Machined Parts

What is Machined Parts

Machining generally describes a manufacturing process in which a worker uses sharp cutting tools to remove excess material from a part in order to create a desirable new shape. Castings, forgings, extrusions, bar stock and even raw materials can all provide substrates for the process of machining. Typically, machining constitutes a secondary operation. It usually involves cutting away and discarding a portion of the material. The final shape of the part conforms to dimensions specified by the manufacturer. Companies employ machining to add features to or refine an existing metal component. Machinists may also smooth the surface of a part to achieve a finer finish. Nowadays, machining allows for the production of metal parts within high tolerance levels.

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Advantages of Machined Parts

Exceptional precision and accuracy
Precision-machined parts are engineered to meet exceptionally tight tolerances, ensuring that every dimension and feature is precisely controlled. This level of precision is critical in industries such as aerospace, medical devices, electronics, and automotive, where even the slightest deviation can lead to performance issues or compromised safety. By employing advanced machining techniques and cutting-edge technologies like CNC machining, precision parts manufacturers achieve consistent, repeatable results with exceptional accuracy.

Reliability and consistency
Machined parts are made using cutting-edge machinery and are subject to strict quality control measures throughout manufacturing. As a result, they have consistent dimensions, a smooth surface finish, and uniformity, which makes them easy to integrate into larger systems or assemblies. The dependable nature of precision machined parts helps enhance the overall performance and life of the final products.

Enhanced functionality and performance
Precision-machined parts are designed and manufactured to provide optimal functionality and performance in their intended applications. Whether it's high-speed rotating components, intricate electronic connectors, or critical medical device parts, precision machining techniques enable the production of complex geometries, fine details, and tight fits. These components are engineered to deliver precise motion, efficient energy transfer, and reliable functionality, contributing to the overall performance of the systems they are incorporated into.

Customization and versatility
With a high degree of customization to meet specific application requirements, precision machined parts allow manufacturers to tailor the design, material selection, and manufacturing processes to achieve desired characteristics such as strength, durability, heat resistance, or electrical conductivity. This versatility allows precision machined parts to fulfill diverse industry needs, ranging from intricate micro-components in electronics to vital structural elements in aerospace.

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Types of Machined Parts

Machined Metal Parts: These are parts that are machined from various types of metal such as steel, aluminum, brass, or copper. Each metal has its unique properties that make it suitable for certain applications. For instance, machined aluminum parts are lightweight, resistant to corrosion, and excellent for heat dissipation, making them ideal for use in automotive and aerospace applications.

Milled Parts: These are parts produced through the milling process, where a rotating cutting tool is used to remove material from a workpiece. Milled parts can be incredibly precise and can have complex geometries, making them suitable for a wide range of applications.

Lathe Parts: Parts produced on a lathe, often referred to as turned parts, are rotated against a cutting tool to remove material. This process is ideal for producing parts with a symmetrical shape about an axis, such as shafts and rods.

CNC Parts: CNC, or computer numerical control, parts are produced using a computer-controlled machine. This allows for high precision and complex geometries. The wide variety of CNC machined parts include gears, bushings, manifolds and more.

Custom Machined Parts: These are parts that are specially designed and machined to meet specific customer requirements. They can be made from a variety of materials and can have unique shapes and features.

Machined Part Tolerances

Machined parts can be made to tight tolerances, which may be necessary for critical mechanical parts that interact with other components. Looser tolerances may be chosen for prototypes and non-mechanical parts.

Tolerance Standard
Tolerance Lever			Overall Dimension Range
Specifications	<<3, >0.5	<<6, >3	<<30, >6	<<120, >30	<<400, >120	<<1000, >400	<<2000, >1000
F	±0.05	±0.05	±0.1	±0.15	±0.2	±0.3	±0.5
M	±0.1	±0.1	±0.2	±0.3	±0.5	±0.8	±1.2
C	±0.2	±0.3	±0.5	±0.8	±1.2	±2	±3
V	–	±0.5	±1	±1.5	±2.5	±4	±6

What Are the Applications of Machined Parts

Machined parts are used in virtually all industries, from aerospace to medicine. Some popular everyday and sector-agnostic parts are listed below, followed by applications in specific industries.

