Adaptive control in CNC – what is it, and what are its benefits ？
Posted on June.21th, 2023, | By Kenzi, WayKen Project Manager
Jewelry manufacturing is one of the oldest trades of the world, however, it is early to say that everything that could be useful for manufacturing jewels has already been invented. Progress moves on and CNC Rapid Prototyping of Jewelry can be improved with metal rapid prototyping services as well as laser and water jet cutting. You will be able to know how by reading this article.
The Conventional Process of Manufacturing Jewelry
Jewelry has been traditionally manufactured by casting. That is so because precious metals have good casting properties and the mold can be made with very low surface finishes. The casting process is fast and has good repeatability. However, it requires a master model. The overall quality of the mold and the cast part is highly dependent upon the quality of the master model? So, how were they manufactured originally?
Master models are conventionally made from wax. That usually meant them being carved from a piece of wax by the jeweler. The process was time-consuming and required a lot of skill from the manufacturer.
Once the master model is complete, it is encased in a special substance similar to concrete. You heat up the substance once it has solidified and the wax is evaporated from the concrete. Then you pour molten metal and break the concrete mold to get the jewel out. So, you have to make the master model for each piece from scratch.?Modern industry and the consumer simply doesn’t provide enough time to manufacture jewels commercially this way. If you manufacture each master-model manually, you won’t produce enough products at the required rate and your competitors will overcome you. This is where CNC rapid prototyping comes in handy.
How to Speed up Your Jewelry Business with CNC Machining Services
CNC Machining Services
There is a number of good options CNC prototyping can offer to increase your jewelry business competitiveness. At WayKen, not only CNC metal machining is useful but wax machining and laser and waterjet cutting can be a successful addition in the jewelry business as well.
CNC Jewelry Master-Models
The first thing that comes to mind is implementing CNC machining to manufacture wax master models. And it really is an efficient way implemented in a lot of modern plants. However, you can’t use any simple CNC machining equipment and cutting parameters as the wax is easily bent and melts under high temperatures. In addition, since it’s very soft, you’ll need extremely high spindle speeds ( up to 70,000 rpm). Overall, you will be able to manufacture wax master models at a terrific rate. Additionally, laser and water-jet cutting techniques are highly useful for this type of work as well. They generate little heat and can be further cooled down with special coolants.
Manufacturing Metal Molds
Another efficient way to manufacture cast rings or bracelets is to make reusable molds through metal machining. That way, you won’t even need the master model. You can just create a 3D model of the jewel and make a cavity from it by using specific Boolean operations present in all CAD systems. Then, just add elements necessary for the mold halves to be joined and you can manufacture. The result is a durable mold that will serve you for tens of thousands of jewel pieces. One thing though, it is vital to manufacturing mold halves to match as close as possible. Otherwise, you’ll have a stepover and you’ll have to do a lot of postprocessing afterward.
CNC Machining of Jewelry
Jewels are usually quite small themselves and their ornaments and features are smaller still but if your machine tool and cutter are small enough, It is always possible to make jewels straight on the CNC machine. Machining silver and gold is not unheard of though they are quite soft so the clamping devices must be of similar hardness and with more contact area. The spindle speeds must be very high as well, otherwise, the metal will stick to the tool and it will be more pushed rather than cut resulting in unwanted deformations. In addition, CNC machining has some limits. Basically, it can’t cut where there is no space for the tool to operate. However, it can create intricate patterns and it can offer a very good surface finish, which will drastically cut polishing time.
Engraving Jewelry with CNC Machining
Even if you consider new rapid prototyping methods Cermet Inserts of creating jewelry unnecessary and prefer to use conventional methods. They are great as well since each jewel is hand-made. However, even if you prefer the old ways, you could still use CNC Rapid Prototyping for Jewelry. How? Well, a lot of bracelets, pendants, and rings are engraved with an intricate pattern that is hard to produce manually and CNC machining centers can be mounted with engraving tools and create perfect patterns with a tolerance less than 0,05 mm.
