Laying A Good Foundation for Machining Can Improve Machining Accuracy
Knowledge

Laying A Good Foundation for Machining Can Improve Machining Accuracy

Machining is one of the most important cutting process used in any manufacturing industry. There are many different processing methods and each of these methods may require the use many different cutting tools. With each tool corresponding to a different cutting process, often problems can occur which not only affect the machining accuracy, but also the quality of the workpiece, and can even cause accidents. Understanding the cutting processes, machine tools used, and factors affecting accuracy are important for avoiding problems. Understanding the basics of cutting processing and smart tools will make your machining more effective and require less effort.
Published: Apr 13, 2022
Laying A Good Foundation for Machining Can Improve Machining Accuracy

What Is Machining?

Machining refers to the procedure of using some sort of tool to remove material from a workpiece to give the material the desired shape. There are two general categories of processing which machining can be divided into; milling and turning. Milling is the process where the workpiece is held in a fixed position and a tool is moved to remove material from the workpiece. Turning is where the workpiece is rotated, and the tool maintains a set position to cut the workpiece as it rotates. 

Some cutting processes such as turning, drilling, broaching, etc. will use tools with single blades, while other procedures such as cutting, grinding, and polishing often use tools with several blades. Various types of abrasive tools are used for grinding processes.  By selecting the most appropriate tools for the processing required, a broad range of products can be manufactured with high precision and low surface roughness for a broad range of applications.

During machining, the temperature of the workpiece may be regulated to obtained a desired effect on the workpiece. When machining is performed at ambient temperature it is called cold processing.  Hot processing is when the work is done at a temperature higher than ambient temperature. This is usually done when some form of chemical reaction is desired in order to change the properties of the workpiece material such as for hardening the workpiece. 


Machine Tools:

Machine tools come in many designs and are produced to meet to various specifications. Many current machine tools are digitized to meet set specifications according to international standards. By being familiar with these standards you can choose machine tools that will achieve the best results for your machining needs. Some manufacturers will improve on technology and develop their own specialty tools to face market competition. When operators are familiar with the tool options available, they can adapt their machine parameters to achieve high-precision machining.

Factors Affecting Machining Accuracy

  1. Many parameters need to be maintained in order to maintain quality of production. Compromised quality in the workpiece can result from errors in the machining tools. Spindle rotation error, guide rail error, and transmission chain error are problems that can occur as a result of improper installation or from wear on a machine tool over time. All these will affect manufacturing efficiency and accuracy of the workpiece to be processed.
  2. The external force of the machine tool: When a force is applied to an object, the object will generate a force that resists deformation, which is called rigidity. To perform high-precision processing, the rigidity of the machine tool is important. The more rigid the machine tool, the higher the dynamic precision. The rigidity of the machine tool itself as well as the rigidity of the workpiece needs to be considered. The rigidity of the machine tool will mainly depends on its material, cross-sectional shape, size, etc., while the rigidity of the workpiece material, will depend on its geometric size, hardness, processing method, and surface roughness.
  3. Thermal deformation: The object will expand with the change of temperature, and the degree of change from heating will vary with different materials. Therefore, it is necessary to pay attention to the change in temperature during processing and understand the relationship between the operating time and temperature of the machine tool and workpiece.
  4. Use of cutting fluid: Cutting fluid is important for machine tools. It can provide effective protection for workpieces and tools, reduce tool wear and improve the machining accuracy of workpieces.
  5.  Influence of speed: Under normal circumstances, the higher the cutting speed, the higher the efficiency, but it will be restricted by the hardness, plasticity, carbon content, tool hardness, and geometric properties of the workpiece. Therefore, the speed should be adjusted according to the tool and workpiece material to ensure machining accuracy.


