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How does cnc machining work and solutions to decrease the cnc machining costs
Learn how CNC machining works and explore effective strategies to reduce machining costs. Discover key insights and practical solutions to optimize your production process and improve efficiency.
CNC machining (Computer Numerical Control machining) is a precision process that automates the cutting, milling, drilling, and other operations on metal/non-metal materials using machine tools (such as milling machines, lathes, and machining centers) through programmed instructions. The core principle is “program-driven + automated execution”.
Core Features
High precision: Repeatability accuracy can reach ±0.005mm, suitable for precision part production;
High efficiency: Automated operation reduces manual intervention, ensuring strong consistency in batch processing;
High flexibility: Simply modify the program to switch between processed parts, making it suitable for multi-variety, small-batch production.
Key process
1. Drawing Design: Create 3D/2D drawings of parts using CAD software;
2. Programming: Convert the drawings into machine-readable G/M code (including parameters such as machining path, spindle speed, feed rate, etc.) using CAM software;
3. Machine Debugging: Clamp the workpiece and tools, then conduct trial runs to verify the program’s rationality;
4. Batch Processing: The machine tool automatically completes the cutting process, with real-time monitoring during operation.
Common Applications
Widely used in mechanical manufacturing, mold, automotive, aerospace, and other fields, it can process various materials such as steel, aluminum, copper, and plastics, and is suitable for machining complex curved surfaces, high-precision holes, threads, and other structural features.
The core of reducing CNC machining costs lies in design simplification, material optimization, process efficiency improvement, batch cost sharing, and management loss control. Focusing on these five directions can significantly reduce costs.
1、 Design optimization (source cost reduction, can reduce by 30% -50%)
Simplified structure: add an R angle to the inner right angle (≥ 1/3 of the cavity depth) to avoid small cutting tools and spring-loaded tools; Reduce deep cavity depth (hole depth/diameter ≤ 4:1); Thin wall ≥ 1.5mm anti deformation.
Standard universal: use standard hole/thread sizes, prioritize standard cutting tools for machining features; Strictly mark the tolerance on critical surfaces (such as ± 0.01mm), and relax it to ± 0.1mm on non critical surfaces.
Avoid redundancy: Do not engrave unless necessary, do not create features with low aspect ratios, and reduce additional processing.
2、 Materials and utilization rate (cost reduction of 15% -30%)
Choose easily machinable materials: When meeting performance requirements, priority should be given to easily machinable materials such as aluminum, low-carbon steel, and PP, replacing difficult to machine materials such as titanium alloys and stainless steel.
Improve utilization: CAD/CAM optimized layout, nesting and cutting; The blank should be 2-3mm larger than the finished product on one side to reduce excess.
Batch procurement: Long term cooperation with suppliers, bulk procurement of raw materials, and striving for preferential prices.
Waste reuse: Edge materials are used for small parts or sampling, reducing the loss rate to 3% -10%.
3、 Process and programming (efficiency improvement of 20% -40%)
Optimize tool path: CAM generates the shortest path to reduce idle running; Rough machining with high speed and large feed rate, precision machining with fine finishing to reduce processing time.
Tool management: Use coated tools (such as TiN, TiAlN) to improve their lifespan; Prioritize standard cutting tools and reduce non-standard customization; Match cutting parameters according to materials to reduce wear.
Process merging: One clamping is used to complete milling, drilling, and tapping, reducing secondary positioning and handling.
Equipment matching: Three axes can be used without five axes, ordinary precision parts do not require high-precision machines, and equipment can be selected according to demand to reduce time and cost.
4、 Batch and production organization (cost reduction of 20% -60%)
Batch production: Small batch consolidation of orders or joint production, sharing fixed costs such as programming and machine adjustment; The larger the batch size, the lower the unit cost.
Automation efficiency improvement: Batch parts are automatically loaded and unloaded with robot assistance, reducing manual labor and improving equipment OEE (target ≥ 85%).
Scheduling optimization: Balance machine load, reduce downtime and waiting, and prioritize bottleneck process scheduling.
5、 Management and Quality (Loss Control 10% -20%)
Preventive maintenance: Regularly maintain machine tools and cutting tools to reduce downtime and waste caused by malfunctions.
Process quality inspection: first article inspection is mandatory, process sampling is conducted to avoid batch scrapping; Use SPC to monitor dimensions and correct them in advance.
Reduce rework: clarify technical requirements to avoid rework caused by ambiguous drawings; Simplify surface treatment and do not require multiple treatments unless necessary.
Reasonable delivery: Avoid urgent delivery (with an urgent fee of 20% -50%) and plan the delivery date in advance.
6、 Quick cost reduction checklist (execute immediately)
1. Add R angle to the drawing, reduce the depth of the cavity, use standard holes and tolerances
2. Replace processing materials, optimize layout, and improve material utilization rate
3. CAM optimization path, using coated tools, merging processes
4. Batch production of orders to improve equipment OEE
5. First article inspection, regular maintenance, reducing rework and downtime
Want to understand how CNC machining works and effective solutions for cost reduction? This article provides an in-depth analysis of the CNC process flow and offers 10+ practical cost-reduction strategies to help you optimize production and improve cost-effectiveness. Read now to get your personalized cost-reduction solution!
