Precision Machining

1.1 Part 2: Process and Application

1.1.1 Description of the machining process (illustrative diagram).

The machining process is a synthesis of techniques used in the machining process,

these techniques will be arranged in a certain sequence depending on each business
to ensure that all machines are operated in the right order, minimizing errors while
increasing consistency among employees in each stage.
1.1.2 Practical applications in industry

Profession Application Tolerances

Mechanical Engineering Roast cake processing
Machining of keys, pins
Automobile Gearbox, engine, brake
parts,... +/- 0.05mm to
Aerospace Aircraft engines, +/- 0.001 mm
propellers, drones,
missiles...
Electrical – Electronics Electronic components,
telephone equipment,
computers...
Health Surgical equipment,
health index
measurement equipment
1.1.3 Advantage

1. High Accuracy:

High-precision machining ensures the parts are correctly sized and shaped,
meeting strict technical requirements.

2. Good product quality:

Precision-machined parts typically have a smooth surface and few defects,

enhancing the overall quality of the product.

3. Uniformity:

Precision machining helps ensure uniformity in mass production, minimizing

deviations between parts.

4. Long product life:

Precision-machined parts are more likely to perform better and last longer in
harsh applications.

5. Compatibility:

Precision machining makes components easy to assemble and compatible

with each other in complex systems.

1.1.4 Shortcoming

1. High cost:

Precision machining often requires large investments in machinery,

equipment, and technology, resulting in higher production costs.

2. Long processing time:

Precision machining processes may require longer times to complete,

affecting delivery times.

3. Labor Skills:

Highly skilled technicians and intensive training are required, which can
create difficulties in recruiting and retaining human resources.
4. Fault Risk:

During precision machining, any minor mistake can lead to a serious failure,
increasing the cost of repair or replacement.

5. Maintenance Requirements:

Equipment and machinery used in precision machining require regular

maintenance to maintain accuracy, which adds cost and time.
Surface smoothness, high aesthetics, few errors or affected, tolerances within the
allowable range without affecting the structure.
Based on your design, CNC Lathe can reach tolerances up to ± 0.005". The standard
tolerances for CNC turned metals are ISO 2768-m and ISO 2768-c for plastics.
Length size +/- 0.025 mm
Hole diameter (non-reaming) +/- 0.025 mm
Shaft diameter +/- 0.025 mm
Section size limit: 950*550*480mm
- CNC milling tolerances

Based on the shape of your part and the selected material, it can meet standard
thread sizes, customized tire tread of the machine, and reach tolerances up to ±
0.001". The standard tolerances for CNC milled metals are ISO 2768-m and ISO
2768-c for plastics.
Length Dimensions: +/- 0.025 mm
Bore diameter (non-boring): +/- 0.025 mm
Shaft diameter: +/- 0.025 mm
Part Size Limit: 950*550*480mm

Material Tolerance (mm)

Carbon Steel ±0.005 to ±0.01
Stainless Steel ±0.005 to ±0.01
Aluminium ±0.01 to ±0.05
Copper ±0.01 to ±0.05
Alloy Steel ±0.005 to ±0.01
Tool Steel ±0.005 to ±0.01
Titanium ±0.01 to ±0.05

1.1.5 Improvement measures

1. Optimization of the machining process:

Cutting Planning: Use planning software to optimize the path of the cutter,
minimizing machining time.
Choose the right tool: Use the right type and size cutting tool to minimize
wear and increase accuracy.
2. Ensure the accuracy of the machine:
Routine Maintenance: Perform regular CNC machine maintenance and
calibration to ensure accuracy.
Check for straightness and squareness: Make sure that the components of
the machine are assembled correctly.
3. Using advanced technology:
Sensors and automation: Use sensors to monitor machine status and
automatically adjust machining parameters.
5-axis CNC: Switch to 5-axis CNC machines for the ability to machine more
complex parts with greater precision.
4. Employee Training:
Technical Training: Provide training for workers on how to operate CNC
machines and troubleshoot.
Technology Updates: Ensure employees are up to date with new technology
and modern machining processes.
5. Quality Control:
Product Inspection: Perform regular product quality checks to detect
problems early.
Cause and Root Cause Analysis: Use analysis tools like the 5 Whys or
Fishbone Diagram to identify the root cause of problems.
6. Material optimization:
Choose the right material: Use high-quality raw materials with properties
that are suitable for the machining requirements.
Inventory Management: Ensure there are enough raw materials in stock so
that there are no disruptions in the production process.
7. Using CAD/CAM software:
Precision Design: Use CAD software to design parts with high accuracy.
Automatic G-code generation: Use CAM software to convert designs into
G-codes accurately.
1.1.6 Illustrative example

CNC turning is used to shape components in motorcycle gearboxes

CNC milling is used to shape the frames and shells of motorcycles, or decorative
American products in the furniture industry.

Laser cutting processing is used to cut and shape gears.

