Mass production of machines and devices is currently strongly connected to the outsourcing of manufacturing – especially parts and elements of a bigger mechanism. That is why by talking today about 'a production line' of some bigger arrangements or systems most often we mean 'an assembly line'.
Such a rule applies to almost any industry – from electronics and furniture to automotive and even space industry. Thus – the production of machine parts, devices, or car parts is scattered (decentralized) and usually outsourced to specialistic shops or factories that are focused on manufacturing such elements in a short time.
That solution is an industry standard – on the one hand, it can decrease the cost of manufacturing parts; on the other – lead to cost optimization of the logistics and final product or increase the margin. The outsourcing of parts manufacturing leads to significant savings –companies do not need to launch new shops focused on such production (eg. CNC machined), especially highly-specialized parts. To better understand that process it is worth knowing what a parts manufacturing process is and what areas can be a source of significant profits for a client.
Manufacturing machine parts - what types of parts can be produced?
Parts production – new elements, designed to be put in new systems, and replacement parts – is executed contemporary mainly with the CNC machining processes like milling, turning or laser cutting, and recently – even metal 3D printing.
The technology of the computer numerical control allows manufacturing of a wide range of high-quality parts like:
- pins and bushings,
- gears,
- shafts and rings,
- guides and profiles (e.g. stringers),
- complicated structure parts (eg. engine blocks, pistons, or transmission housings),
- small construction elements (eg. turbo snails, specialized connectors),
- and many more, that are created on particular demand and based on technical specifications delivered by clients.
Większość części do maszyn i urządzeń jest wytwarzana z różnego rodzaju stopów metali (stali, aluminium, miedzi, brązów), jednak zamiennie mogą być stosowane również tworzywa sztuczne (np. polimery), których właściwości fizyczne mogą odpowiadać warunkom pracy.
Dlatego też odnosząc się do „produkcji części do maszyn”, najczęściej mówi się o obróbce metali – współczesne stopy zapewniają wysoką wytrzymałość przy zachowaniu dobrych właściwości skrawania i odpowiedniej wagi, a zarazem mogą być dobierane ze względu na oczekiwane zastosowania.
Warto dodać, że współczesny przemysł odchodzi od obróbki ręcznej czy zautomatyzowanej na rzecz maszyn CNC, które pozwalają na masową produkcję elementów o wysokiej powtarzalności, a przez to optymalizację procesu wytwórczego.
O ile frezarki czy tokarki sterowane ręcznie nadal mają zastosowanie przy obróbce pojedynczych elementów, o tyle w produkcji seryjnej park maszynowy jest najczęściej wyposażony w urządzenia sterowane numerycznie. Oznacza to, że produkcja części do maszyn i urządzeń jest realizowana obecnie przy pomocy:
Most machinery parts are manufactured out of a vast variety of metal alloys (eg. steel, aluminum, copper, bronze). In some applications – such parts can be also produced out of polymers and plastics – such materials can be used in exchange for metal alloys, especially in less demanding applications.
Despite that, 'machining of machine parts' still mainly focuses on machining services and the usage of a vast variety of metal alloys. Such materials can deliver high rigidity and (very) good mechanical features while being easily machined and reasonably light. A big variety of alloys helps to match appropriate material for application – eg. lighter, more resistant to corrosion, stiffer, etc.
It is worth mentioning the contemporary machining industries are focused almost exclusively on CNC manufacturing. Automatic mills or lathes are still used in the shops to manufacture one-off parts, not for mass production. CNC technology allows the production of big batches of parts with tight tolerances in less time. That is why machine parts suppliers use in their shops or plants mainly numerically controlled devices as:
- CNC mills – that allow fast and repetitive manufacturing of big quantities of parts with minimal or negligible differences in diameters out of almost any material (eg. alloys, polymers, wood, stone),
- CNC lathes – that are focused on the fast and repetitive machining of cylindrical parts,
- CNC grinders – that allow to achieve a smooth surface, eliminate the tool marks, and automatize the surface finish process,
- 3D printers, but focused on alloys – although that technology is today on the cutting edge, allow to manufacture of very complicated parts, especially with complex internal structures, most often used in automotive and military industries (eg. SIG uses that technology to produce very complex suppressors for a new US Army rifle, the XM7). Such technology is called by many 'beyond precision engineering', but allows one to achieve complexity unreachable with traditional machining tools.