Cutting Diamonds with CNC
Last but not least is using CNC metal prototyping equipment with abrasive tools to create multifaceted beautiful diamonds from raw uncut stones. As you well know, raw diamonds are not those gorgeous sparkling crystals seen on our rings. They are actually quite plain. It’s the masters that make them shine. They cut off bits creating facet by facet to point Cutting Inserts out the stones’ beauty. This is a tense and time-consuming task. However, it can be done and at a considerably faster rate by implementing CNC grinding. The wheel is programmed to grind off facet to facet with a precision unreachable even by the best masters.
Conclusions
Having analyzed the main uses of CNC rapid prototyping for Jewelry, we can make a few conclusions. First, using rapid prototyping significantly decreases Jewelry production cost despite?CNC prototyping cost per hour being larger than that of manual labor. The advantage in time is so large that the overall price of the jewel made using CNC machining is smaller than paying the master for his work that he does much longer. Secondly, the quality of modern CNC machine tools is so great that no master can achieve as much. And lastly, CNC Rapid Prototyping can be implemented at almost any stage of the jewelry manufacturing process
Quality Assurance 3E Rapid Prototyping Company
Jack Burley, VP of Sales and Engineering at BIG KAISER shared his knowledge to?Fabricating & Metalworking?magazine for options targeted to make positive impacts on vibration without breaking the bank.
As all machinists know, vibration is the sworn enemy of high quality and efficient metal working operations. The effects of vibration impede speeds & feeds, reduces tool life and wreaks havoc on the products finish. Typical culprits of vibrations are;
- Carbide Aluminum Inserts Abrupt changes in direction; stops & starts
- Instability in part processing
- Inconsistent forces during operations
Important information inside regarding unlicensed BIG-PLUS? tool holders – download now!
A leading countermeasure for vibration is our original Dual-Contact spindle system?BIG-PLUS?. Many machine tool builders depend on simultaneous taper and flange contact for improved rigidity and vibration reduction. At BIG KAISER, we are obsessed with precision so,?Buyer Beware; not all dual contact systems are created equally. BIG-PLUS is?THE ONLY?true dual contact system for 7:24 taper systems. So, choose wisely grasshopper and don’t discount the value of this technology and only purchase it through licensed producers. If you still don’t believe us, let us prove it with our GUARANTEE. APKT Insert Check it out –?https://us.bigkaiser.com/about-us/.
Another important concept dealing with vibration, is using the largest possible diameter and the minimum possible length. This is an ideal situation however, we all know ideal does not apply in many machining operations. This is where you want to invest in BIG KAISER Smart Damper system for your tough finish boring and milling applications. Smart Damper incorporates passive damping mechanism that functions as a counter action by way of high resonance friction action. This patent-pending system’s damping capability minimizes effects of high frequency oscillations, absorbing vibrations and allowing higher machining accuracy. Keep in mind this system is a modular design allowing customers to customize and manage setups.
While the latest machine tool technology may go a long way towards eliminating vibration and chatter, adding a new machine may not be realistic. Luckily, there are less financially limiting options that will make positive impacts on your vibration problems without breaking the bank.
Please read more details of Jack’s article?here.
Fashion Business？ From Tungsten Cube To “Land of Hope”
End Mill Troubleshooting Guide
End mill tools eventually wear out due to frequent use. Modern engineering, improved materials, and advanced cutting tools have helped extend end mills' lifespan despite Milling inserts the workload they are exposed to. Outstanding manufacturers train their operators to handle cutting tools and common causes of frequent tool malfunction.
Although reliable end mills tools suppliers like SCTools provide a troubleshooting guide, machinists should be aware of the most frequent causes of premature carbide end mills failure. They should also acquire the skills to recognize and correct minor problems. Today, we will discuss common causes and solutions to carbide end mills' problems.
Running the End Mill Too Fast or Too Slow
Inexperienced machinists can have a challenge matching the right machine speed to the end mill types available. They need to internalize the ideal speeds required because running a tool too fast causes suboptimal chipping or tool failure. On the other hand, running it too CNMG Insert slowly can cause deflection, decreased metal removal rates, and poor finish—as indicated in the SCTools end mill troubleshooting guide.