Milling Machine Processing:

Milling Machine Processing is any of the procedures performed on a workpiece using some form of cutting tool attached to a rotating shaft. The tool intermittently contacts and cuts the workpiece to machine the surface of the workpiece into a flat or curved surface. Other various operations can be performed such as drilling and grooving. Milling machines can be divided into horizontal and vertical types according to the spindle direction of the tool. One type of machine called a gantry-type milling machine has a structure that straddles a horizontal long-bed and can simultaneously machine with multiple cutters.  

  • General purpose milling machine: A general-purpose milling machine is a milling machine that is manually operated by the operator. When moving the relative position of the tool and the workpiece, the operator needs to judge and set the machining conditions such as the position, feed, speed, and cutting amount of the tool. Fine and high-quality finished products can be completed manually.
  • CNC milling: CNC milling is a machining process that uses a computer to control the processing conditions. The machine's built-in computer performs CNC controlled operations automatically using 3D CAD/CAM software. They save labor and can be used in the machining of complex shapes.
  • Machining center:  A machining center refers to a machine tool with CNC control. It is a multi-axis, compound machine that can be installed with different tools on multiple spindles. A machining center makes it is possible to simultaneously perform different types of cutting, drilling, or surface machining. By combining linear motion with rotary motion, the machining center can complete machining of more complex shapes.
  • CNC gear processing machine: Using the CNC gear processing machine with a built-in computer, it is possible to process and manufacture gears of various shapes and sizes, such as those used in clocks and automobiles.

Lathe Processing:

Lathe processing is a procedure performed on the outer periphery of a workpiece as it turns. The workpiece can be machined into round or tapered shapes, and threads and grooves can also be cut into the workpiece.

  • General lathe:  This is a lathe in which the operator manually feeds and replaces tools. The  lathe uses a fixture called a collet to hold the workpiece as it is spun it at high speed for machining. Very compact desktop lathes can be used on a workbench to machine very small parts.
  • CNC lathe: Lathe machining using computer-control, allows even beginners to perform machining with high quality. Since it automatically replaces multiple tools, it also increases work efficiency. CNC automatic lathes can be programed to process irregular shapes such as cams.

The Basic Process of Cutting:

  • Cutting action: Cutting refers to the action of using a tool to cut off a part of the target workpiece.  The cutting action involves the action of successively shaving off strips of material from the workpiece. The tool, such as a turning tool, moves in a straight line across the surface of the workpiece. The workpiece is then fed into the machine in a direction perpendicular to the cutting direction, and the cutting action is repeated. Successive repetitions of this action create a plane surface on the workpiece.
  •   Processing and resistance: Since the tool and the target are in contact with each other during processing, and the forces interfere with each other, resistance occurs. When working, resistance produced must be considered. When cutting with a turning tool, the resistance will vary depending on factors such as the material of the workpiece, the cutting area, or the type of cutting tool. The cutting area will affect the resistance, and special attention must be paid to the size and shape of the area being processed. When drilling, the type of drill (tip shape), torque resistance, drill rotation speed, feed rate, and material of the target, must all be considered.
  • Processing and speed: Work efficiency as well as quality control are important issues. Machining increases efficiency by increasing the processing speed. But increasing the speed may have negative effects such as increased drag, and thermal deformation, etc. Increasing the machining speed may also shorten the life of the turning tool, increasing the frequency of tool changing required, making the cost per machining unit higher. Therefore, it is very important to consider how speed will affect the tools performance and lifespan.
  • Processing and temperature: As we mentioned earlier in resistance and speed, when performing machining such as cutting, the contact between the target and the tool generates heat. This may increase the temperature inside the target, affecting machining accuracy or tool durability. The faster the processing speed, the more heat is generated. The larger the processing area, the higher the friction, which will increase the temperature. Therefore, when performing machining, it is important to keep an eye on temperature changes. Cutting fluids play an important role in the temperature management of machining. They can reduce the wear between the target and the tool, therefore reducing the heat generated. In the past, most the cutting fluids were oil-based, but now, due to the rising awareness of environmental protection, water-soluble cutting oils have become the mainstream. In addition, because machining requires a large amount of cutting fluid, most of them will use a circulating type device to filter the used cutting fluid and reuse it.

