align with global sustainability goals and meet consumer expectations.

  1. Implementation of 3D Printing:

3D printing, also known as additive manufacturing, will witness broader adoption across various manufacturing sectors in 2023. This technology enables rapid prototyping, customization, and cost-effective production, empowering manufacturers to accelerate product development cycles and respond swiftly to market demands.

  1. Enhanced Supply Chain Management:

Supply chain resilience and optimization will be crucial in the post-pandemic era. Manufacturers will invest in robust supply chain management systems powered by data analytics, artificial intelligence, and blockchain technology to minimize disruptions, improve transparency, and ensure efficient logistics operations.

  1. Integration of Augmented Reality (AR) and Virtual Reality (VR):

AR and VR technologies will find increased application in the manufacturing industry in 2023. These immersive technologies will enable manufacturers to enhance worker training, simulate complex assembly processes, and facilitate remote collaboration, ultimately leading to improved productivity and reduced downtime.

  1. Focus on Cybersecurity:

As manufacturing becomes more digitally connected, the risk of cyber threats intensifies. In 2023, manufacturers will prioritize cybersecurity measures to safeguard sensitive data, protect intellectual property, and fortify their digital infrastructure against cyberattacks, ensuring uninterrupted operations and maintaining customer trust.

  1. Shift towards Smart Factories:

The concept of smart factories will gain further momentum in 2023. By leveraging advanced technologies like AI, IoT, and big data analytics, manufacturers will transform their production facilities into intelligent, interconnected ecosystems that optimize efficiency, enable predictive maintenance, and enable real-time decision-making.

  1. Reskilling and Upskilling the Workforce:

To thrive in the era of advanced manufacturing, reskilling and upskilling the workforce will be paramount. In 2023, manufacturers will invest in training programs to equip employees with the necessary skills to operate and maintain automated systems, analyze data, and adapt to evolving technologies, fostering a highly skilled and agile workforce.

  1. Increased Focus on Customer-Centricity:

In an increasingly competitive market, customer-centricity will be a key driver of success for manufacturers in 2023. To meet evolving consumer demands, manufacturers will leverage customer insights, gather feedback, and employ agile manufacturing practices to deliver personalized products, shorter lead times, and exceptional customer experiences.

Conclusion:

The manufacturing industry is on the brink of transformative changes in 2023. Automation, IIoT, sustainability, 3D printing, and other technological advancements will shape the industry’s landscape. By embracing these trends, manufacturers can unlock new opportunities, drive

How CNC Machining Is Changing the Medical Industry

CNC machining has been a game-changer in the manufacturing industry, revolutionizing the way products are made with high precision and accuracy. The medical industry has not been left behind in this revolution as CNC machining is changing the way medical devices and implants are manufactured. This article discusses how CNC machining is transforming the medical industry and the benefits that come with it.

Customization

One of the most significant advantages of CNC machining in the medical industry is the ability to customize medical devices and implants. CNC machining allows for the production of highly customized medical devices that can be tailored to fit a patient’s specific needs. This level of customization is critical in cases where a patient has a unique medical condition that requires a specialized device or implant.

For example, in dental implantology, the use of CNC machining has enabled dentists to produce implants that are customized to fit a patient’s unique jawbone structure, resulting in improved patient outcomes. The ability to produce customized implants is also vital in orthopedic surgery, where implants need to fit precisely to minimize the risk of complications.

Accuracy and Precision

CNC machining is renowned for its high level of accuracy and precision, and this is critical in the medical industry where the stakes are high. With CNC machining, medical devices and implants are produced with unmatched precision, ensuring that they meet the strict quality and safety standards.

The use of CNC machining in the production of surgical instruments, for instance, has led to the production of tools with precise geometries and tolerances, ensuring that they perform their intended function optimally. Similarly, in orthopedic surgery, CNC machining has made it possible to produce implants that fit perfectly into the patient’s bone structure, resulting in reduced risk of complications and improved patient outcomes.

Speed and Efficiency

Another significant advantage of CNC machining in the medical industry is the speed and efficiency it offers in the production of medical devices and implants. CNC machines operate at high speeds and can produce medical devices and implants in large quantities in a short time.

This level of speed and efficiency is critical in emergency situations, where the need for medical devices and implants is urgent. CNC machining has made it possible to produce devices and implants quickly and efficiently, ensuring that they are readily available when needed. This has significantly improved patient outcomes and reduced the waiting time for patients.