Solution
- Use the correct speed
- Slow down on the first bite to prevent progressive chipping
- Cut less amount per pass if you are using the right speed, and chipping occurs
Feeding the End Mill Too Little or Too Much
Another critical aspect related to speed is the feed rate. If you run your carbide end mill tool with a slow feed rate, you are likely to recut chips, accelerating tool wear. If the feeding rate is too fast, you can cause tool fracture. The best feed rate for any job depends on the end mill types and the material being worked on.
Solution
- Use the proper speed
- Adjust to a small cutting amount per tooth if a fracture occurs while using the correct speed
- Regrind in the earlier stages to reduce wear
Poor Machine to Tool Connection
Improper tool holding can cause tool pullout, tool runout, and scrapped parts. The more firm the tool holder's contact with the tool's shank, the better the connection. Shrink fit tools, and hydraulic tool holders offer superior performance over mechanical tightening methods and some shank modifications.
Solution
- Check the overall condition of your tools, machines, and attachment
- Repair machine or holder
- Replace worn-out tools with durable end mills?
Operating with a Long Length of Cut
A long length of cut (LOC) reduces the strength and rigidity of cutting tools. Sometimes it is unavailable to use LOC because it is necessary for finishing some operations. Generally, a tool's LOC should be the exact length required to ensure your tools retain their original substrate. A longer than necessary tool is more susceptible to deflection, decreasing its lifespan and increasing the likelihood of a tool fracture.?
Solution
- Use proper tool length
- Hold shank deeper if you use the correct tool length
- Stock various end mill types to prevent using the wrong tool length
Selecting the Wrong Flute Count
A tool's flute count significantly impacts your output performance and running parameters. A tool with a low flute count of two to three has a smaller core and larger flute valley. This variable causes the tool to weaken and become less rigid if used on the wrong material. Low flute counts are ideal for aluminum and non-ferrous materials because they help reduce chip recutting. End mills with a high flute count of five or more have a larger core which is great for working on harder and ferrous materials.
Solution
- Use end mill with more or less flute count depending on the material
- Regrind at earlier stages if you are using the correct flute count?
- Add margin if you are getting a rough finish while using proper flute count
Picking the Wrong End Mill Coat
The best tool to use is one with a coating optimized for your workpiece material. End mills sourced from a reputable cutting tools company increase lubricity, slowing down natural tool wear. Other available coatings increase hardness and abrasion resistance. Which coating should you choose?
Contact us today and receive a professional answer from cutting tools experts who will help you choose the perfect carbide end mills coating to optimize your production and extend your end mills tool life.
| If you have any questions about carbide?cutting tools, end mills, drills, etc. be sure to reach out to us @?sctools.co/Home?or call us at (877)737-0987.?We help you machine better!? |
Publication Shares Some of Our Tips for Deep Hole Drilling
This automated storage and retrieval system used in Modula’s own Franklin, Ohio, facility is 52 feet tall and includes 100 trays for storage.
What is the most labor-intensive task manufacturing employees perform? Even in sophisticated manufacturing facilities using a high degree of automation, the answer might be this: look for stuff. That is, seek and obtain the items they need to do their work.
Here is one tray within the 100-tray system. Storing many different types of objects is an important benefit, but controlling and tracking this inventory is equally important.
Storage unintentionally creates drains on time and effort. The best thing to do with bulky resources that are not required immediately for production is to get them out of the way, and the most natural way to do this is to store them on shelves. But then, when the resource is again needed — whether the resource is a tool, raw material, a set of fasteners or other supplies — the one who needs it will have to go to the shelves to get it; search the shelves to find it; and likely enlist the aid of someone with a towmotor in order to retrieve it.
Increased recognition of this drain on capacity is spurring the adoption of automated storage and retrieval systems, says Antonio Pagano, CEO of Modula USA, a provider of vertical storage systems manufactured to order for industrial facilities (tailored, for example, to the extent of a facility’s available ceiling height). Shelves, as companies are coming to see, represent an important opportunity for automation.
How the storage system is used in Modula's production: An automated storage unit near a press brake stores and organizes press brake tooling.