Matters Needing Attention in Cutting Processing:

As the resistance generated by different tools is varies from tool to tool, the influence of resistance must be considered during processing. Different processing methods can be considered to choose the process best suited to give the best efficiency, improve tool durability, and product the best quality.

Improper rotational speed will lead to problems such as increased resistance, thermal deformation, and shortened tool life. Before processing, adjust the speed according to the job situation, pay attention to temperature changes, and make good use of cutting fluid.

The key to striking a balance between speed and quality machining is not based on just a single factor. Correct selection of cutting tools, arranging reasonable procedures, improving environmental conditions, and selecting high-performance cutting fluids can ensure efficient and high-quality machining. Smart tool handling and proper monitoring of the cutting process will optimize the process, improve the quality of the finished product, reduce costs, and even help to avoid accidents.


Published by Apr 13, 2022 Source :machsync, Source :keyence

Further reading

You might also be interested in ...

Headline
Knowledge
Redefining Makeup Removal: Evolving from Traditional Nonwovens to Medical-Grade Standards
As skincare routines become increasingly refined, makeup removal products are no longer secondary tools used solely for eliminating cosmetics. Instead, they have become the first line of defense for skin health, anti-irritation performance, and the sensory experience of daily rituals. The material composition and structural engineering of removal substrates—such as cotton pads, cleansing cloths, and wipes—are undergoing continuous optimization. The industry is shifting from simple absorbent functions toward advanced development that combines low friction, minimal residue, enhanced skin compatibility, and environmental sustainability.
Headline
Knowledge
The Superpower of PCBs: Unveiling the Magic of Heat Dissipation
Every PCB is like a bustling miniature city: the electric current flows like nonstop traffic, and the electronic components are the lively citizens. When “traffic jams” occur, heat builds up quickly. Without proper thermal design, LEDs, CPUs, and power transistors can “overheat” and fail. A PCB isn’t just a circuit-connecting board—it also acts as the city’s “air-conditioning engineer.” Copper traces serve as high-speed distribution lanes, thermal vias function like air ducts, and the board material and metal backing work as invisible heat-dispelling magic. Combined with airflow management inside the enclosure, the PCB efficiently channels heat away, ensuring components perform reliably and quietly safeguarding the entire electronic system.
Headline
Knowledge
From Marine Polysaccharides to Pet Wellness: A New Milestone in Fucoidan Applications
In recent years, companion animals have come to occupy an increasingly significant role in human life—not merely as pets, but as integral members of the family. As pet owners place growing emphasis on animal health and longevity, the demand for functional health ingredients has surged. Among these, fucoidan, a marine-derived polysaccharide extracted from brown seaweed, has emerged as a key player in the field of pet nutritional science. Recognized for its immunomodulatory, antioxidant, and cellular repair properties, fucoidan is redefining the standards for preventive care and holistic wellness in companion animals.
Headline
Knowledge
Eco-Friendly Tableware and Food Safety: A Choice for Both the Environment and Health
With a global increase in plastic reduction and environmental awareness, a growing number of businesses and consumers are opting for eco-friendly tableware made from natural or biodegradable materials to replace traditional plastic items. Eco-friendly tableware—such as that made from bamboo fiber, sugarcane bagasse, leaf fiber, or PLA—typically does not contain harmful substances like plasticizers or BPA, thus reducing potential health risks. According to the European Union's Food Contact Materials Regulation (EC No. 1935/2004), "food contact articles shall not transfer their constituents to food in quantities that could endanger human health." However, when production processes or manufacturing technologies are inadequate, eco-friendly tableware can still pose food safety risks.
Headline
Knowledge
Food Cleanliness and Its Impact on the Human Body: A Farm-to-Table Guarantee
The cleanliness of food, defined as the hygienic state of food surfaces and production environments, is crucial for consumer health. The World Health Organization (WHO) reports that globally, approximately 600 million people fall ill each year from consuming contaminated food, leading to about 420,000 deaths.