On top of the manufacturing process, a very important step in production is often the selection of the right finish method. Most machine parts are subjected to additional processes that are focused on bettering their surface and increasing mechanical and sometimes aesthetic features. Such processes are often thermal, chemical, thermochemical, and electrochemical (eg. hardening, annealing, anodizing).
Spare parts production - then the CNC machining is crucial?
Każdy proces produkcji wymaga pewnej formy optymalizacji – czasu pracy (roboczogodzin), czasu niezbędnego do wytworzenia czy balansu między precyzją a szybkością wykonywania zadania (np. produkcji części). Większość przedsiębiorstw zajmujących się współcześnie wytwarzaniem części (zarówno konstrukcyjnych, jak i zamiennych) kładzie ogromny nacisk na czas niezbędny do wyprodukowania wysokiej jakości elementów.
Poza wiedzą i doświadczeniem pracowników, najważniejszą składową tych procesów jest zastosowanie maszyn sterowanych numerycznie, czyli CNC. Umożliwiają one przyspieszenie produkcji części, a w perspektywie produkcji masowej (powyżej 100 czy 1000 elementów tygodniowo) i mogą być źródłem dużej oszczędności czasu.
Dzieje się tak z prostego powodu: tokarki czy frezarki CNC, w połączeniu z zaawansowanym parkiem maszynowym producenta części, pozwalają na automatyzację wytwarzania elementów.
Jest to możliwe m.in. dzięki temu, że:
Each production process requires some form of optimization – time of work, amount of machine hours required to manufacture a particular part, or finding a balance between precision and speed of machining. Most of the leading manufacturers of parts (that will be assembled into new devices or spare parts), put a strong emphasis on the time required to produce high-quality parts.
On top of the knowledge and experience of workers/operators on the factory floor, the most important element of that equation remains the CNC technology. Numerical control allows for an increased efficiency of manufacturing, especially in higher quantities – from 100 to even 1000 weekly – and reduces the cost of production, due to automatization.
The reason for that is simple: CNC mills or lathes – combined with advanced machine parks of the parts manufacturer – allow automation of a big part of the manufacturing process.
It is possible due to:
- the precision of CNC machining – parts are almost identical, within minimal differences and tight tolerances,
- one operator can maintain and control more than one numerically controlled device,
- automatized production lines allow almost maintenance-free production of high quantities of parts (eg. automatized feeders),
- high machining precision decreases the number of parts rejected by the quality control – which leads to significant cost reduction, especially in comparison to traditional machining tools.
The reasons mentioned above highlight the advantages of a CNC-equipped machine park, specially dedicated to the mass production of parts.
What parameters of work are the most important in parts manufacturing?
First of all: the mass production of parts requires the precise following of the specification and client requirements. Deviation from it can lead to problems with the quality of manufacturing parts (from the client's perspective) and can impact professional relations between the manufacturing company and the client.
In mass production of parts, the most important are combined knowledge and experience of operators and precision of CNC machining services. Such resources can provide additional profits for the client – for example better selection of material for ordered jobs (cheaper alloy but with almost identical features) that can lead to cost optimization.
Neither do less – the key parameters for serial production of parts for machines and other devices are:
- precise following of the specification delivered by the client or agreed on,
- repeatability of the manufacturing process and maintaining tight tolerances,
- meticulous quality control focused not only on dimensions but also on the parameters of the parts,
- maintaining CNC machines – for example, regular calibration and regular inspections to provide maximally available precision of machining. On top of that – maintaining continuous control of the parameters of work, eg. temperature in the CNC machining station to avoid thermal deformations.
Production of high-quality parts - the source of unexpected profits
Production of high-quality parts for machines and other devices can be – more often than not – a source of unexpected savings for clients and machining plants. A stronger emphasis on the quality of manufacturing can lead to:
- smaller risk of returns – poorly machined parts break more often and should be changed for new more often; that generates cost. High-quality parts last longer,
- a smaller percentage of parts rejected by quality control – well-machined parts are rarely returned due to non-compliance with the specification,
- good quality can create a foundation for long-lasting cooperation between machining plants and their customers. That can lead to an increasing amount of orders, margin, and overall financial profit.
At RADMOT, we operate for many industries - you will also find parts for machines and automation
At RADMOT, we can offer CNC milling services, CNC turning services as well as many additional services, including washing, aluminum anodizing, laser marking and assembly.
Contact us and tell us what you need. We have been providing CNC services for 40 years. Our quote is completely free. And if you are in doubt about which technology will work best for you, we are able to advise customers from many industries on machining and quickly determine the price of machining the parts you order - our expertise is at your disposal.
