Precision CNC machines are utilised across a wide assortment of industries. Its prevalence is also growing, with more and more components being manufactured with this machining method.
Yet why is this the case? Compared to conventional machining methods, purchasing CNC machines is typically done at a higher price. However, to explain why the additional investment is worth it, below are the main precision machining advantages:
It’s not just a name. Precision machining is all about being precise and meeting tight tolerances, aka dimensional accuracy. For the uninitiated, tolerance refers to a machined part and any deviations in its size from its initial CAD blueprints.
When CAD programs are combined with precision machining, with the latter using specialised CNC machine tools and processes, it reduces tolerances to the lowest possible values. The result: parts are produced with higher accuracy.
As mentioned in the previous section, CAD software is used in partnership with precision machining, which further refines the design process and overall product development. Better yet, you can use various software options – including cloud-based and free CAD software – as these are compatible with the machinery and necessary file formats.
With the accuracy of product designs, it is recommended to use 3D CAD software. 3D model designs provide you with greater scope for dynamic creations, which account for all product details.
Unlike machines that are operated by individuals, precision machining effectively takes human error out of the equation. All that needs to be done is for the right specifications to be keyed in, and the machine does the rest of the work.
This helps to reduce material waste, but it also means you don’t necessarily have to hire skilled workers to operate the machinery. Working with CNC machines leads to greater consistency, fewer defects, and more successful production sessions. It’s a solid solution for any business.
Yes, the initial investment for precision CNC machining is higher than conventional options. Yet, in the long term, it helps lower costs across the board and makes for more cost-effective production, and you need to be thinking long-term when making this decision.
With fewer detective productions, it makes sense that fewer parts need to be rejected – keeping material waste down as a result. Labour costs are also reduced, while production is faster with robotics compared to manual manufacturing.
The flexibility of precision machining, which is available in different forms and compatible with numerous materials, makes it an excellent solution for a wide assortment of applications. This is why many industries, ranging from automotive to consumer goods, benefit from precision machining.
In terms of machine types, CNC plasma cutting machines are a popular option with industries working with metal materials. Milling machines and cutting machines are other choices regularly chosen by manufacturers. This is just the start of the benefits gained from precision machining. If you would like more information or want to learn more about which machine is the best fit for your business, feel free to contact us.
The use of precision machining companies has become an important manufacturing requirement across many industries. If a manufacturing task requires precision and high-quality components, computer numerical control (CNC) precision cutting tools are a must for requirements with tight tolerances.
While observers may feel there are restrictions on what precision machining can do, the industry uses many tools and processes to create different finished product types. Milling, turning, and cutting are just some of the methods used.
A CNC mill helps to take raw materials and reshape these with a rotating cutting tool. CNC turning, on the other hand, involves the raw materials being rotated while the cutting tool remains stationary. A CNC plasma cutting machine is a high-powered solution for cutting metal materials like stainless steel with high precision. Other machines include grinders, drill presses, and electrical discharge machines (EDM).
The precision machining process comes with numerous benefits. It offers competitive pricing, improved lead times, and better performance and reliability for finished products. Another advantage is the wide range of applications precision machining can be used for, with it compatible with various materials like metals and plastics. It is also used in many industries, including the:
Medical industries benefit greatly from precision machining. Because of tolerance specifications, healthcare equipment demands precision of the highest level. Implants, orthotic devices, MRI matches, safe enclosures, etc., all have tight tolerances, and only precision machining can meet those requirements.
The automotive industry has undergone a significant technological revolution, and this is helped with precision machinery during the manufacturing process. Before a vehicle manufacturer moves forward with full-scale production, they use precision machining to produce high-quality prototypes. They can then perform market testing and analyse if any changes are necessary to the design.
Along the same lines as the aforementioned automotive industry, aerospace and aircraft vehicles must maintain a high level of precision and accuracy across their build. If any parts feature errors, this could lead to people’s lives being endangered. As a result, high-precision machining is necessary to create important components for the aerospace industry. These parts include manifolds, bushings, and landing gear ports.
Precision machining assists armed forces with developing their defence systems. CNC machining is used to bring new designs into existence, providing added quality and saving time in the process. With this technology, the arms industry can make everything from communication components to ammunition for weapons.