Common machined parts:
Fasteners
Valve bodies
Ball joints
Gears
Shafts
Housings
Brackets
Rollers
Aerospace

Machinable aerospace parts include prototype engine components, fuel panels, landing gear components, and engine mounts.

Automotive
Automotive machined parts include function testing components such as lighting, engine, transmission & steering systems, as well as one-off custom parts.

Medical
Machined titanium and stainless steel parts include implants, medical devices, and surgical tools such as scalpels.

Consumer products
Machined parts are found in household goods and appliances. Sporting equipment may also be CNC machined, while many machined metal and plastic components are found in consumer electronics. Items such as laptop casings, connectors, and sockets can all be machined.

Machined Part Surface Finishes

Machined parts can be treated after machining in order to alter their surface texture and appearance. Finishes can be either functional or cosmetic.
As-machined: No surface finish added. This is suitable for many internal, non-cosmetic functional components.
Bead blasted: The bead blasting process involves firing abrasive media at the machined part, leaving it with a matte appearance. The process can be adjusted to give a specific level of roughness. It may not be suitable for fine features, since bead blasting removes material and therefore affects the geometry of the machined parts.
Anodized: The electrolytical passivation process of anodization is suitable for aluminum machined parts, creating a scratch-resistant, colorful coating. Type II anodization creates a corrosion-resistant finish; Type III is thicker and creates wear resistance in addition to corrosion resistance.

Machined Part Materials

Machined parts can be made from many different materials, including metals and plastics.
However, some materials are easier to machine than others. Very hard materials are difficult to penetrate with a cutting tool and may cause the tool to vibrate more (consequently reducing quality). Very soft materials and materials with a very low melting point may deform upon contact with the cutting tool.
The most common machined part materials are listed below. Other materials can also be machined upon request to the manufacturer.

Metal: Aluminum, Steel, Stainless Steel (17-4, Inconel 625 & 718), Magnesium, Titanium, Zinc, Brass, Bronze, Copper.
Plastic: ABS, PC, ABS+PC, PP, PS, POM, PMMA (Acrylic), PAGF30, PCGF30, Teflon, DHPE, HDPE, PPS, PEEK. (Less common: PA GF50, PPS GF50.)

How to Design Machined Parts

It is always best to employ design for manufacturing (DfM) principles: design parts based on the manufacturing process that will be used. Parts for machining need to be designed differently to, for example, parts for 3D printing.

Undercuts
Undercuts are cuts in the workpiece that cannot be executed using standard cutting tools (because a section of the part is obstructing it). They require special cutting tools — T-shaped ones, for example — and special machining design considerations.
Since cutting tools are made in standard sizes, undercut dimensions should be in whole millimeters to match the tool. (For standard cuts this doesn't matter, since the tool can move back and forth in tiny increments.)
Undercut width can range from 3–40 mm, depending on the cutting tool, with undercut depth up to twice the width.
If undercuts can be avoided altogether, the machined parts can be made much faster and with less effort.

Wall thickness
Contrary to molded parts, which deform if walls are too thick, machined parts cannot handle especially thin walls. Designers should avoid thin walls, or use a process like injection molding if thin walls are integral to the design.
When machining, wall thicknesses should be a minimum of 0.8 mm (metal) or 1.5 mm (plastic).

Protrusions
As with thin walls, tall protruding sections are difficult to machine, as the vibrations of the cutting tool can damage the section or result in lower accuracy.
A protruding feature should have a height no greater than four times its width.

Cavities, holes, and threads
When designing machined parts, it is important to remember that holes and cavities are dependent on the cutting tools.
Cavities and pockets can be machined into a part to a depth of four times the cavity width. Deeper cavities will necessarily end up with fillets — rounded rather than sharp edges — because of the required cutting tool diameter.
Holes, which are made with drill bits, should also have a depth of no more than four times the drill bit width. And hole diameters should, where possible, correspond to standard drill bit sizes.
Threads, used to incorporate fasteners like screws, do not need to be deeper than three times the diameter.

Scale
CNC machined parts are limited in size because they are fabricated within the build envelope of the machine. Milled parts should measure no more than 400 x 250 x 150 mm; turned parts should measure no more than Ø 500 mm x 1000 mm.
Larger dimensions are possible with larger machines, but this should be discussed with the machinist before fabrication.