Cost-effectiveness

CNC machining is a cost-effective manufacturing process that has significantly reduced the cost of producing medical devices and implants. The level of automation offered by CNC machining reduces the need for manual labor, which minimizes the cost of production.

This cost-effectiveness has made it possible to produce high-quality medical devices and implants at an affordable cost, making them accessible to more patients. CNC machining has made it possible to produce complex orthopedic implants at a lower cost than traditional casting methods, making them more affordable to patients.

Innovation

CNC machining has opened up new possibilities in the medical industry by enabling the production of highly complex medical devices and implants that were previously impossible to manufacture. The ability to produce highly customized devices and implants has led to the development of new treatment options for various medical conditions.

For example, CNC machining has enabled the production of patient-specific implants for the treatment of spinal injuries, resulting in improved patient outcomes. Similarly, CNC machining has made it possible to produce customized prosthetic limbs that match the unique anatomy and functional requirements of the patient.

Conclusion

CNC machining is changing the medical industry, and the benefits are immense. From customization to accuracy, speed, cost-effectiveness, and innovation, CNC machining has transformed the way medical devices and implants are produced. The use of CNC machining has led to improved patient outcomes and has made medical devices and implants more accessible to patients. As technology continues to advance, it is exciting to see the new possibilities that CNC machining will bring to the medical industry

CNC MILLING VS CNC TURNING – THE DIFFERENCES EXPLAINED

One of the biggest challenges in modern manufacturing is understanding the different machines and processes involved. CNC turning and CNC milling are two of the most common and useful machining processes, and understanding the difference between them can help machinists achieve better results. In addition, CAD and CAM operators can create parts that can be machined more efficiently, resulting in a more streamlined manufacturing process.

Although CNC turning and milling processes have some overlap, they use fundamentally different methods to remove material. Both are subtractive machining processes that can be used on small or large parts across a wide range of materials. However, the differences between them make each more suitable for certain applications.

CNC milling involves using a variety of rotating cutting tools to remove material from a workpiece based on a custom design created using computer-assisted design programs. The result is a custom part that can be reproduced as many times as needed to achieve a production run of identical parts. CNC milling is used in both heavy-duty industrial facilities and small machine shops and is suitable for all kinds of materials.

Milling machines generally fix the workpiece in place on a bed, and the bed may move along the X, Y, or Z axis. The cutting tools are typically mounted along a horizontal or vertical axis, and milling machines can bore or drill out holes or make repeated passes over the workpiece to achieve a grinding action.

CNC turning, on the other hand, involves holding bars in a chuck and rotating them while feeding a tool to the piece to remove material until the desired shape is achieved. CNC turning is great for cutting asymmetrical or cylindrical parts and can also be used for processes like boring, drilling, or threading. Everything from large shafts to specialized screws can be crafted using CNC turning machines.

In CNC turning, the part itself rotates while a stationary cutting tool is used. The stability that comes from mounting a workpiece on a rotating spindle between the headstock and tailstock allows turning centers to use cutting tools that are fixed. Tools with angled heads and bits can produce different cuts and finishes. Live tooling, or powered cutting tools, can also be used on CNC turning centers, although it is more commonly found on CNC milling machines.

Both CNC turning and milling use CNC control to pre-determine the exact order of operations, meaning that the entire process can be pre-set exactly. As a result, both processes are highly automated, with actual cutting operations being completely hands-free. Operators only need to troubleshoot and, if necessary, load the next round of parts.

When designing a part, CNC milling is best-suited for surface working, grinding, and cutting, as well as symmetrical and angular geometries. Horizontal or vertical milling machines are available, each with its own unique properties. CNC turning, on the other hand, is generally well-suited for prototyping low-volume production or for asymmetrical and cylindrical geometries. CNC turning centers can also be used for high-volume production of certain specialized parts, such as screws or bolts.

Both CNC machines are critical to modern CNC machining, with turning machines rotating the part and milling machines rotating the cutting tool. A skilled machinist can use either machine, or both, to create parts cut to exacting tolerances.