This is a distinctly North American insight. “In Europe, we had a leg up because of floorspace limitations,” he says. Modula was founded in Italy. Among their earliest adopters, the company’s systems made sense as a solution for using plant space more efficiently. But in North America, floorspace is more available; preserving it is less of a concern. Yet there is a growing premium on employee attention and labor hours. “In the U.S., we started to make inroads once we realized floorspace is not the issue — we have an automation solution instead.”
In fact, an automated storage and retrieval system is a foundation for widespread automation throughout the facility. Each system consists of a vertical set of moving trays (in vertical increments of 200 mm, but variable for objects of different heights), with each shelf delivered as needed to a fixed retrieval area at human level near the base of the system. Delivering every stored object to the Carbide Inserts same location creates a natural fit with other automation systems. Example: A robot could retrieve an item from the vertical system and place it on an automatic guided vehicle for delivery where it is needed.
But as much as it is a foundation for plant-wide automation, the automated storage and retrieval system is also a foundation for Industry 4.0. As Pagano notes, data from the unit provide both greater control over, and greater insight into, the production process.
Knowing when each tool is retrieved from the system provides an automatic way to track tool use and flag tools for replacement as they near the end of their expected life.
“You can restrict particular employees to particular trays,” he says. “You can also track how many times a given object is retrieved.” An example of Cemented Carbide Inserts this is in use in Modula’s production facility in Franklin, Ohio. An automated storage and retrieval system holds tooling for a nearby press brake. Tracking the retrieval for each press brake die allows the engineering team to know precisely when each tool is nearing the end of its expected life.
This last point might prove to be the ultimate reason why the automated systems are adopted, Pagano says. Floorspace is valuable. Labor is more valuable still. But in an environment of increasingly more tightly controlled production of increasingly valuable products, the knowledge of how a shop’s resources are being deployed might be the most valuable benefit of all.
Analyze the development and application of high
The strength of metals is one of the most important mechanical attributes necessary in classifying metal applications and usage. Some metals may be suitable to be used in the construction industry but not in the aerospace industry. This is a critical determinant used by scientists, manufacturers, CCMT Insert and engineers in assuring the functionality and practicality of metal on any of their projects.
In the materials industry, strength is defined by a material’s ability to withstand an applied load without exhibiting failure and plastic deformation.
Types of Strengths
Materials exhibit different types of strength depending on how a load is applied. These strengths are used as parameters to be considered when choosing a material for certain applications. Below are the different types of metal strength:
Yield strength- This is the maximum strength a metal can withstand before it exhibits permanent plastic deformation in a tensile test. Engineers use this value to determine the maximum load that a component can carry.This is used as a criterion for defining failure in many engineering Indexable Inserts codes.
Ultimate tensile strength or just called tensile strength- This is defined by the maximum stress the material can withstand during a tensile test. In simpler terms, this is the maximum load a metal can resist before fracturing or being pulled apart.
Compressive strength- This is the maximum strength wherein a material can withstand failure during a compression test. In this type of strength, the load is applied on the top and bottom of the specimen.
Impact Strength- This is a metal’s ability to resist sudden sharp loads without failure. It is the maximum energy a metal can absorb before exhibiting breakage or fracture.
Why Do We Need To Learn About Metal Strength?
You probably have grasped a bit of the importance of learning about mental strength now that you have been oriented on its fundamental types. To explain it further below is a comprehensive discussion on why metal strength is important in various industries:
Mechanical/ Structural Design
When it comes to mechanical and structural elements, engineers need to be aware of the strength of the parts they design. They use this to identify at what point may a material potentially break or fail. In this way, they’ll be able to set the limits and define necessary constraints for certain parts they design.
Material selection
Metal strength is a very relevant criterion in choosing materials that are capable of withstanding the demands or requirements of different applications in the industry. Different metals exhibit different strength ratings. There are certain metals suitable for high-stress applications and there are also some that are more appropriate for low-stress applications. For example, a metal with high tensile strength is preferred for making parts needed for hoisting or pulling.
Safety
It all boils down to safety. Metal strength sets various limits to help avoid failure in any application. Knowing the strength rating of metal allows for a foolproof and safe design of parts that are capable of supporting their intended loads without causing harm to its users.
