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The fine art of machining ceramics
Since 2021, Kern Microtechnik GmbH’s job shop manufactures different ceramic parts which are being used in a wide variety of applications.To get more news about machining ceramics, you can visit runsom.com official website.
The ductile cutting mode, developed by Kern, is playing a vital role. Engineers and technicians, together with the customer, succeeded in generating a reliable process which provides high-quality results and zero rejects.
Many different industries, such as analytics, chemical and waveguides have been waiting for this, as have manufacturers of highly precise parts for measurement devices, jewellery, watchmaking and satellite technology for example. It’s all about the reliable manufacturing of technical ceramics like silicon carbide and aluminium oxide. The extreme hardness, stiffness, heat and chemical resistance of these materials and their excellent thermal connectivity make ceramics a very interesting material for many different applications.
However, the many advantages pose a challenge at the same time: the manufacturing process is very demanding. Also, because ceramic products need to be 100% perfect, cracks, breakoffs, or damaged material result in a failure of the part. Unlike metal, there is no protection to limit the spread of a crack. Furthermore, parts need to be manufactured to high dimensional accuracies.
Lapping, honing and grinding are established as traditional manufacturing processes, however, this limits the profiles and shapes that can be produced. Also, reliability becomes an issue as soon as contours and outlines need to be cut. This is where the new ductile cutting mode, developed by Kern engineers, comes into play. Special milling tools, with a geometrically defined cutting edge remove material from brittle ceramics with flying chips.
High-quality, high reliability
Alexander Stauder, head of applications at Kern explains: “We gain many advantages with this process – most important are the excellent quality in terms of accuracy and surface finishes and also process reliability. Depending on the quality of the ceramics, Ra/Sa roughness in the range of a few tens of nanometres and accuracies in the lower micrometre range can be achieved.”
Often it is possible to cut machining times considerably, which results in more efficiency. However, there is a rule of thumb: the larger the parts and respectively the drills and grooves are, the more it makes sense to use grinding as the first metal removal method.
Finishing is then the only thing remaining for milling, where tools are sometimes more costly. The smaller the parts and respectively the drills and grooves are, the more productive it becomes to work directly with the ductile cutting mode.
For either process, a reliable machine with highest accuracies is essential. A high stiffness and running smoothness, a spindle with a high RPM and resistance against the abrasive ceramic removal are prerequisites for working with either ductile cutting mode or grinding.
Many different industries, such as analytics, chemical and waveguides have been waiting for this, as have manufacturers of highly precise parts for measurement devices, jewellery, watchmaking and satellite technology for example. It’s all about the reliable manufacturing of technical ceramics like silicon carbide and aluminium oxide. The extreme hardness, stiffness, heat and chemical resistance of these materials and their excellent thermal connectivity make ceramics a very interesting material for many different applications.
However, the many advantages pose a challenge at the same time: the manufacturing process is very demanding. Also, because ceramic products need to be 100% perfect, cracks, breakoffs, or damaged material result in a failure of the part. Unlike metal, there is no protection to limit the spread of a crack. Furthermore, parts need to be manufactured to high dimensional accuracies.
Lapping, honing and grinding are established as traditional manufacturing processes, however, this limits the profiles and shapes that can be produced. Also, reliability becomes an issue as soon as contours and outlines need to be cut. This is where the new ductile cutting mode, developed by Kern engineers, comes into play. Special milling tools, with a geometrically defined cutting edge remove material from brittle ceramics with flying chips.
High-quality, high reliability
Alexander Stauder, head of applications at Kern explains: “We gain many advantages with this process – most important are the excellent quality in terms of accuracy and surface finishes and also process reliability. Depending on the quality of the ceramics, Ra/Sa roughness in the range of a few tens of nanometres and accuracies in the lower micrometre range can be achieved.”
Often it is possible to cut machining times considerably, which results in more efficiency. However, there is a rule of thumb: the larger the parts and respectively the drills and grooves are, the more it makes sense to use grinding as the first metal removal method.
Finishing is then the only thing remaining for milling, where tools are sometimes more costly. The smaller the parts and respectively the drills and grooves are, the more productive it becomes to work directly with the ductile cutting mode.
For either process, a reliable machine with highest accuracies is essential. A high stiffness and running smoothness, a spindle with a high RPM and resistance against the abrasive ceramic removal are prerequisites for working with either ductile cutting mode or grinding.
Basic Guide To CNC Machining Tolerance
NC machining refers to the use of computer programming and electromechanical equipment to automatically process metal parts (and non-metallic) as required. CNC machine tools perform all operations on the workpiece according to the program and provide us with the final product.To get more news about machining tolerances, you can visit runsom.com official website.
CNC machining refers to the use of computer programming and electromechanical equipment to automatically process metal parts (and non-metallic) as required. CNC machine tools perform all operations on the workpiece according to the program and provide us with the final product.
