Your complete guide to machining

Your complete guide to machining

Machining plays an essential role in the production of high-quality precision parts. Whether you are an engineering professional or just curious, and want to learn more about this industrial technique, then this complete guide to machining is perfect for you.

The definition of machining

What does machining mean?

Machining is a manufacturing process that consists of shaping a rough material, such as metal, plastic or wood, by removing material to make a finished part with precise dimensions and specific characteristics. Machining is one of the most widely-used methods used in industry, from automotive and aerospace, to energy and electronics.

The main goal of machining is to create complex shapes and finished surfaces with a high degree of precision. This can include the creation of cavities, grooves, threads, drill holes, flat surfaces or curves, according to the technical specifications of the end product.

One of the main advantages of machining is its versatility. Machining can be used to produce a broad range of parts, from simple individual components, to more complex assemblies. In addition, machining is well adapted to different types of materials, in particular ferrous and non-ferrous metals, technical plastics and composites.

Close-up on the machines

The machining process involves the use of a machine tool, such as a lathe, a milling machine, a grinding machine or a drill, which is precisely controlled to progressively and methodically remove the material. Different cutting tools, such as drills, milling cutters, reamers and blades are used, according to the specific needs of the machining operation.

Machining has evolved over the years, with the introduction of new technologies and techniques. Modern machine tools have become increasingly automated, featuring numerical control systems and advanced sensors that improve the precision, productivity and safety of machining operations. These days, most companies use numerically controlled machine tools, in combination with a computerized system (CAM), that partially or totally automates the machining procedure.

What is a machining technician?

A machining technician is a qualified professional, specialized in the execution of machining operations. They are responsible for the preparation and installation of the machine tools, the choice of the right cutting tools, the adjustment of the cutting parameters and the execution of the machining operations. To do this, they must be capable of understanding and interpreting technical drawings, selecting the right machining methods for the specifications and using the machines and measuring instruments with precision in order to guarantee conformity with the required tolerances.

In addition to their technical skills, machining technicians must have a sound understanding of the materials, the machining processes and safety standards. They must be capable of analyzing potential problems, solving manufacturing defects and taking corrective measures to guarantee the quality of the machined parts. With the rapid evolution of the machining industry, machining technicians must keep up to date with the new technologies and progress in the field. They may have to work on advanced machine tools, integrate numerical control systems and use computer-assisted design (CAD) software to optimize the machining processes.

 

What are the four basic machining operations? Turning

This technique uses a lathe to produce cylindrical, conical or complex-shaped parts, such as threads or grooves. The part to be machined is fixed on a rotating spindle, while the cutting tool moves along the part to remove material and produce the required shape.

Milling

Milling consists of using a rotary milling machine to remove material and create complex shapes, such as grooves, flat surfaces, pockets or contours. Milling machines can be used for 2D or 3D machining, depending on the movements of the part and the cutting tool.

Note that the milling of flat surfaces consists of using a special milling tool to produce smooth and precise flat surfaces. The milling of flat surfaces is often used to produce the bearing or reference surfaces of parts.

Drilling / boring / tapping

Drilling consists of making holes in a part with a drill bit. The drill bit turns and penetrates the part, removing material in order to make a hole of a precise diameter and depth. A conventional drill or a more advanced machine tool can be used for drilling operations.

Tapping makes internal threads inside a hole that has already been drilled. The tapping tool cuts thread-shaped grooves inside the hole, so that bolts and other threaded parts can be screwed into the hole.

Finally, boring increases and improves the quality of a hole that has already been drilled in a part. This operation is generally used in order to obtain very precise tolerances, high quality surface finishes or specific dimensions.

Grinding

Grinding is a high-precision machining operation used to produce very smooth surfaces and precise dimensions. This operation consists of using a grinder with abrasive grinding wheels to remove small quantities of material and obtain very strict tolerances.

These machining operations form the basis of numerous other more advanced machining techniques. It is important to choose the right machining operation, according to the specifications of the part to be machined and the required tolerances and geometric characteristics.

 

The range of CAD, CAM and PDM TopSolid solutions

What is the future of machining?

There are several major trends in the world of machining.

Increased automation

Machining is becoming more and more automated, with the introduction of robots and smart manufacturing systems. Modern machine tools are equipped with advanced sensors, numerical control systems and artificial intelligence technologies that optimize the production processes, improve precision and speed, and reduce human errors.