Strongest Metals Used in Metals Fabrication
In the industry, there will be the strongest ones that may be preferred depending on the application and design requirements. Below are the strongest metals commonly used in various industries:
1.? Titanium
This naturally occurring metal possesses a high tensile strength given its less dense structure than that of the common metals. Titanium is popular for its low strength to weight ratio and high corrosion resistance which make it perfect for aerospace, automotive, and medical applications. Aside from its pure state, titanium is commonly alloyed with other metals to enhance its strength further. An example is the titanium aluminide in which the alloying elements are aluminum and vanadium
2.? Chromium
Chromium has made the list of the strongest metals as it is considered the hardest metal on earth. Chromium might not be commonly used by itself, but it does wonder when it is alloyed to other metals. One popular application where chromium is the key ingredient in the manufacturing of stainless steel, one of the most in-demand metals used in any industry.
3.? Tungsten
This is hailed as the strongest and toughest naturally occurring metal for its ultimate tensile strength of 250,000 psi or 1725 MPa. To compensate for its brittleness, this metal is commonly alloyed with other elements. The most popular alloy is the tungsten carbide. The strength of tungsten has been very useful for various applications in the military, aerospace, mining, and other metalworking industries.
4.? Steel
Generally, steel is one of the strongest metals and the most important engineering and construction material. This metal is made by alloying iron, carbon, and some other elements depending on the type of steel produced. The ultimate stress of steel depends on its other alloying compounds. Below are some types of steel commonly seen:
- Stainless steel- and alloy of steel, chromium, and manganese. This metal is known for its excellent corrosion-resistant properties. It has a yield strength of 1560 MPa and ultimate tensile strength of up to 1600 Mpa
- Steel – Iron – Nickel alloys- Generally, alloying nickel to carbon steel increases its ultimate strength to up to 1450 MPa. Different manufacturers have made their own variations of this alloy.
- Tool Steel- This type of steel alloy is made by mixing in the right proportions of cobalt and tungsten. Its strength and hardness make it a perfect material used in manufacturing CNC cutting tools and even axes.
5.? Inconel
Another alloy that made it to the list is Inconel. This is an alloy of austenitic nickel and chromium. These superalloys are extremely strong and corrosion-resistant which makes them perfect for applications with extreme environments and conditions. These are commonly used for manufacturing turbines, turbocharger rotors, heat exchangers, pressure vessels, and many more.
Processes That Enhance Metal Strength
1.? Solid Solution Strengthening and alloying
This is the method used for the alloyed metals mentioned previously where it is used to improve the strength of pure metal. Solid solution strengthening involves forming a “solid solution” by adding atoms of an alloying element to the crystal lattice structure of the base metal .
2.? Heat treating
This special process may be done at any point in manufacturing a metal part to enhance its properties. During the heating process, the metal’s microstructure is altered which makes a metal or alloy stronger, tougher, and more durable. Below are the common methods of heat treatment:
- Annealing- Metals like copper, silver, aluminum, steel, and brass are heated to lessen their chances of fracturing while being worked on. In annealing, there are three phenomena that happen, recovery, recrystallization, and grain growth.
- Tempering- tempering involves heating the metal to a temperature just below its hardening temperature and holding it at a specified period. This process is done to reduce the brittleness of metal while still retaining its hardness and strength.
- Normalization- This process is done to make steel tougher and ductile.
- Hardening- In this process, the metal is heated at a sufficient temperature that is high enough to dissolve solute-rich precipitates. This process then increases the metal’s hardness and strength. The downside to this however is that the metal has already lost its ductility, making it brittle.
3.? Strain Hardening or cold working
This method involves strengthening metal by inducing plastic deformation to increase its hardness, yield strength, and tensile strength. The dislocations made during this process result in entanglement in the grain dislocation. This entanglement then prevents further deformation in the grains affected, hence increasing the mental strength. Strain hardening is commonly seen in cold working and forming processes such as squeezing, shearing and bending.
The Difference Between Strength And Hardness
Strength and hardness may have a close relationship to each other but it is important to take note that these properties are measured differently. Strength is defined as a material’s ability to resist deformation caused by an external load, while hardness is the ability of a material to resist penetration or scratching.
