Tool Manufacturing for Dummies: The Role of CNC Machines

In the world of hand & striking tools manufacturing, precision and accuracy are paramount, where even the slightest deviation can lead to inferior products and, in some cases, dangerous situations and product recalls. This is where CNC machines come in - an essential process that has revolutionized the tool manufacturing industry.

What is CNC machining?

CNC machining stands for Computer Numerical Control machining. It is a process where computer-controlled machines are used to shape and cut materials into precise and intricate shapes. It is a subtractive manufacturing technology: parts are created by removing material from a solid block (called the blank or the workpiece) using a variety of cutting tools. This is a fundamentally different way of manufacturing compared to additive (3D printing) or formative (Injection Moulding) technologies.?

Almost every material can be CNC machined. The most common examples include?metals?(aluminum and steel alloys, brass) and?plastics?(ABS, Delrin, Nylon). Foam, composites and wood can also be machined. The basic CNC process can be broken down into 3 steps. The engineer first designs the CAD model of the part. The machinist then turns the CAD file into a CNC program (G-code) and sets up the machine. Finally, the CNC system executes all machining operations with little supervision, removing material and creating the part.

Advantages of CNC Machines

• Ability to produce consistent and accurate parts. Unlike manual machining, which is prone to human error, CNC machines use precise measurements and mathematical calculations to ensure that each tool is identical to the last.
• CNC Machines can produce complex shapes and designs. With traditional machining, producing intricate shapes and designs was challenging and time-consuming. However, CNC machines can easily produce the most complex shapes and designs, resulting in tools that are functional & visually appealing.
• CNC machining is incredibly efficient, allowing manufacturers to produce quickly and cost-effectively. This also means that tools can be produced and delivered to customers much faster than traditional manufacturing methods.

Drawbacks of CNC Machines

• Being a subtractive technology, machining complex geometries come at an increased cost. It is also restricted by the mechanics of the cutting process. Parts with complex geometry either require the use of a multi-axis CNC machining system or manual labor from the machinist.
• Startup costs are mainly connected to process planning. This step requires manual input from an expert, so start-up costs are usually relatively high when compared to 3D printing, where process planning is highly automated.?

CNC Machines vs 3D Printing

Both CNC machining and 3D printing are exceptional tools in the arsenal of an engineer. Their unique benefits make each more suitable for different situations though. When choosing between CNC machining and 3D printing, there are a few simple guidelines that you can apply to the decision making process.

As a?general rule of thumb parts?with relatively simple geometries, that can be manufactured with limited effort through a subtractive process, should generally be CNC machined, especially when producing metal parts.

Choosing 3D printing over CNC machining makes sense when you need:

• A low-cost plastic prototype
• Parts with very complex geometry
• A turnaround time of 2-5 days
• Specialty materials

Growing Influence of CNC Machines

A very common industrial application of CNC machining is the fabrication of tooling for other processes. For example, the molds in Injection Molding are commonly CNC machined from aluminum or tool steel. As the demand for reliable tools continues to grow, CNC machining will undoubtedly play a vital role in meeting those demands.

Overall, CNC machining plays a crucial role in the manufacturing of hand and striking tools, ensuring that they are precise, durable, and reliable. It enables manufacturers to create that are perfectly balanced, comfortable to use, and perform their intended function with great efficiency.