Unlocking Precision: Mastering 8 Key CNC machining Techniques for Rapid Prototyping

Sen.H: Rapid prototyping & Manufacturing

8s English reading summary:CNC techniques|precision prototyping|hard material machining|aerospace applications|±0.01mm accuracy

At Brightstar, we specialize in rapid prototyping and precision machining. Understanding the mastering 8 key CNC machining techniques is essential for optimizing our production processes and delivering high-quality prototypes to our clients. Whether you are a product designer, engineer, or manufacturer, knowing these techniques can help you make informed decisions and achieve the desired results. In this blog post, we will explore the essential CNC machining techniques and how they can benefit your projects.

Turning

Turning is a fundamental CNC machining technique that involves fixing the workpiece on a rotating workpiece holding device. A cutting tool is then used to gradually remove material from the workpiece to achieve the desired shape and size. This method is particularly suitable for manufacturing cylindrical parts such as shafts and sleeves.

Types of Turning

External Turning: Used for machining external cylindrical surfaces, including shafts, cylinders, and cones.
Internal Turning: Involves inserting the cutting tool into the workpiece's inner hole to process the diameter and surface to the required size and accuracy.
Facing: Creates flat surfaces, such as the base or end face of a part.
Threading: Achieves internal and external threads by gradually cutting the thread shape using the cutting edge of the tool.

At Brightstar, our largest lathe machines can process workpieces with dimensions up to Φ320mm in diameter and 1000mm in length, with a precision of up to +/- 0.01mm.

CNC turning technique for cylindrical prototypes on Brightstar lathe

Milling

Milling is a versatile CNC machining technique that involves rotating a cutting tool on the workpiece surface to remove material. It allows for the production of parts with complex shapes, such as planes, concave and convex surfaces, and gears, by precisely controlling the tool's movement.

At Brightstar, we are equipped with advanced milling machines featuring 3/4/5-axis capabilities. Our state-of-the-art facilities include the latest German DMG 5-axis linkage machines and over 100 precision Japanese Fanuc and Mitsubishi brand machining devices.

Types of Milling

Flat Milling: Produces flat surfaces by cutting with the cutting edge of the tool.
Vertical Milling: Used for machining grooves and holes along the height direction of the workpiece.
End Milling: Cuts on the side of the workpiece, suitable for machining profiles, grooves, and edges.
Gear Milling: Utilizes special tools with cutting edges to cut the gear teeth shape.
Profile Milling: Processes complex curves or contour shapes with precise tool path control.

5-axis CNC milling machine creating complex gear geometries

Drilling

Drilling is a widely used CNC machining technique that involves cutting material on the workpiece using a rotating drill bit to create holes of the desired diameter and depth. It is commonly applied in manufacturing, construction, and maintenance fields.

Types of Drilling

Conventional Drilling: Uses drill bits with spiral cutting edges, suitable for smaller holes and general drilling needs.
Center Drilling: Creates a small pilot hole on the workpiece surface before using a larger drill bit to ensure accurate positioning of larger holes.
Deep Hole Drilling: Processes deeper holes, requiring special drill bits and cooling techniques to maintain accuracy and quality.
Multi-Axis Drilling: Uses multiple drill bits at different angles simultaneously, ideal for drilling multiple holes at once.

Multi-axis CNC drilling system manufacturing engine block holes

Grinding

Grinding is a precision CNC machining technique that involves gradually cutting or grinding material on the workpiece surface using an abrasive to achieve the desired shape, size, and surface quality. It is commonly used for parts with high precision and surface quality requirements, such as molds, precision mechanical parts, and tools.

Types of Grinding

Flat Grinding: Processes flat workpiece surfaces to achieve smooth surfaces and precise dimensions.
External Grinding: Used for processing the outer cylindrical surface of workpieces, such as shafts and pins.
Internal Grinding: Processes the inner surface of holes, such as inner holes and shaft holes.
Profile Grinding: Processes complex contour shapes, such as the cutting edge of molds and tools.

Precision grinding of medical device prototypes with ±0.002mm tolerance

Boring

Boring is a CNC machining technique used to process internal circular holes in workpieces by cutting in existing holes with a rotating tool to achieve precise dimensions and flatness goals. Unlike drilling, which forms holes by cutting material on the workpiece surface, boring involves inserting the tool into the workpiece to cut holes.

Types of Boring

Manual Boring: Suitable for small-batch production and simple machining tasks.
CNC Boring: Uses programming to determine cutting paths, feed rates, and rotation speeds for automated high-precision machining.

CNC boring process refining medical device mounting holes

Planing

Planing is a CNC machining technique that involves cutting material on the workpiece surface using a planer to achieve the desired flat surface, precise dimensions, and surface quality. It is commonly used for machining flat surfaces of larger workpieces, such as bases and beds, providing a flat surface for workpieces to fit with other components.

Types of Planing

Roughing: The planer cuts deeply to quickly remove material.
Finishing: The cutting depth is reduced to achieve higher surface quality and dimensional accuracy.

Planing Methods

Manual Planing: Suitable for small-batch production and simple machining tasks.
Automatic Planing: Uses automated machine tools to control the movement of the planer for a more stable and efficient machining process.

Broaching

Broaching is a CNC machining technique that involves gradually deepening cuts using a broaching tool to create internal complex contours. It is commonly used for machining the contours, grooves, and holes of workpieces with complex shapes and can achieve high machining accuracy and surface quality.

Types of Broaching

Flat Broaching: Used for machining flat workpiece surfaces to achieve smooth surfaces and precise dimensions.
Contour Broaching: Processes complex contour shapes, such as molds and parts.
Groove Broaching: Used for machining grooves and slots, with the cutting edge entering the workpiece and cutting along the surface.
Hole Broaching: Used for machining the inner contour of holes, where the cutting edge enters the hole and cuts the inner surface.

Broaching tool cutting turbine blade cooling slots with contour precision

Electrical Discharge Machining (EDM)

EDM is a highly advanced CNC machining technique that uses electrical discharge to cut and process conductive materials. It is capable of creating high-precision, complex-shaped parts such as molds and tools. EDM is widely used in the manufacturing of molds, plastic injection molds, aerospace engine parts, medical equipment, and other fields where traditional machining methods are insufficient.

Key Features of EDM

Non-Contact Cutting: Unlike traditional mechanical cutting, EDM is a non-contact machining method. Material removal occurs through electrical discharge, with no direct physical contact between the tool and the workpiece.
High Precision: EDM can achieve high-precision machining, often reaching sub-micron level dimensional accuracy, making it suitable for manufacturing molds, models, and other precision parts.
Complex Shapes: As a non-contact machining method, EDM can process very complex shapes, including internal contours, small holes, slots, and more.
Suitable for High-Hardness Materials: EDM is ideal for high-hardness materials, such as tool steel, hard alloys, and titanium alloys, as it does not rely on the hardness of cutting tools in traditional cutting methods.

EDM machining process for aerospace titanium components

How Brightstar Can Help

At Brightstar, we have extensive experience in all these CNC machining techniques. Our team of experts can help you choose the right technique for your project based on the material, shape, size, and surface requirements. Whether you need a simple prototype or a complex high-precision part, we are here to assist you.

If you are interested in our prototyping and want to discuss a purchase, please contact us.