How AI can help your production processes with CNC machines

AI can provide significant benefits to production processes that involve CNC (Computer Numerical Control) machines, which are used to automate the production of complex parts with high precision. Here are some ways that AI can help improve production processes with CNC machines:

  1. Predictive Maintenance: AI can monitor the performance of CNC machines and detect early signs of wear and tear, allowing maintenance teams to schedule preventative maintenance before a failure occurs. This reduces the risk of unexpected downtime and extends the lifespan of the machines.
  2. Quality Control: AI can analyze data from sensors on the CNC machines to detect anomalies in the production process that could lead to defective parts. This allows production teams to quickly identify and fix any issues before they become larger problems, reducing waste and improving the quality of the final product.
  3. Optimization: AI can analyze data on past production runs and use machine learning algorithms to optimize the CNC machine settings for future runs. This can improve production efficiency, reduce production time, and decrease the cost of production.
  4. Virtual Simulation: AI can create virtual simulations of the production process using digital twin technology. This allows production teams to test different scenarios and optimize the production process before running it on the actual CNC machines, reducing the risk of errors and improving the final product.
  5. Real-time Decision Making: AI can provide real-time data analysis to production teams, allowing them to make informed decisions quickly. For example, if a CNC machine encounters an issue during production, AI can quickly analyze the data and recommend the best course of action, reducing downtime and improving production efficiency.

CNC Machining Parts In New Energy Vehicle

New energy vehicles

The term new energy vehicles (NEV) refers to plug-in electric vehicles, which include battery electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), and fuel cell electric vehicles (FCEVs), also called hydrogen vehicles. This term is often used in Chinese territory, referred simply to as electric vehicles in other parts of the world.

New energy vehicles and hybrid vehicles are changing the transportation industry departing from conventional fossil-fueled vehicles towards a more sustainable and greener technology. The applications and functioning of each type of NEV are different, however, the non-conventional vehicle market is expected to grow exponentially in the next two decades.

1. The status of new energy vehicles

According to recent studies, the global market for New Energy Vehicles is growing continuously at an annual rate of approximately 22% and is expected to grow from 8.1 million units to 39.21 million units by 2030 without taking into consideration alternative fuels such as hydrogen and bio-combustibles. The machining parts have a big market.

1.1 The background of new energy vehicle

New alternatives for internal combustion cars started developing decades ago, however, electric cars entered the global market around 2010 when concerns about pollution impact started to hit at an international scale.

Nowadays, the automobile industry assimilated the greener energy initiative among their business goals, and big automobile and tech brands such as Tesla, Nissan, and Volvo joined the new energy vehicle market, especially around electric and hybrid vehicles.

In the last decade, China has become the largest seller of plug-in electric passenger cars in the world and new energy vehicles have more than doubled their sales from 2015 to 2020, selling over a million units. And many China machining vehicle parts manufacturer grows up very fast.

1.2 Electric vehicle and hydrogen vehicle

Electric vehicles, also called battery electric vehicles (BEVs), use electricity instead of internal combustion to run the engine. These vehicles use a large traction battery pack to power the electric motor and must be recharged with a piece of outer charging equipment or station to maintain the electric supply to the engine.

On the other hand, hydrogen vehicles (fuel cell electric vehicles) produce electricity using a fuel cell powered by hydrogen instead of drawing electricity from a battery like regular electric vehicles. In this case, the vehicle is designed so the hydrogen fuel cell has the appropriate size to power the electric motor and stored energy. Hydrogen cells don’t generate emissions or by-products during the energy conversion, since hydrogen is a clean (not-fossil) fuel.

1.3 The famous brand of new energy vehicle

As stated above, many brands and companies have joined the new energy vehicle market worldwide, however, the industry leader is Tesla Motors without any doubt. The company led by famous entrepreneur Elon Musk is the number one seller and manufacturer of electric and autonomous vehicles, electric traction motors, electric machining traction motors parts, independent battery motors, and machining battery motors parts.

With a focus on vision-based solutions for auto-piloting vehicles, Tesla mass produces autonomous driving cars in the United States combining green technologies with intelligence and technology. They focused on creating powerful vehicle batteries and building multiple charging facilities for their drivers. Sylue is a lucky machining parts company, which is a machining parts supplier of Tesla Europe.

Other only-electric automobile companies are gaining popularity around the world including Li Auto, Rivian, and BYD Auto, the last one being the world’s best-selling manufacturer of highway-legal light-duty plug-in electric vehicles in 2016.

2. The development trend of new energy vehicles

Although fuel cell electric technology is growing in importance in the clean transportation movement, the automotive industry nowadays is more oriented toward improving the battery range and autonomy. Also, as long as the machining parts production technology improved, they help battery to be improved.

In this sense, the key to developing electric vehicles with longer driving changes is to improve the characteristics of batteries to gain higher performances without harming the environment. In the early stages of electric car manufacturing, lead acid batteries were the first option for energy supply.