1.2 Part 3: Comparison and Evaluation

1.2.1 Compare other methods

1. Accuracy
Precision machining: Provides high precision (typically within ±0.001 mm),
making it suitable for applications that require delicate detailing.
Other Methods: Methods such as traditional machining (cutting, drilling)
are typically less accurate and can range from ±0.01 mm to ±0.1 mm.
2. Production Speed
Precision machining: Usually slower because it takes time to program and
set up machines, but offers higher quality for small quantities or specialized
products.
Other methods: Traditional machining or batch machining can be faster for
large quantities but not with high precision.
3. Cost
Precision machining: The initial investment cost is high (machinery,
software), but it can be long-term cost savings for products that require high
precision.
Other methods: The investment cost is lower, but it can consume more in
defect handling and product recycling.
4. Product complexity
 Precision Machining: Capable of machining complex shapes and small
parts, suitable for the aerospace, medical, and electronics industries.
Other methods: Often limited by the shape and size of the product, it is
difficult to implement complex designs.
5. Flexibility
Precision machining: Can be easily adjusted for new products or design
changes without changing too many machines.
Other Methods: Often requiring setup or machinery changes for different
products, which can reduce flexibility.
6. Surface Quality
Precision machining: Provides a better surface finish, less need for
remachining.
Other Methods: Additional machining steps may be required to achieve the
desired surface finish.
For example, a comparison between 2 common precision machining
methods, namely milling, CNC turning and mechanical turning milling

Criteria Milling, CNC Turning Milling, turning

Accuracy High, can reach a size of Smaller in size by about
±0.001 mm ±0.05 mm to ±0.1 mm
Automation Fully automatic Manual or semi-automatic
Production Speed Slower for initial setup, but Fast for low-volume
fast for mass production production
Commonality Diverse from easy to complex Limitations when machining
complex edges
Investment costs High (machinery, software) Low – medium
Surface Quality Good finish, low tolerance Large tolerances, need to be
further measured and
machined to achieve the
 closest accuracy
Operating High technical requirements Mechanic with the ability to
Requirements are required, from software operate
and machine operation

1.2.2 Economic efficiency and productivity

1. Reduce production costs

Reduce material waste: Precision machining helps optimize material use,

minimizing waste due to unnecessary cutting.

Reduced recycling costs: With high accuracy, the percentage of qualified

products will be higher, reducing the cost of reprocessing or recycling
broken products.

2. Increased productivity

Mass Production: Precision machining allows for mass production at a fast

and stable speed, thereby increasing productivity.

Short machining time: With automation machinery, set-up and machining

time is reduced, which saves production time.

3. Improve product quality

High accuracy: High-precision products are usually of better quality,

minimizing errors and scraps.

Satisfying customer requirements: High-quality products help increase

customer satisfaction, which in turn can generate higher revenue.

4. Increased competitiveness

Market: Companies that adopt precision machining can be more competitive

thanks to their high-quality products and reasonable production costs.
 Rapid Responsiveness: Quickly respond to market and customer
requirements.

5. Reduce labor costs

Automation: Using CNC machines and automation technology helps reduce

the number of workers needed, thereby saving labor costs.

Skill Enhancement: Investing in precision machining technology can

minimize the requirement for high skills, due to the automation of many
stages of machinery.

Product Machining Dimension Material Product Price

Method

Motorcycle Monolithic 355x76 Aluminum 150USD

Wheel Rims CNC Needle Box

Motorcycle Mass Casting 355x76 Aluminum 100USD

Wheel Rims and steel
needle box

1.2.3 Environmental Impact Assessment

Negative impact

1. Energy Consumption:

CNC machines often consume a lot of electricity, resulting in carbon

emissions if the energy source is not renewable.

2. Waste:

The machining process can generate a lot of metal chips and other
waste. If not disposed of properly, they can pollute the environment.
 3. Chemical Use:

Greases and chemicals used for cooling in machining can be

contaminating if not handled carefully.

Positive impact

1. Reduction of raw materials:

Precision machining optimizes material utilization, reducing the

amount of waste compared to traditional methods.

2. Enhanced Performance:

Precision-machined products often have a longer lifespan, reducing

the need for remanufacturing, which in turn reduces the environmental
impact.

3. Recyclable:

Many materials used in precision machining (such as aluminum, steel)

can be recycled, helping to reduce the amount of solid waste.

1.2.4 Future development potential

1. Advanced technology

Automation and robotics: The application of automation technology and

robotics in machining helps increase production efficiency and minimize
errors.

CNC (Numerical Control Machine): The development of CNC machines

allows for the machining of complex parts with high precision.

2. Market Demand
 Industry 4.0: The transformation to industry 4.0 creates an increased
demand for precision products and components in sectors such as
automotive, aviation, electronics, and medical.

Evolution of Industries: Industries such as information technology, mobile

phones, and healthcare are in need of precision components.

3. Training and human resources

Intensive training programs: Educational institutions are increasingly

focusing on training highly skilled human resources in the field of precision
machining.

Highly skilled technicians: The demand for highly qualified technicians is

huge.

4. Global Market Expansion

Globalization trend: Businesses can export products to the international

market, expanding business opportunities.

International cooperation: Links and cooperation with foreign companies

help improve technology and production processes.

5. Innovation

Research and development: Invest in R&D to improve machining

processes and develop new materials with high strength and precision.

1.2.5 Application in modern manufacturing.

1. Automotive Industry

Engine components: crankshaft, piston, gear, valve, cyclone surface

Brake system: brake discs, brake pads and other equipment related to
vehicle safety
2. Aviation

Aircraft parts: Details such as the airframe, wings, and engines all require
high precision to ensure safety and flight performance.

Aviation electronics: Processing electronic components for control and

navigation systems.

3. Electronics Industry

Printed circuits and electronic components: Processing printed circuit

boards and small electronic components such as chips and capacitors with
high precision.

Consumer Devices: Manufacture parts for devices such as smartphones,

laptops.

4. Health sector

Medical Equipment: Machining machine parts such as ultrasound

machines, X-ray machines, and surgical equipment with high precision.

Implants: Implants such as artificial joints and dentures need to be

sophisticatedly processed to ensure safety and efficiency.

5. Energy industry

Wind turbines: Machining wind turbine parts to optimize performance and

durability.

Renewable Energy Equipment: Manufactures components for solar and

hydropower systems.

6. Machine building industry

 Machinery Department: Machining machine parts for all kinds of industrial
machines, from CNC machines to plastic injection molding machines.

Automation Equipment: Manufacture of components for automation

systems in production.

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