For the electronics industry, there is a continually growing demand for more powerful yet smaller parts. These have to be both lightweight and compact, as well as maintain tight tolerances. That is where machined parts with precision machining assist the industry. Circuit boards, heat sinks, and semiconductors are examples of components made with CNC machines.
If you require further information about what precision machining can be used for, including if it’s suitable for your own project, do not hesitate to contact us. We are always happy to help.
Plasma cutting processes evolved from plasma welding in the 1960s; today, they’re a highly effective and efficient method of cutting conductive metals. Given the scope of plasma cutters available as well as their capacity to slice through most metals, these tools are commonplace in any metal fabrication shop, no matter the size.
While they’re widespread across industry and home workshops, plasma cutters do have limits – from the gas type needed to the materials they cannot cut. These variables, as well as how the machinery works, will be discussed below.
How Does a Plasma Cutting Machine Work?
A plasma metal cutting machine cuts through conductive materials via a plasma torch – specifically electrically conductive metal. The plasma cutter cut is cleaner than many alternative methods, including oxy-fuel cutting.
Most mechanical metal cutting methods shear or burn the metal, which is the case with oxy-fuel cutting. However, plasma cutting machinery melts the metal with high-velocity ionized gas. The machine sends an electrical arc through the gas, which passes through a constricted opening and creates a clean, precise cut. The gas then blows away the molten metal from the cut, producing a smooth edge.
Types of Plasma Cutter
Plasma cutters come in different forms; for example, portable handheld machines, combination units with a plasma cutter, a stick, and a TIG welder, and also those with built-in compressors. CNC plasma cutting machines are also available, with “CNC” standing for “computer numerical control”. These high-tech cutters employ a computer to control and direct an accelerated hot plasma at the electrically conductive metal, slicing through it accurately.
Typically, most types of plasma cutters can easily cut metals ranging from 1-2mm to 1-2 inches thick – any more than that, and it gets a little tricker. Metals that plasma cutters can cut include:
Still, no matter the type of plasma cutting tool, there are some materials it cannot cut – or, if it can, gas selection must be considered.
Gas Selection
Compressed air typically isn’t enough; depending on the metal thickness, specific gases are needed to produce higher temperatures of ion plasma for cutting through certain kinds of metal.
When cutting thicker materials, like thick aluminium, for instance, argon and hydrogen gas mixtures are normally used, while thin stainless steel would need nitrogen and methane. For mild steel and carbon steel cutting, pure oxygen via oxy-fuel cutting is ideal.
The Materials That Plasma Cutters Don’t Cut
Given how they work, along with their cutting power and precision, plasma cutters sound like the ultimate replacement for cutting all materials. Unfortunately, it’s not time to throw away the old trusty saw.
Plasma cutting machinery cannot cut:
A plasma cutting machine requires conductivity to complete the electrical circuit; otherwise, it cannot do its job. Because the above materials aren’t conductive metals, plasma cutters can’t slice through them.
Furthermore, these units cannot cut non-electrically conductive metal. Many metals are poor electrical conductors or simply too problematic to deal with and thus cannot be cut using plasma metal cutting processes. Some of these challenging metals include:
Other rarer materials that plasma cutting tools cannot cut include the following:
Do You Need a Plasma Cutter?
Various plasma cutter types with different capacities are suited to certain metals and tasks. If you’re unsure which plasma-cutting tool you require, please contact us today. Our friendly team can use their specialist industry knowledge to help you select the right plasma cutter for your needs.
Plasma cutters cut conductive materials, namely metal, by sending air (or inert gas) at high speed through a plasma torch. It passes through an electrical arc and forces plasma through the tip of the torch, which cuts the metal. Because the arc can reach 25,000 °C, plasma cutters are one of the fastest ways of cutting metal. Still, how do you choose the right one? Much like a welder, the type of plasma cutter required depends on your work.
Plasma cutting machines can cut almost every metal, so the thickness and quantity of metal requiring cutting are the primary considerations. You’ll also need to select one based on the following:
Also, combination units exist: a plasma cutter, a stick, and a TIG welder. This option is ideal for the occasional job. As for portable units powered by generators, you must choose one that can cope with said generator’s fluctuating power.
Other features and variables you must account for when selecting a plasma cutter are covered in the following sections.
The output power determines what the unit can cut. For instance, 12 amps from a 120V machine can cut most 1/8-inch-thick metals. In contrast, higher-powered units with 60 amps of output from a high voltage 230V device can slice through most metals around 7/8 inches thick.