However, advancements have been made to improve their performance by trying new materials in battery composition and the CNC machining technology improve the battery housing, The alloys of lithium with phosphate and manganese have shown successful results in this matter. Likewise, manufacturers lean towards the use of gel and silicon batteries to replace common lead acid batteries without the need to significantly increase the price of vehicles.

2.1 The new energy vehicle will be the most important part of automotive industry in the future (Carbon neutral agreement)

In 2015 the United Nations gathered to commit first-world countries and industrial powers to the Net Zero initiative, and as part of this agreement, nations agreed to reduce carbon emissions to a minimum and establish a road to emission-free transportation, considering the impact that fossil fuels and the energy sector have on the environment.

In this sense, international and national policies are focusing on achieving carbon neutrality before the year 2050, investing millions of dollars to transform the energy sector and include renewable energy and fuel alternatives to achieve the zero emissions goal. Hence, the new energy vehicle market is predicted to keep growing worldwide, expecting to become the first option for buyers in the car market by the year 2060.

2.2 Electric vehicle will be more popular – green energy and intelligence system

Due to their scale, car markets create millions of job opportunities, specifically in the electric vehicle supply chain including CNC machining parts, from the investigation of advanced materials for battery packs to power electronics, machining, engineering, motor manufacturing, assembling, and more. Electric vehicles promote the pace of innovation in the transport sectors, as part of the green energy initiative.

Electric car manufacturers are focusing on decreasing battery costs to make new energy vehicles affordable and incorporating artificial intelligence algorithms and controllers to improve driving range and optimize energy conservation.

3. The application of machining parts in new energy vehicles

As the new energy vehicle industry becomes more competitive, efforts to implement data-driven manufacturing technology and advanced machining tools will increase to meet high-performance standards. As the electric vehicle market grows, the demand for CNC machining parts such as gear wheels, transmission components, compressors, battery cells, and trays will increase exponentially. This involves tighter tolerances in machining processes and advanced/updated grinding, milling and drilling methods.

3.1 Machining parts in vehicle body and chassis system

Several parts of the vehicle skeleton or chassis are made of plastic polymers nowadays, where molding technology plays an important role. The frame or main structure of a car is made of metal alloys with high impact and tension resistance. However, laser CNC machines aid engineers in the manufacturing process of roof panels, bumpers, fenders, and other machinining parts of the car’s body system.

3.2. Machining parts in vehicle braking system

The braking system in new energy vehicles is quite similar to the internal combustion cars, with the only difference being that electric vehicles use an electric-powered system to trigger the brakes. However, if the power supply runs out or fails they still have the regular hydraulic brake system installed.

The main parts of the braking system such as braking pads, brake discs, plates, studs, and bearings are often mass-produced with CNC machines with lathes and milling tools. Especially the CNC machining parts with tight tolerances such as wheel bearings and adjustment ratchets.

3.3 Machining parts in the vehicle steering system

A key part of the steering system in any automobile (new energy vehicles and conventional vehicles) is the steering gearbox. Gearboxes are also part of the transmission system with shafts and gear components allowing vehicle movement. These machining parts are also manufactured with CNC machines (mostly drills and mills).

3.4 Machining parts in vehicle drive motor

Just like their internal combustion engine counterparts, electric vehicle motors consist of a chamber, gears, bearings, wires, and so on. The main difference is the source of energy that makes the motor run, in which the electric motors use electromagnetism as the main functioning principle.

What gears, tensors, bearings, chains, pumps, cylinders, bolts, etc., have in common is that they are made of steel and are highly detailed steel machining parts that need CNC machining processes to adjust to the tight tolerances of vehicle performances. This involves drills, mills, lathes, and modern machining centers to manufacture these components.

3.5 Machining parts in vehicle battery

In electric vehicles and new energy vehicles in general battery trays need to be carefully manufactured to ensure the safety and proper functioning of the battery. These trays are usually made of highly detailed aluminum machining parts, needing precise CNC machinery to tap and drill small holes and other characteristic features.

3.6 Machining parts in vehicle drive system

Not to forget that CNC machines are versatile when it comes to different cutting materials. Not only steel and its alloys but also wood, plastic, carbon fiber, and other materials manufactured using CNC lasers or routers.

Routers are useful to cut dashboard frames and manufacture interior panels, gauges, and light cases made with plastic materials to produce plastic CNC machining parts and brass materials to produce brass CNC machining parts.