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Developed from numerically controlled (NC) machining using punched tape, CNC machining is a process that utilizes computer control to operate and manipulate machines and cutting tools to shape stock materials such as metal, plastic, wood, foam, and composite manufacturing process. Etc – into custom parts and designs. While CNC machining processes offer a variety of functions and operations, the fundamentals of all processes remain largely the same. The basic CNC machining process includes the following stages: Design CAD models Convert CAD files to CNC programs Preparing the CNC machine Perform machining operations

CNC 101: The term CNC stands for 'computer numerical control', and the CNC machining definition is that it is a subtractive manufacturing process that typically employs computerized controls and machine tools to remove layers of material from a stock piece—known as the blank or workpiece—and produces a custom-designed part. This process is suitable for a wide range of materials, including metals, plastics, wood, glass, foam, and composites, and finds application in a variety of industries, such as large CNC machining, machining of parts and prototypes for telecommunications, and CNC machining aerospace parts, which require tighter tolerances than other industries. Note there is a difference between the CNC machining definition and the CNC machine definition—one is a process and the other is a machine. A CNC machine (sometimes incorrectly referred to as a C and C machine) is a programmable machine that is capable of autonomously performing the operations of CNC machining. CNC machining as a manufacturing process and service are available worldwide. You can readily find CNC machining services in Europe, as well as in Asia, North America, and elsewhere around the globe.

The structure of many metals is weakened by the oxidation process, but not aluminum. Aluminum can actually be made stronger and more durable through a process called "anodizing." Anodizing involves placing an aluminum sheet in a bath of chemical acid, usually acetone in laboratory experiments. The aluminum sheet becomes the positive pole of the chemical battery, and the acid bath becomes the negative pole. Electricity is passed through the acid, which causes the surface of the aluminum to oxidize (essentially rust). Aluminum oxide replaces the original aluminum on the surface, creating a strong coating. The result is an extremely hard substance called anodized aluminum. With the right anodizing process, anodized aluminum can be almost as hard as diamond. Many modern buildings use anodized aluminum where the metal frame is exposed to the elements. Anodized aluminum is also a popular material for high-end cookware like frying pans and pots. Heat is evenly distributed across the anodized aluminum, and the anodizing process provides a natural protective finish. Another plating process can be used to make anodized aluminum looks like copper or brass or other metals. Specialty dyes are also available for coloring anodized aluminum for decorative purposes.   Due to its strength and durability, anodized aluminum is also used in many other applications. Many satellites orbiting Earth are protected from space debris by layers of anodized aluminum. The automotive industry relies heavily on anodized aluminum to decorate and expose the protective casing of components. Furniture designers often use anodized aluminum as the frame of outdoor furniture and as the base metal for lamps and other decorative items. Modern household appliances and computer systems can utilize anodized aluminum as protective housing. Due to its non-conductive nature, anodized aluminum may not be suitable for all applications. Unlike other metals such as iron, the oxidation process does not appear to weaken aluminum's strength. The "aluminum rust" layer remains part of the original aluminum and will not transfer to food and will not flake off easily under pressure. This makes it especially popular in food service applications and industrial applications where durability is critical.

Titanium did not become commonly used as a useful metal alloy until the late 1940s. It is most commonly alloyed with molybdenum, manganese, iron and aluminum. Titanium is one of the strongest metals available by weight, making it ideal for a wide range of practical applications. It is 45% lighter than steel of equivalent strength, twice as strong as aluminum, and only 60% heavier. As an element, titanium has an atomic number of 22. It has an atomic mass of 47.867 amu and a relatively high boiling point of 1660 degrees Celsius (3020 degrees Fahrenheit). Titanium 44, Titanium 45, and Titanium 51 are all radioactive isotopes that are produced when deuterons are bombarded.   In commercial use, titanium alloys are used wherever strength and weight are an issue. Bicycle frames, automotive and aircraft parts, and structural members are some common examples. Titanium needles are used in medical applications because titanium needles do not react when in contact with bone and flesh. For this reason, many surgical instruments, as well as body piercings, are made of titanium. Titanium is suggested for desalination plants due to its high resistance to seawater corrosion (especially when coated with platinum). Many ships use titanium for moving parts that are often exposed to seawater, such as propellers and rigging.   The military uses titanium extensively for a variety of tasks. Titanium alloys are used in large quantities in missiles, aircraft and helicopters, submarines, and virtually all vehicle coatings. During the Cold War, the Russians built their subs out of titanium to give them higher maximum speeds and greater pressure tolerance (thus allowing them to sail deeper).   In jewelry, titanium is one of the most popular metals. This is because it is easy to color and relatively inert. Even people with metal allergies are usually not affected by wearing titanium jewelry.   Titanium's commercial applications are not limited to its metal alloys. Both ruby and star sapphire get their star-shaped reflections due to the presence of titanium dioxide, so artificially produced titanium is used in gemstones. Due to its barrier properties, titanium dioxide is also widely used in sunscreens and general-purpose paints. Titanium tetrachloride (TiCl4) is used for aerial writing (writing letters in the air by flying planes).