Categorization of Machining Processes

In general, all machining processes can be divided into two distinct machining categories: conventional and non-conventional. The processes differ with regards to the tools used for removing excess material.

Conventional Machining
Conventional machining represents a mechanical process. Machinists use a sharp tool to cut away excess material from a part. The process can be further divided into three sub-categories:

1) Single point cutting: This process refers to using a cutting tool with a single sharp edge that turns, planes and shapes the part.

2) Multi-point cutting: Multi-point cutting involves a cutting tool with two or more cutting edges to mill, drill, broach or saw the part.

3) Abrasive machining: During the process of abrasive machining, a machinist uses small abrasive particles to hone, grind, lap or polish the part. The process may also include ultrasonic and abrasive jet machining.

Non-Conventional Machining
Non-conventional machining processes encompass two sub-categories: Chemical machining and thermal machining.

Chemical machining: This process involves using baths of temperature-regulated etching chemicals. The chemicals remove material from the part, thus creating a metal component of a specified shape. Chemical machining can be a regular or an electrochemical process.

Thermal machining: This process employs a source of thermal energy, such as a laser or an industrial torch, to direct intense heat towards a metal part in order to remove excess material. Types of thermal machining include torch cutting, electrical discharge machining and high energy beam machining.

Machining Operations

The operations include turning, drilling, and milling. During these processes, machinists utilize sharp cutting tools to mechanically cut away small chips of material from the initial segment.
Each operation differs slightly from the others:

Turning
Turning refers to the operation in which a machinist moves metal against the cutting tool by carefully rotating the workpiece on a lathe machine. A lathe helps to shape metal by means of a rotating drive which turns the metal component at desired angles.
Turning will generate cylindrical-shaped parts that display various specified internal or external features. Typically, turning operations encompass boring, facing, grooving, thread cutting and the cut-off process, also known as parting.

Drilling
Drilling is used to create holes on a workpiece, or refine the size of existing holes. A machinist usually performs this step by using a cylindrical, rotating tool drill bit.
The bit penetrates the stationary metal part in order to create a hole. The machinist relies upon a drill press to perform rapid precision drilling.

Milling
A third widely performed machinist operation, milling involves passing a metal part in front of a cylindrical rotating tool with multiple cutting edges called a milling cutter. A machinist uses a milling machine to effectively remove any excess parts of the material.

Machined Part Surface Finishes

Machined parts can be given a variety of surface finishes to enhance their functionality, durability, and aesthetics. The surface finish of a part can have a significant impact on its performance and lifespan. So, what are the surface finish options for machined parts, and how do they affect a part's properties?

Surface finishes in machined parts vary significantly depending on the application and material used. Some of the common options include:

As-Machined Finish: This is the standard finish you get right after the machining process. It might exhibit some tool marks but is generally acceptable for many applications.

Bead Blasting: This process uses glass beads blasted at the surface to provide a smooth and non-reflective finish.

Anodizing: Anodizing is a common finish for aluminum parts. It not only enhances wear and corrosion resistance but also provides better adhesion for paint primers and glues.

Powder Coating: This finish provides a hard, durable, and corrosion-resistant layer to the parts. It's available in a variety of colors, making it suitable for parts that need aesthetic appeal.

Polishing: Polishing gives parts a shiny and smooth finish. It's commonly used for aesthetic purposes or when a high degree of smoothness is required.

The Role of CNC Machines in Creating Machined Parts

One of the primary tools used in the creation of machined parts is the CNC machine. CNC stands for Computer Numerical Control, a modern technology that uses computers to control machine tools. This method provides unprecedented precision, flexibility, and repeatability in part production, making it a cornerstone in machining parts.

There are various types of machined parts, each serving a unique purpose. Some common examples include gears, bushings, shafts, and housings, all of which are vital in mechanical systems. However, with advanced technology and skilled engineers, virtually any shape or form can be achieved through machining, from simple blocks to intricate 3D shapes.

FAQ

Q: What does machining parts mean?

A: Machining of parts is a process where a piece of raw material is cut to fit specific measurements. Actually, the final shape, size, or design achieved is through material removal. The processes of machining parts using material removal is known as subtractive manufacturing.

Q: What is machined material?