Inverter-based plasma cutters deliver high cutting output power but are also much lighter than standard cutting units with the same cutting ability.
Some plasma cutters have built-in air compressors, while others may require separate purchases. The required air pressure varies; a portable machine running at 20-30 amps may need 80 psi (5.5 bar), whereas a larger automated system on 130-800 amps might need 115 psi (8 bar) or more.
Plasma cutter speed is recorded in IPM (inches per minute), and the job dictates the speed you’ll need. However, some units can cut through 1/2 inch of metal in a minute; others may take five minutes if the cutting speed is slow.
“Duty cycle” refers to the time the unit can operate within 10 minutes before needing to cool off. Generally, a plasma cutter with a five-minute duty cycle can run for 5 minutes, after which it must cool down for another 5 minutes. A machine operating at a lower power may have a longer duty cycle, but very high operating temperatures might reduce it.
Shorter duty cycles are great for smaller tasks in a home workshop, perhaps creating small, regular cuts, whereas a longer cycle is better for making longer, deeper cuts on large metal pieces.
Two common types of plasma cutting torches exist. The high frequency starting system is the most popular, which creates a spark with a high voltage transformer, spark-gap assembly, and capacitors. High frequency torches don’t have moving parts and are more reliable, although they need occasional maintenance and can interfere with other electric-powered machinery due to their electrical noise.
The second common type is the contact start torch; it uses a moving electrode or “nozzle” to ignite a spark and light the pilot arc. This torch switches on instantly without a pre-flow cycle and doesn’t interfere with electrical devices.
Consumables will be an ongoing cost – the electrodes and cutting tips, to be precise. It’s important to learn how fast your chosen cutter will use these up. Replacing damaged or worn-out electrodes and tips is essential in maintaining cutting speed and quality.
Our knowledgeable teams at Kerf Developments can help you select the ideal plasma cutter for your needs. If you need assistance or have a general inquiry, contact us today – we’re here to help.
Are you thinking about investing in a water jet cutting machine?
If yes, then it can be a good idea to first find out how this high-speed cutting tool works.
Offering unrivalled precision cutting and the ability to cut a wide range of different materials, read on to find out exactly everything you need to know about this superior cutting process and how it can benefit your home or business.
A “Waterjet Cutting Machine” is an industrial tool that uses high-pressure jets of water generated via a high-pressure pump – and that pump generates a lot of pressure – to cut through a variety of different materials. Waterjet cutting is most commonly used during the fabrication of machine parts in industries such as mining and aerospace.
There are many benefits to this type of cutting, including the ability to produce intricate cuts in metal without warping or affecting tempers.
As briefly touched upon above, water jet cutting relies on jets of water, sometimes combined with an abrasive, to cut through materials.
The abrasive is added in the nozzle so that you can easily switch between water and abrasive cutting depending on the type of material that you are cutting, or you can use a mixture of water and abrasive.
The abrasive waterjet nozzle uses the configuration of a mixing chamber and a tube to ensure efficient cutting. Although, if you are cutting soft material, an abrasive jet may not be needed, and a simple jet of water will be enough to make a clean cut. These cutters permit the production of accurate parts with minimal experience.
A water jet cutting machine can make sure you are cutting a wide variety of materials in no time due to its high-velocity cutting stream and the unique design of its cutting head.
Some materials that you can effectively cut through using a water jet cutter are:
In fact, there are very few materials that cannot be cut using a water jet cutting machine, unlike other cutting tools that are limited to only metals. Just remember to be careful when cutting soft materials.
As well as the ability to cut through a wide range of different materials, there are many other benefits to choosing this method of cutting, including:
If you would like more information about how water jet cutting machines work or you want advice on how to choose the right water jet cutting machine for you or your business, then “contact us” here today and one of our friendly and knowledgeable team will do our best to help you.
If you want to retrofit your CNC machine but don’t know where to even begin, then you have come to the right place.
With control technology being more advanced than ever before, there has never been a better time to make mechanical improvements to your CNC system.
Whether you want to achieve increased performance and quicker lead times, or you simply want to keep up to date with the latest innovations that are happening in CNC machine tools, read on to discover how you can retrofit your CNC machine in just a few simple steps.
CNC retrofitting is the process of either adding or replacing an existing CNC machine tool with more advanced technology. There are multiple ways that you can upgrade your CNC machine, such as replacing any obsolete components, updating the system, and even a complete rewiring.