Brazing joins two pieces of base metal as a molten metal filler flows through the joint and cools to form a strong bond. Similar to welding, brazing creates an extremely strong joint, often stronger than the base metal piece itself, without melting or deforming the component. Two dissimilar metals or base metals such as silver and bronze are well suited for brazing. Using this method creates an invisible bond, is resilient over a wide temperature range, and can withstand shock and twisting movements. Although the metals and temperatures are different, the brazing process is the same as soldering. You can braze pipe, rod, flat metal, or any other shape as long as the parts fit neatly into each other without large gaps. Brazing handles more unusual configurations with linear joints, while most welding is spot welded on simpler shapes.   First, the entire area to be joined must be cleaned, otherwise, the molten brazing mixture will clump instead of flow, creating an inconsistent joint. Clean the surface, then apply molten flux. Flux removes oxides, prevents more oxidation during brazing, and smoothes the surface so that the brazing material "flows" evenly through the joint.   Next, collect the torch and braze the alloy. Torches use fuels such as acetylene and hydrogen to generate extremely high temperatures, typically between 800° F and 2000° F (430 – 1100° C). The temperature must be low enough to ensure that the base metal does not melt, but high enough to melt the solder. The torch has sensitive controls to achieve the proper temperature based on the relevant melting point. Finally, the joint is completed by brazing. Brazing, like solder, comes in rods, disks, or wires, depending on your preference or the shape of the joint. After heating the base metal near the joint with the torch, bring the wire over the hot piece, causing the solder to melt and flow around the joint. What brazers mean by "flow" is that it penetrates the seam, into every cavity. If the brazing is done correctly, when the bond cools and sets it is virtually unbreakable.   Brazing has many advantages over spot welding or soldering. For example, brazed joints are smooth and complete, creating an air- and water-tight bond for the pipe, and can be easily plated so that the seam disappears. It also conducts electricity like the base alloy. Only brazing can join dissimilar metals with different melting points, such as bronze, steel, aluminum, wrought iron and copper.

EDM is a machining method mainly used for hard alloys or metals that cannot be machined by traditional techniques. However, a key limitation is that EDM is only applicable to conductive materials. EDM (Electrical Discharge Machining) is especially suited for cutting complex contours or delicate cavities that are difficult to machine with grinders, end mills or other cutting tools. Metals that can be machined with EDM include Hastelloy, hardened tool steels, titanium, carbides, Inconel and Kovar. EDM is sometimes called "spark machining" because it removes metal by creating a series of rapid, repetitive electrical discharges. These discharges are passed between the electrodes and the metal piece being machined. The small amount of material removed from the workpiece is washed away by the continuous flow of fluid. Repeated discharges create a series of progressively deeper pits in the workpiece until the final shape is produced.