A: Machining is a major process of the manufacture of many metal products, but it can also be used on other materials such as wood, plastic, ceramic, and composites. A person who specializes in machining is called a machinist.

Q: What are the most common machined parts?

A: There are various types of machined parts, each serving a unique purpose. Some common examples include gears, bushings, shafts, and housings, all of which are vital in mechanical systems.

Q: What is machined metal?

A: Metal machining is a process of shaping elements made of alloys, modification of their dimensions, and sometimes: also properties. The goal of such a process is a production of an element that has the desired size and shape.

Q: Is machining the same as manufacturing?

A: What is the difference between machining and manufacturing? Manufacturing is a vast area that covers additive processes and subtractive processes. However, machining only includes subtractive manufacturing processes.

Q: What do you mean by machining?

A: Machining is the process of cutting, shaping, or removing material from a workpiece using a machine tool. All our machining is done on the highest quality machine tools. A reamer is a tool used in machining to make existing holes more accurate.

Q: What is the difference between forged and machined parts?

A: Forging provides a higher level of structural integrity than any other metalworking process. By eliminating structural voids that can weaken parts, forging provides a level of uniformity to help maximize part performance. During machining, grain ends are exposed, making parts more susceptible to weakening and cracking.

Q: What are CNC machined parts examples?

A: CNC machining is used to manufacture components like turbine blades, engine mounts, landing gear parts, and structural elements. The ability to create intricate designs and meet strict tolerances makes CNC machining indispensable in this industry.

Q: How are metal parts machined?

A: The controlled process of cutting a piece of raw material and creating a desired final shape and size is known as machining. Metal machining uses milling machines, lathes, drill presses and various other machines to manufacture shapes in a wide variety of metals.

Q: How are machine parts made?

A: How are machined parts manufactured? They are manufactured through machining processes such as milling, turning, drilling, and grinding. These techniques remove material from raw material to shape it into the desired form, following specific designs and tolerances.

Q: What are the 3 main types of machining technologies?

A: Three of the most common include turning, drilling and milling. Machining is a versatile and common manufacturing process. Therefore it is possible to machine different kinds of materials using the above three methods. Wood, composites, plastics and metals are all possible workpiece materials.

Q: What metal is easily machined?

A: Machining both brass and aluminum is generally considered easier compared to many other metals because they are relatively soft and have good machinability characteristics.

Q: What is the difference between machined and cast metal?

A: Choose machining when you have very strict tolerance requirements for part precision and surface finish. Metal casting is the preferred method for producing large volumes of identical products. It can also be used to produce complex internal cavities that are challenging or impossible to recreate with other methods.

Q: What is the difference between fabricated and machined?

A: Machining and fabrication are both industrial terms that refer to the process of producing or constructing a product. Machining converts raw materials into a finished products via large-scale industrial operations, while fabrication assembles various standardized parts to make a finished product.

Q: What is the difference between machined and milled?

A: Machining is a broader term that encompasses various processes for shaping and removing material from a workpiece, and milling is one of those specific processes.

Q: Is CNC a machining?

A: Computer Numerical Control (CNC) machining is a manufacturing process in which pre-programmed computer software dictates the movement of factory tools and machinery. The process can be used to control a range of complex machinery, from grinders and lathes to mills and CNC routers.

Q: Is CNC the same as machining?

A: CNC (Computer Numerical Control) by definition uses computer and computer programs to move the cutting tools and/or the part to perform the material removal. Conventional machining uses human control of the tools and/or the part to perform the material removal.

Q: What is the main purpose of machining?

A: Machining is the process used to remove material, typically metal, to create parts for machines, tools, transportation, and more. Machine shops and machinists use equipment like lathes, mills, and drill presses to turn material into useful tools using precise cuts.

Q: What is the difference between metal cutting and machining?

A: Metal cutting, which uses machine tools to form and size metal items, is often referred to as machining or subtractive manufacturing. Wood, plastic, ceramic, and composite materials are only a few examples of the materials on which metal cutting can be performed.

Q: Is CNC better than forged?

A: Generally, CNC machining is less expensive than forging, though it is most cost-efficient when making small batches of complex parts. But due to forging's ability to make stronger components, forging may be more cost-efficient in the long run if your project requires durable and long-lasting parts.

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