Headline
Knowledge
Green Printing Transformation Becomes the Core Competitiveness of a Sunset Industry
As global concerns over climate change, plastic pollution, and carbon emissions intensify, the printing industry is undergoing a profound green transformation. From packaging and commercial publishing to labels and promotional materials, green printing is no longer just an added value—it's becoming a fundamental requirement for brand compliance and supply chain standards.
Headline
Knowledge
From Equipment to System: Building a Highly Consistent and Maintainable Smart Coffee Platform
In today’s retail and service environments, smart coffee solutions that offer high consistency, scalability, and ease of maintenance have become key criteria for commercial adoption. Based on advanced automation control technologies and incorporating Specialty Coffee Association (SCA) brewing standards, this platform integrates modular hardware architecture, data-driven algorithms, and cloud-based remote management. It enables comprehensive deployment—from standalone machines to full-site integration. This system-oriented design not only enhances product stability and flavor reproducibility, but also significantly reduces maintenance costs, making it an ideal solution for chain retailers, branded venues, and smart vending scenarios.
Headline
Knowledge
Development Trends of Intelligent Industrial Lifting Equipment
As global manufacturing accelerates its transition toward smart transformation, the demand for industrial lifting equipment and lubrication systems continues to rise. The Taiwan and Asia-Pacific markets are steadily expanding, with increasing demand for high-safety and precision-controlled lifting and lubrication equipment in the automotive repair and industrial manufacturing sectors. The advancement of smart manufacturing has promoted the integration of intelligent sensing and remote monitoring technologies, making these devices the core driving force of smart factories, fueling rapid market growth and serving as a key driver for Fugimaku’s continuous innovation and development.
Headline
Knowledge
The Tough Hero of the Tool World: The Secrets of Tungsten Carbide
In the world of industrial cutting tools, tungsten carbide is like a superhero: extremely hard, wear-resistant, heat-tolerant, and remarkably tough, able to stay sharp without chipping during high-speed cutting and prolonged machining. From rough milling to precision engraving, its variety of tool shapes and coating technologies allow it to tackle diverse challenges. Its applications even extend beyond cutting tools to wear-resistant parts, mining bits, and even fashion accessories. Whether in automotive components, aerospace molds, or everyday aesthetics, tungsten carbide stands as a reliable powerhouse in modern manufacturing. This article will take you deep into the material’s properties, machining principles, and real-world applications.
Headline
Knowledge
Professional Analysis and Application Value of Pneumatic Tools
Pneumatic tools are a category of industrial equipment powered by compressed air, widely used across manufacturing, assembly, maintenance, and construction sectors. Compared with electric tools, pneumatic tools are lighter in weight, deliver consistent output, offer high durability, and provide superior safety. These advantages make them the preferred choice for professionals in scenarios that require prolonged, high-frequency, and high-precision operations.
Headline
Knowledge
Common Chronic Diseases and Their Characteristics: A Personalized Health Management Guide
In pursuit of a fast-paced life, we often overlook our body's warning signs. According to the Health Promotion Administration, Ministry of Health and Welfare, chronic diseases like hypertension and diabetes have become a hidden threat to public health. Though these conditions progress slowly, long-term neglect can lead to serious consequences such as heart disease or stroke. This article will help you understand their causes and provide a simple “self-health management process” to proactively take control of your health.
Headline
Knowledge
Professional Analysis of Freight Logistics: From Transportation Management to Smart Supply Chains
Freight logistics is a critical component of modern supply chains. It encompasses not only the transportation of goods from origin to destination but also transportation planning, risk management, warehousing, and the integration of information technology. Professional freight operations can significantly enhance transportation efficiency, reduce costs, and ensure the safety of goods.
Agree