Waterjet cutting is a relatively new innovation that enables precise and inexpensive cutting of a wide variety of materials. The principle behind a waterjet is simple, but surprising nonetheless. As the name implies, a jet of water exits an orifice at approximately three times the speed of sound. The intense pressure of the narrow stream allows the water to cut virtually any material placed in front of it. While waterjets can cut almost any material, they are primarily used to cut slabs of plastic, aluminum, steel, tile, and stone. Sometimes abrasives, such as garnet or sand, are added to the water to improve cutting efficiency. Some waterjets can cut steel up to 12 inches (15 cm) thick! There are many waterjet cutting systems available, but most contain a similar set of components. At the heart of the system is a pump that increases the water pressure in the tank to 4,200 kg/cm2 (60,000 psi). The material to be cut is placed on a large table. A computer-controlled robotic arm or X-Y system controls the flow of water to cut the desired shape. The water stream is very narrow (typically 0.03 inch or 0.75 mm), which allows the waterjet to cut details that are impossible with traditional cutting tools.   Waterjet systems are usually computer controlled so that cutting instructions can be generated using digital drawings. Although the cuts are complex and precise, water jet cutting is often less expensive than traditional cutting methods. Another benefit of this type of cutting is that negligible heat is generated during machining, thus protecting materials sensitive to this stress. One obvious downside, however, is the water itself. Wood, paper, and some fabrics are not acceptable because they are moisture sensitive.

Aluminum has become a popular alternative to steel in manufacturing because of its lighter weight and non-conductive properties. But many applications require a process called anodizing to give aluminum a stronger surface. Essentially, anodizing involves immersing aluminum in a bath of sulfuric acid called an electrolyte and passing a low-voltage electrical current through the acid solution. The result of normal anodizing is a thin layer of aluminum oxide (rust) on the surface of the original aluminum sheet. However, if the acid solution is cooled to the freezing point of water and the amount of electrical current increases substantially, the process is called hard anodizing. Hard anodizing is more common in industrial or commercial applications than in consumer products. Some aluminum cookware can be hard anodized, but regular anodizing usually results in a durable nonstick finish that consumers love. Hard anodizing produces a thicker coating of aluminum oxide that penetrates the pores and cracks in the surface, resulting in a more uniform appearance than regular anodized aluminum. Hard anodized aluminum may have a dark brown or black finish, but other colors can also be produced.   The advantage of using hard anodized aluminum instead of stainless steel is lower overall cost and lighter weight. It is easier to machine hard anodized aluminum than to penetrate a similar block of stainless steel. Hard anodizing also produces products that are resistant to severe weather, salt spray and abrasive processes. Hard-anodized aluminum is only a few percent harder than diamond.   Both the automotive industry and the commercial cookware industry have long been supporters of hard anodizing. Nonstick coatings such as PTFE must have a reliable application method to produce a strong bond. Hard anodizing can add Teflon or other substances during electrolysis. Some auto parts also benefit from the hard anodizing process, as the finished product can be heat-resistant and non-conductive. The medical field also benefits from hard anodizing technology. The aluminum used in the prosthetic joint is hard anodized for strength and resistance to the corrosive effects of blood.   Hard anodizing shares many features with sulfuric acid anodizing, but the results of the two processes differ significantly. Hard anodizing creates a thicker aluminum oxide surface that bonds more strongly to the original aluminum layer. When shopping for new aluminum cookware, you may want to look for the description "anodized aluminum" or "hard anodized." Cookware marked "hard anodized" may last longer, but maybe a little more expensive.

Sandblasting or bead blasting is a general term for the process of smoothing, shaping, and cleaning hard surfaces by forcing solid particles through them at high velocity; the effect is similar to that of using sandpaper, but provides a more even surface, in nooks and crannies no problem. Sandblasting is one of the most common and effective methods of surface cleaning and maintenance. The restoration of the surface is achieved by blasting fine grit directly onto the object being cleaned at very high velocities through the blasting machine nozzle. One of the greatest advantages of sandblasting is its speed and efficiency. The properties of sand, including its fine grain size and composition of small particles, make this substance a powerful abrasive. What would normally take hours of cleaning by hand or other less efficient methods can be reduced to minutes with sandblasting.

Polymer resins melt when heated, so they can be molded as desired and then allowed to harden. The resulting plastic is called thermoplastic. There are several types of thermoplastics, each with unique properties that make them especially useful for certain applications and budgetary requirements. Thermoplastics are highly resistant to extreme temperatures, corrosive materials or environments. Common types of thermoplastic materials include: Acrylic (acrylic) Acrylonitrile Butadiene Styrene (ABS) Polyamide (PA) Polylactic acid (PLA) Polycarbonate (PC) Polyetheretherketone (PEEK) Polyethylene (PE) Polypropylene (PP) Polyvinyl chloride (PVC) High Impact Polystyrene (HIPS) Let's take a deeper look at some of the materials listed above...