1. Process design optimisation: cutting down on time waste at the source
Make geometric shapes simpler and make design consistent.
Deep grooves and curving surfaces are examples of complicated geometric features that can make machining take longer and tools need to be replaced more often. The machining route can be made much shorter by making the part design simpler and getting rid of features that aren't needed. For instance, a German vehicle firm modified the engine bracket's curved surface to a mix of flat and sloped surfaces, which cut processing time by 20%. Using common threads, holes, and materials (such aluminium alloy 6061-T6) at the same time can cut down on the requirement for custom cutting tools and make it easier to fix equipment.
Centralised processing and one-time clamping processing
When using traditional machining, you have to change tools and clamps many times. But a five-axis CNC machine tool can cut, drill, and tap complex pieces all at once. For instance, one business cut the number of steps from 12 to 5 by machining the engine cylinder block with five axes. This cut the clamping time by 60% and the coaxiality error from 0.05mm to 0.02mm. Also, adopting composite cutting tools, like tools that combine drilling and milling, can cut down on the number of tool changes even more and make machining more continuous.
Digital scheduling of materials and better use of materials
Advanced CAM software like Radan and Mastercam can figure out the best cutting path on its own, which cuts down on waste. For instance, one company used smart nested algorithms to make better use of sheet metal, cutting down on raw material loss from 25% to 8% and lowering processing allowances and time. To make sure that resources are used up, set up a digital management system for sorting and recycling extra materials and for processing small parts.
2. Improving the efficiency of equipment: getting the most out of CNC machine tools
High-speed machining (HSM) and optimising parameters
Changing the cutting settings (such the speed, feed rate, and back cutting amount) for different materials (like aluminium alloy and stainless steel) can make machining much more efficient. For example, while working with aluminium alloys, employing high cutting speeds (800–1500m/min) and big feed rates (0.2–0.5mm/r) can boost the rate of material removal by 400%. while working with stainless steel, on the other hand, you should cut less often and increase the amount of back cutting (2–5mm). Some high-end CNC systems can monitor the load in real time and change settings on the fly to keep efficiency from dropping as the load changes.
Changing tools automatically and making things without people
Automated tool changing systems, like bucket hat-style tool magazines that hold at least 60 tools, can cut down on the time it takes to change tools from 30 seconds to 5 seconds, which means less time not cutting. Automated pallet systems and robot loading and unloading can work together to make production go around the clock without any people. For instance, one company has cut the time it takes to shift over a production line from two hours to 15 minutes by adding robotic arms and AGV handling vehicles. It has also raised the use of its equipment from 65% to 92%.
Machining on many axes and flexible manufacturing
A five-axis machining centre can control the movement of cutting tools in five different directions at the same time. This makes it great for machining complex surfaces like turbine blades and gearbox housings. By adjusting the tool's direction, you may eliminate machining interference and make the surface smoother. For instance, one company employs five-axis machining for gear parts, which cuts machining time by 85% and quality inspection time by 70%. Flexible fixture systems, like zero positioning systems, make it easy to adjust production quickly and can be used for a wide range of products and small batch production.
3. Working together throughout the supply chain: Making the time it takes to prepare materials shorter
Working together with suppliers and getting supplies just in time
Use APS (Advanced Planning and Scheduling) software to share your demand plans with suppliers. This will make sure that raw materials and parts arrive when you need them. For instance, a certain automobile maker cut downtime caused by material shortages by 60% and sped up inventory turnover by 30% after using a supplier coordination platform. When you add an intelligent warning system, real-time tracking of supplier delivery status, and automatic changes to the production plan or activation of backup supplier solutions if delays are expected, you have a better system.
Planning the best distribution routes and optimising logistics
Plan the best delivery route based on where the parts are and how much transportation space they have. This will cut down on the time it takes to get them there. For instance, one company has cut the time it takes to move goods between provinces from 72 hours to 48 hours and cut transportation expenditures by 15% using a logistics optimisation system. Air freight or a dedicated vehicle delivery is employed for urgent orders to make sure that important parts are delivered on time.
4. Digital Management: Monitoring in real time and quick response
APS scheduling of production and changing priorities on the fly
APS software may automatically optimise the order of production based on how urgent the order is and the customer's level, making sure that critical orders are made first. For instance, a well-known luxury automobile maker has used smart scheduling to cut the time it takes to deliver high-priority orders from 8 weeks to 5 weeks and the time it takes to switch production lines by 20%. At the same time, look for ways to run many operations at the same time in the manufacturing process. For example, you might set up interior assembly preparation ahead of time while waiting for painting to finish. This would cut down on the time spent waiting for the process to finish.
Optimisation of Digital Twin and Simulation
Digital twin technology can be used to create a virtual environment that simulates manufacturing processes. This can help find problems before they happen. For instance, a company that makes commercial vehicles used the simulation feature of APS software to cut delivery cycle fluctuations in half and make manufacturing much more stable. Emergency plan drills can be done to make sure that deliveries are stable in case of unusual situations like equipment failures or a lack of workers. Real-time order tracking and consumer transparency
Customers and distributors may see how their orders are progressing using digital platforms. This makes things more open and cuts down on delivery delays caused by bad communication. For instance, a real-time order tracking system helped a business cut the number of customer complaints by 40% and raise customer satisfaction by 25%.
5. Case study: The effects of CNC machining in real life
Processing case for engine cylinder blocks
A major car maker uses five-axis CNC machining to make aluminium engine cylinder blocks. By fine-tuning cutting settings and process management, they get the following results:
The accuracy of the dimensions has gone up by 85%, and the tolerances are now within ± 0.005 inches.
Increase the life of your tools by 300% and cut down on how often you need to change them by 70%.
The scrap rate has dropped from 12% to 0.8%, which saves more than 10 million yuan per year.
A case study of machining parts for a transmission system
A certain company was able to improve the processing of complex gear parts by using integrated sensing systems and automated fixtures.
85% less time spent processing, with the time it takes to process one piece going from 45 minutes to 7 minutes; 70% less time spent inspecting quality; 60% less time spent setting up; and quick mould replacement tools and standardised positioning pads allowing for quick production changes.
