CNC Machining Product

3-axis milling

3+2 axis milling

5 axis milling

After machining, most parts standard surface roughness (Ra) of 1.6 to 3.2 μm. This finish is suitable for many applications. For applications requiring a finer surface, such as precision components or aerospace parts, roughness can be improved to 0.8-1.6 μm or even 0.2-0.8 μm. Achieving these finer finishes involves additional processes like fine milling, grinding, and polishing, which increase machining time and costs.

Additionally, other post-machining surface treatments like anodizing, bead blasting, or plating can further enhance both the appearance and functionality of the parts, depending on the intended use. These processes can also be considered for improving the surface properties, such as corrosion resistance or wear resistance, beyond what is achieved through machining alone.

Casting  is a manufacturing process where molten metal is poured into a mold to solidify into a desired shape.

The shape and size of castings are often very close to the final part specifications, which significantly reduces the need for extensive machining and cutting processes.

Material Properties in Castings

Cast Iron

 Gray Cast Iron:

• Properties: Good machinability, high pressure strength, excellent vibration absorption, poor welding performance, limited to temperatures below 300-400°C.
• CNC Use: Suitable for applications needing vibration damping and machinability but not high temperatures or stresses.

 Malleable Cast Iron:

• Properties: Better strength, toughness, and corrosion resistance than gray cast iron, with improved machinability.
• CNC Use: Ideal for small, thin-walled parts requiring strength and toughness, offering better performance than gray cast iron.

 Ductile Cast Iron:

• Properties: High machinability, strength, and plasticity, with good low-temperature performance and fatigue resistance, better heat and corrosion resistance.
• CNC Use: Best for parts needing high strength, toughness, and durability under demanding conditions.

Cast Steel

Carbon Steel

• With high cost-effectiveness and strength, it is suitable for mass production. Its excellent toughness enables it to withstand heavy loads.
• Poor corrosion resistance requires additional surface treatment; machinability is moderate, with tool wear occurring quickly; casting processes may result in larger dimensional tolerances, requiring subsequent CNC machining to meet precise requirements.

Stainless Steel

• Stainless steel casting has excellent corrosion resistance and high-temperature resistance, making it suitable for use in harsh environments. It is strong and tough.
• Higher costs, usually requiring more complex processing techniques; poor machinability, with cutting tools wearing out quickly; and the casting process may result in significant internal stresses, requiring subsequent heat treatment to alleviate.

Aluminum alloy

• Aluminum alloy casting has excellent lightweight characteristics, low density, high strength, good corrosion resistance and thermal conductivity
• Lower tensile strength and hardness, which may not be suitable to withstand heavy duty applications. In addition, the coefficient of thermal expansion of aluminum alloys is large, which may lead to size changes and a decline in strength at high temperatures.

Copper Alloy

• Copper alloys have excellent electrical and thermal conductivity, making them suitable for use in electrical and heat exchange applications. Their corrosion resistance and strength make them widely used in the construction, manufacturing and automotive industries. Additionally, copper alloys are easy to machine and mold, allowing for delicate designs.
• Higher cost, especially in certain alloys where the price of copper can significantly affect the overall cost. Also, copper alloys have relatively low strength at high temperatures and tend to deform or soften in high-temperature environments.

Zinc Alloys

• Zinc alloy casting has good flow and molding properties, making it suitable for the manufacture of complex shaped parts. Its low melting point and relatively low cost make it widely used in automobiles and electronics. In addition, zinc alloys have good corrosion and oxidation resistance, which extends product life.
• The disadvantages of zinc alloys are their relatively low strength and toughness, which makes them unsuitable for applications subjected to high loads. In addition, zinc alloys are prone to deformation at high temperatures, limiting their use in certain high-temperature environments.

Common Materials Used in Forging

1. Stainless Steel

• Forging improves the internal structure of stainless steel, ensuring uniformity and enhancing mechanical properties.
• Forging increases the ductility of stainless steel, making it more resistant to cracking, and suitable for manufacturing complex-shaped parts.

2. Aluminum Alloy

• Aluminum alloy is lightweight (about one-third the density of steel). It has excellent forgeability, no need preheating and heating temperature is usually between 300°C and 500°C.
• Forging aluminum alloy enhances its mechanical properties, increasing strength while maintaining its lightweight advantage.

3. Copper Alloy

• Copper alloys exhibit excellent plasticity at high temperatures.
• Forging increases the tensile strength and hardness of copper alloys while preserving their good ductility and electrical conductivity.

4. Carbon Steel

• Depending on the carbon content, carbon steel can offer a range of strength levels, from low to high.
• Forging significantly improves the grain structure of carbon steel, reducing internal stresses and defects, thus enhancing overall strength and toughness.
• Post-forging heat treatments (such as quenching and tempering) can further adjust hardness and wear resistance.

5. Titanium, Nickel, and Magnesium Alloys

• These materials are commonly used in aerospace applications. Hot forging improves their workability, allowing for the formation of complex parts.