Once your machine’s CNC retrofit is complete, you can enjoy a whole host of benefits, including enhanced performance, productivity, and capacity, without the need to buy a new plasma cutting machine.
There is an extensive selection of CNC machines that can be retrofitted, so it is highly likely that your Plasma Cutting Machine can be upgraded in this way. Some of the different types of CNC machines that you can retrofit include:
Each CNC retrofit can be tailored to suit the bespoke requirements of your machine.
A number of factors affect how long a CNC machine retrofit will take, such as the complexity of the machine itself and the scope of supply. That being said, most retrofits can be completed within 7 days if you use a professional and reputable service provider.
Again, this is dependent on several different factors, such as what mechanical improvements you want and what type of CNC system you have. If you have a more complex machine, it will cost more for a retrofit than a basic CNC retrofit. Although, it is worth mentioning that a retrofit is always less than the cost of a new machine and any future repair costs.
If you would like to discover more about how much a CNC machine retrofit costs. It can be a good idea to seek out a company that offers complimentary, no-obligation quotes.
If you are ready to retrofit your CNC machine, then all you must do is follow these simple steps; Create a plan.
Decide exactly what you want to do to your CNC machine, and think about what supplies you need to achieve this.
Remove any old components, such as an old CNC controller and motor. Make sure you put safety first and hire an electrician if you are not qualified to do this.
Once you have removed the old components, now you need to mount your new CNC electrical enclosure.
Next, mount the new motors and design and fabricate the new motor adapter plates.
You are now ready to mount the new CNC machine controller and run the cables from the motors to the CNC electrical controller.
Finally, you need to connect all the wiring in the right locations on the panel.
The only step left to do now is power on the machine and set up any relevant software.
If you need more information on retrofitted machines, contact us here.
If you want to use a CNC plasma cutting machine for the first time, then you may be feeling a little nervous.
With super-high temperatures and high voltages, you need to ensure that you know exactly what you are doing before you operate a plasma torch. Luckily, the below blog will tell you exactly what you need to know about operating CNC plasma machines, including how difficult these laser systems are to operate.
How does a CNC plasma cutting machine work?
If you are new to plasma cutting, you may be interested to know a little bit more about how these types of laser machines work. As a cutting process, CNC plasma cutting machines are designed to cut through electrically conductive sheet metal such as aluminium and mild steel. They do this by using compressed gas to ionise the air into a plasma arch that melts the material. Not all CBC plasma cutting machines are equal, though. This is why you will want to get hold of a high-quality plasma cutter for the best results. Fortunately, you can check out our Ultrasharp Plasma Range here and find one that is suitable for you.
Is a CNC plasma cutting machine difficult to use?
It can be a little overwhelming to use any new machinery for the first time. However, you will be very pleased to hear that, once you learn the basics, CNC plasma cutting is not that difficult.
As a piece of machinery, a CNC plasma cutter is fairly straightforward to use, especially if you opt for a simple handheld model. All it takes is three steps. First, set up the air, then plug in your machine, and finally, mark up your meta. Once this is all done, you are good to go. That being said, if you are a beginner, it can take some practice to achieve good cut quality, particularly if you are cutting through thicker metals.
How to use a CNC plasma cutting machine safely and effectively
If you are still feeling nervous about using a CNC plasma cutting machine or you want to ensure you get the best possible end results, then the below top tips are just what you need:
As with most things in life, practice makes perfect, so it may take a little bit of time before you feel fully comfortable using your new CNC plasma cutting machine.
It is also important that you choose a high-quality CNC plasma cutter from a reputable manufacturer, as this will help to ensure that you achieve a good quality cut and an effective cutting experience.
Do you need more help using a CNC plasma cutting machine for your next laser engraving project? Or perhaps you want to invest in a new model and don’t understand the CNC Controller when it comes to laser repair jobs? Contact us here, and we will do our best to answer any questions you have.
Waterjet cutting machines are impressive tools that can be used for a wide range of purposes. The range of materials they are capable of cutting through is expansive – ranging from metals to stone, plastics, composites, and glass, among many more.
What’s more, they provide a neat cut that creates minimal waste. This arguably makes it more environmentally friendly than other types of cutting tools.