Although CNC machining service is very accurate in product size, it is not perfect. From the part material to the machining process used, various factors may lead to differences. Therefore, engineers assign machining tolerances to parts during the design process.
What is Machining Tolerance?
Machining tolerance, also known as dimensional accuracy, is the acceptable deviation of part size.
This is expressed as the maximum and minimum size limit of the part. If the size of the part falls between these limits, the part is considered to be within the tolerance range. However, if the size of parts exceeds these limits, these parts exceed the acceptable tolerance range and are considered unusable.
The machining tolerance usually starts with a ± symbol. For example, suppose a 2.0 "(50.8mm) high part requires a tolerance range of ± 0.005" (0.127mm). The variable height of the final part should be between 2.005 "(50.927mm) and 1.905" (48.387mm) to pass the quality inspection.
The tolerance can also be expressed in any decimal place. The more decimal places included, the tighter the tolerance. These different types of tolerances are expressed as follows:
What Are the Standard Machining Tolerances?
There is no true standard machining tolerance, mainly because different applications require different tolerances. However, some manufacturers and industry organizations have established standard tolerances they use or recommend for certain parts and materials. This is particularly true in the military and aerospace manufacturing industries.
Generally, the customer will provide the tolerance of their project to the mechanical workshop. Some mechanical workshops require customers to provide tolerances, but if not, other mechanical workshops operate according to the common tolerance list. For example, in SANS, our standard manufacturing tolerance is ± 0.004 "(0.1mm).
What is Machining Tolerance?
Machining tolerance, also known as dimensional accuracy, is the acceptable deviation of part size.
This is expressed as the maximum and minimum size limit of the part. If the size of the part falls between these limits, the part is considered to be within the tolerance range. However, if the size of parts exceeds these limits, these parts exceed the acceptable tolerance range and are considered unusable.
The machining tolerance usually starts with a ± symbol. For example, suppose a 2.0 "(50.8mm) high part requires a tolerance range of ± 0.005" (0.127mm). The variable height of the final part should be between 2.005 "(50.927mm) and 1.905" (48.387mm) to pass the quality inspection.
The tolerance can also be expressed in any decimal place. The more decimal places included, the tighter the tolerance. These different types of tolerances are expressed as follows:
What Are the Standard Machining Tolerances?
There is no true standard machining tolerance, mainly because different applications require different tolerances. However, some manufacturers and industry organizations have established standard tolerances they use or recommend for certain parts and materials. This is particularly true in the military and aerospace manufacturing industries.
Generally, the customer will provide the tolerance of their project to the mechanical workshop. Some mechanical workshops require customers to provide tolerances, but if not, other mechanical workshops operate according to the common tolerance list. For example, in SANS, our standard manufacturing tolerance is ± 0.004 "(0.1mm).
Sheet Metal Fabrication Services
Amid the COVID-19 crisis, the global market for Sheet Metal Fabrication Services estimated at US$15.3 Billion in the year 2022, is projected to reach a revised size of US$17.2 Billion by 2026, growing at a CAGR of 2.6% over the analysis period. To get more news about online sheet metal fabrication, you can visit runsom.com official website.
Sheet metal fabrication refers to the subtractive processing method to cut sheet metal into parts. Growth in the global market is being driven by rapid urbanization in many developing regions, and a robust trend of R&D investments in several services sectors. Increasing demand for sheet metal fabrication from a wide range of major end users such as military & defense, aerospace, automotive, oil and gas, industrial machinery, medical devices, construction, agriculture, consumer products, and electronics is expected to drive growth.
Moreover, the current focus on enhancing operational efficiency and lean manufacturing is contributing to increased demand for the process of sheet metal forming among OEMs. Innovative prefabrication techniques adopted by sheet metal fabrication service providers to meet the growing demand are expected to further drive the growth. The increasing shortage of labor could be addressed by adopting cobots in metal fabrication processes. Therefore, increasing number of metal fabrication facilities are adopting cobots to enhance operational efficiency and improve product quality.
The Sheet Metal Fabrication Services market in the U.S. is estimated at US$2.7 Billion in the year 2022. The country currently accounts for a 17.78% share in the global market. China, the world's second largest economy, is forecast to reach an estimated market size of US$6 Billion in the year 2026 trailing a CAGR of 3.4% through the analysis period. Among the other noteworthy geographic markets are Japan and Canada, each forecast to grow at 1.5% and 2% respectively over the analysis period. Within Europe, Germany is forecast to grow at approximately 1.8% CAGR while Rest of European market (as defined in the study) will reach US$6.2 Billion by the end of the analysis period.
Moreover, the current focus on enhancing operational efficiency and lean manufacturing is contributing to increased demand for the process of sheet metal forming among OEMs. Innovative prefabrication techniques adopted by sheet metal fabrication service providers to meet the growing demand are expected to further drive the growth. The increasing shortage of labor could be addressed by adopting cobots in metal fabrication processes. Therefore, increasing number of metal fabrication facilities are adopting cobots to enhance operational efficiency and improve product quality.