As mentioned, these two have completely different ways of testing. Metal strength is determined through a tensile or compressive test in a universal testing machine, while hardness test may be done through several methods including Rockwell hardness test, Brinell hardness test, Vicker hardness test, and Shore stereoscope.
These two are both important in the design and engineering industry as they are one of the major parameters being considered. Strength sets the limits on what are the maximum allowable load on the parts being made. This is vital in avoiding failures on structures and machinery. On the other hand, the hardness is a very good indicator of a metal’s resistance to mechanical wear. Harder metals are preferred for making parts that are required to have an excellent resistance to wear.
Metal Strength Chart
When your project requires metal parts, there are some important parameters you need to know about common metals. For example, the yield strength of steel, the tensile strength of steel, density, hardness, etc. There is a metal chart. You can compare and refer to the properties of different metals.
| Types of Metals | Tensile Strength (PSI) | Yield strength (PSI) | Hardness Rockwell (B-Scale) | Density (Kg/m3) |
| Stainless steel 304 | 90,000 | 40,000 | 88 | 8000 |
| Aluminum 6061-T6 | 45,000 | 40,000 | 60 | 2720 |
| Aluminum 5052-H32 | 33,000 | 28,000 | ? | 2680 |
| Aluminum 3003 | 22,000 | 21,000 | 20 to 25 | 2730 |
| Steel A36 | 58-80,000 | 36,000 | ? | 7800 |
| Steel Grade 50 | 65,000 | 50,000 | ? | 7800 |
| Yellow Brass | ? | 40,000 | 55 | 8470 |
| Red Brass | ? | 49,000 | 65 | 8746 |
| Copper | ? | 28,000 | 10 | 8940 |
| Phosphor Bronze | ? | 55,000 | 78 | 8900 |
| Aluminum Bronze | ? | 27,000 | 77 | 7700-8700 |
| Titanium | 63,000 | 37,000 | 80 | 4500 |
Conclusion
It is very important to consider and select the right metal for your projects. You can refer to the metal strength chart and choose a suitable metal material according to the characteristics, functions, application of your projects.? Of course, if you think this is complicated, you can contact WayKen, which has rich experience in metal machining and can always provide professional suggestions for your project.20 Years of The Z Axis
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The Difference Between Carbide Turning Inserts and Milling Inserts [Carbide Inserts]
Carbide Turning Inserts:
Carbide turning inserts are primarily designed for lathe operations, where the workpiece rotates against a stationary cutting tool. These inserts are characterized by their shape, which typically includes a cutting edge, clearance angle, and a chip breaker. The cutting edge is responsible for removing material from the workpiece, while the clearance angle allows for efficient chip evacuation. The chip breaker helps control the formation and flow of chips, preventing them from interfering with the cutting process.
Carbide turning inserts offer several advantages. Firstly, they provide excellent wear resistance due to the high hardness of the carbide material. This allows for extended tool life and reduced downtime for tool changes. Secondly, the inserts are available in various geometries, allowing for versatile machining capabilities. Different cutting edge shapes can be selected to achieve specific surface finishes, precision, and chip control. Lastly, carbide turning inserts are known for their stability and vibration damping properties, resulting in improved surface quality and dimensional accuracy.
Carbide Milling Inserts:
On the other hand, carbide milling inserts are designed for milling operations, where the cutting tool rotates and moves across the workpiece. These inserts are typically square or round in shape, with multiple cutting edges placed around their periphery. The cutting edges engage with the workpiece, removing material as the tool moves along the desired path.
Carbide milling inserts offer several advantages as well. They provide high cutting speeds and feed rates, resulting in faster material removal. This makes them suitable for large-scale production applications. Additionally, milling inserts can accommodate a wide range of cutting depths and widths, allowing for versatile machining capabilities. They are commonly used in various milling operations, including face milling, shoulder milling, and contouring.
In summary, the main difference between carbide turning inserts and milling inserts lies in their intended applications and cutting mechanisms. Turning inserts are suitable for lathe operations, while milling inserts are used in milling operations. Each type offers unique advantages in terms of tool life, versatility, and machining capabilities. By understanding these differences, manufacturers and machinists can select the most appropriate carbide insert for their specific machining needs, ensuring efficient and precise metalworking processes.