If you are thinking of using a waterjet cutter, it is useful to learn more about this innovative tool before you purchase one. This will make it easier to find out how it works, why it can do what it does, and how it might benefit your specific requirements.
Here are five facts about waterjet cutting machines you might not know:
One of the most impressive qualities of a waterjet cutter is its ability to slice through many different materials with relative ease.
The reason why this is so impressive is that other types of cutting techniques are only useful for specific materials. If a woodcutter was to be used on stone, for example, the results would be distinctly underwhelming.
So, a waterjet cutter gives you useful flexibility if you have access to one.
The materials a waterjet cutting tool can be used on include wood, stone, ceramics, metals, plastics, composites, and glass, among others.
You might be surprised by the power of water jet cutters when compared with other types of cutters – especially given it uses pressurized water to cut materials, but it demonstrates the power and reliability of a natural element.
Therefore, if you need a wide range of materials cutting, waterjet cutting machines are your best bet.
Waterjet cutters are famed for their neat and accurate cuts. This is because most cutting methods use a combination of force or heat to get the job done.
The result is a damaged cutting edge, burn marks, abrasions, or weakened material.
Because waterjet cutters use either an abrasive or pure water to cut at high speed, the results are almost immaculate.
If you didn’t think waterjet cutting machines were impressive by now, then you will be amazed by the fact that an abrasive water jet uses sand to cut hard materials.
These cutters essentially combine garnet with water in the cutting head and mixing chamber to shoot a highly effective cutting stream out of the waterjet nozzle at high speed.
This is why abrasive waterjet cutting is so good at cutting dense materials like stone.
Your eyes aren’t deceiving you. Waterjet cutters really can cut through certain foods.
It might sound mad, but the logic is sound. Waterjets are completely sterile, highly accurate, and delicate cutters, making them perfect for food production.
As mentioned above, there are different types of waterjet cutters - pure water and abrasive.
The pure waterjet has a fast cutting speed and is usually used on lighter materials, whereas the abrasive cutter is used to cut metal and other hard materials.
These different cutting processes mean you can choose the cutter which fits your requirements the best. If you want to find out more about waterjet cutters, contact us here.
Waterjet cutting machines are incredibly useful tools because they can easily cut through an incredible range of materials. Many cutters or drills have a difficult time cutting through dense materials like concrete or metals, but waterjets take it in their stride.
This is why they are regarded so highly in a variety of industries – from aerospace to healthcare, automotive to construction. wwwwww
However, it is important to note that waterjet cutters aren’t invincible cutting machines that can be used on everything. Every tool has its limits, and you need to know exactly which materials it can cut, at what width, and with what quality.
Not only will this give you a clearer idea of whether it is the right type of cutter for you, but you will be able to get the most out of your waterjet cutter if you already have one.
For example, although waterjet cutters can theoretically slice through up to 12 inches of the following materials, it is not practical in everyday use. This is because you no longer get a clean cut and the cutting time becomes longer than is desirable.
Instead, it is better to stick to cutting depths of three inches.
In no particular order, these materials can be cut with a waterjet cutting machine:
First off we have metals, which waterjet cutting machines have the ability to cut through with ease, in a way that other cutting tools simply can’t match.
There are several reasons why metal is usually difficult to cut accurately. There are issues with stress and thermal distortion which results in a jagged, uneven cut.
However, because waterjet machines use a cold-cutting method, the metal is not burnt or distorted by the heat involved. Not only does this provide a neat finish to the cut, but there is less waste afterward.
This even includes hardened tool steel and copper materials.
Another material that is often associated with water jet cutting is glass. Usually, glass is a time-consuming and resource-heavy material to cut, because of the number of tooling alterations required.
Not so with waterjet cutting machines, which can accurately cut glass and provide the delicacy required, thanks to their unique cutting process. However, tempered glasses cannot be cut with a waterjet tool.
Composites - such as carbon fiber - are inherently brittle when cut. This is because a lot of the time they are thin materials. Other cutters cause burn marks and other blemishes, but when they’re cut with a waterjet they are preserved immaculately.
Waterjet cutters are great for cutting plastic and reinforced plastics because they provide a neat cut without emitting any hazardous fumes, as there is no heat-affected zone involved.
Waterjet machines can also cut stone. This is because these cutters don’t require any meaningful force to be pressed down on the stone, which is where other, more established cutting methods fail.
If you would like to find out more about waterjet cutters, contact us here.