The Sheet Metal Fabrication Services market in the U.S. is estimated at US$2.7 Billion in the year 2022. The country currently accounts for a 17.78% share in the global market. China, the world's second largest economy, is forecast to reach an estimated market size of US$6 Billion in the year 2026 trailing a CAGR of 3.4% through the analysis period. Among the other noteworthy geographic markets are Japan and Canada, each forecast to grow at 1.5% and 2% respectively over the analysis period. Within Europe, Germany is forecast to grow at approximately 1.8% CAGR while Rest of European market (as defined in the study) will reach US$6.2 Billion by the end of the analysis period.
Smart Services Identifies CNC Machining Quality Issues
A collaboration between Productive Machines (UK) and the Kistler Group allows customers in the machining segment to benefit from a full range of performance optimization services. Dynamic stiffness analysis together with force and vibration mapping are the keys to efficiently enhancing CNC machining processes and boosting productivity, in an approach based on simulations, measurements, and data analysis.To get more news about precision medical machining, you can visit runsom.com official website.
Production equipment such as machinery and robots must be maintained in good operating condition to ensure that manufacturing processes are productive, cost-efficient and highly sustainable. In the specific context of modern CNC machining, it is essential to apply, trace and adjust the right electrical and mechanical settings throughout a machine’s lifetime.
Maximizing Tool And Machine Performance
Kistler has announced the partnership with Productive Machines Ltd (UK) covering extended services to optimize machining processes, with a particular focus on milling applications. Productive Machines was founded by Dr. Erdem Ozturk, who also led the machining dynamics team at The University of Sheffield Advanced Manufacturing Research Centre (AMRC). The company supports manufacturers with dynamic analyses of CNC machining tools, as well as providing both physical and digital services to optimize NC programs.
The collaboration between Kistler and Productive Machines offers customers a range of value-added services in machine tool analysis: methods such as dynamic stiffness mapping, cutting force simulations and feed rate scheduling will help to minimize milling force spikes and maximize tool life and performance. Chatter vibrations can also be minimized by a prediction per stability map and an according adaptation of spindle speed. Another focus of the partnership is holistic optimization of CAM files as an aid to improving productivity and quality.
The physical stage of the service is performed with an impulse hammer – a device containing a piezoelectric force sensor that dynamically excites the structure under test. Resulting vibrations are measured with IEPE accelerometers from Kistler, and a modal analysis then determines the dynamic behavior of the structure (a milling machine, for example).
The partners are also offering DIGI-FORCE – a new digital service to determine key parameters of a machine setup based on machine data. Various levels of the DIGI-FORCE service are available, and it can be combined with physical measurements to obtain a complete account of machine and tool capability and performance. The DIGI-FORCE OPT service adds the FRF file data from the machine measurement to the optimized CNC program – so chatter vibrations, tool wear and machine breakdowns can be significantly decreased or even eliminated altogether.
Researchers and production engineers who opt for these services benefit from simulated force levels as the basis for optimizing their CNC machining programs – leading not only to enhanced productivity but also reduced effort for R&D and process analysis.
Maximizing Tool And Machine Performance
Kistler has announced the partnership with Productive Machines Ltd (UK) covering extended services to optimize machining processes, with a particular focus on milling applications. Productive Machines was founded by Dr. Erdem Ozturk, who also led the machining dynamics team at The University of Sheffield Advanced Manufacturing Research Centre (AMRC). The company supports manufacturers with dynamic analyses of CNC machining tools, as well as providing both physical and digital services to optimize NC programs.
The collaboration between Kistler and Productive Machines offers customers a range of value-added services in machine tool analysis: methods such as dynamic stiffness mapping, cutting force simulations and feed rate scheduling will help to minimize milling force spikes and maximize tool life and performance. Chatter vibrations can also be minimized by a prediction per stability map and an according adaptation of spindle speed. Another focus of the partnership is holistic optimization of CAM files as an aid to improving productivity and quality.
The physical stage of the service is performed with an impulse hammer – a device containing a piezoelectric force sensor that dynamically excites the structure under test. Resulting vibrations are measured with IEPE accelerometers from Kistler, and a modal analysis then determines the dynamic behavior of the structure (a milling machine, for example).
The partners are also offering DIGI-FORCE – a new digital service to determine key parameters of a machine setup based on machine data. Various levels of the DIGI-FORCE service are available, and it can be combined with physical measurements to obtain a complete account of machine and tool capability and performance. The DIGI-FORCE OPT service adds the FRF file data from the machine measurement to the optimized CNC program – so chatter vibrations, tool wear and machine breakdowns can be significantly decreased or even eliminated altogether.
Researchers and production engineers who opt for these services benefit from simulated force levels as the basis for optimizing their CNC machining programs – leading not only to enhanced productivity but also reduced effort for R&D and process analysis.