  • See also – “Boost Milling: how to save time in your machining cycles”.

3D printing for machining

3D printing is being used more and more in machining, especially for the production of complex parts. Metallic 3D printing technologies can be used to produce parts with complex internal geometries, thereby reducing the need for additional machining operations. The integration of 3D printing and traditional machining opens up opportunities for more flexible design and manufacturing.

Hybrid additive manufacturing

Hybrid additive manufacturing combines 3D printing with traditional machining. This approach can build parts with complex structures using 3D printing, and then performing machining operations to obtain finished surfaces, precise tolerances or additional functionality.

The integration of artificial intelligence

The use of artificial intelligence (AI) in machining is on the rise. AI can be used to analyze the data from machine tools in real time, optimize the cutting parameters, detect manufacturing defects and improve the overall efficiency of the machining process.

Sustainability and ecological responsibility

In the future, machining will also focus on sustainability and ecological responsibility. Companies will attempt to reduce their environmental footprint by adopting machining techniques that consume less energy, by using recyclable materials and optimizing their processes to reduce waste.

Irrespective of your business, from medical and aerospace, to general or precision mechanics, molds or progressive dies, clock making, optics or welded parts, TopSolid’Cam can meet all your machining needs. Our different modules offer a broad selection of technical solutions to meet your 2D and 3D milling machining requirements, with four of five axes, positioned or continuous, as well as for turning and bar turning. Want to find out more? Then get in touch!

How 3D design and digital engineering can optimize progress reports

How 3D design and digital engineering can optimize progress reports

Are tunnel projects, without any contacts with the customer, except at the beginning and the end, something of the past? Unfortunately not. It is the dread of many customers and often a last resort for certain service providers that are faced with tight constraints in terms of time and money. When a project starts to go wrong, organization and documentation in particular, such as progress reports, are often the first things that go missing. Nevertheless, they are critically important for all the stakeholders.

In industry, the regular production of these documents can take a long time and often produces fruitless or unusable results. But, thanks to 3D design and digital engineering, it is possible to quickly produce comprehensible documents and efficient views that provide customers with a clear vision of the state of progress of the project.

What is a progress report?

You probably already know what progress reports are. On the other hand, you may not understand all their subtleties or, even worse, you may think that they are pointless. So, let’s get things straight… Progress reports are used to keep track of and communicate the status of a project, at a given point in time, to different stakeholders. It provides an overview of the completed activities and tasks, the results achieved and any problems. Progress reports can be used to assess the state of progress of a project and take decisions on the basis of up-to-date information. A 3D CAD project to design a machine, for example, could contain the following information:

  • A description of the project: The report can begin with a detailed description of the project that contains the goal of the project, the required specifications, the technical constraints, the functional requirements and the planned deadlines.
  • Design steps: An overview of the various design steps that are followed to design the machine using 3D CAD. It may include the initial 3D modeling, the creation of the assemblies, the addition of specific functionality, the optimization of performances, etc.
  • 3D models: Present the 3D models that are produced for the machine using 3D CAD software. These models may show the structure of the machine, the individual components, the connections and the mechanisms, etc. They are used to view and validate the design.
  • Results of the simulations: If any simulations are made to assess the performances of the machine, their results can be included in the progress report. They may include analyses of the strength of the materials, movement simulations, collision tests, etc.
  • Problems encountered: Mention the problems encountered throughout the design process. At this point, technical difficulties, the limitations of the CAD software, manufacturing constraints, delays, etc., are raised. The measures taken to solve these problems may also be mentioned.
  • Progress relative to the initial plan: The report may provide a comparison between the actual state of progress of the project and the initial plan. This comparison can be used to see whether the project is ahead of schedule, running late or on schedule. Any deviations can be explained and adjustments can be suggested.
  • Collaboration and communication: Keep a trace of the interactions with the other members of the design team, suppliers, partners or customers. They include meetings, exchanges of information, requests for clarification, etc.

The next steps: The status report may be closed by highlighting the next steps of the project. This may include the remaining tasks, upcoming deadlines, planned deliverables, tests to be carried out, etc.

It is always possible to simplify the level of detail of the reports and to keep only the information that is really useful.

 

How does a progress report affect the execution of a project?

Progress reports are a part of the global project management process, and they play an essential role. They are scheduled in the planning phases and completed during the execution phases. They are used to identify any deviations and to take corrective measures in the monitoring and control phases, they facilitate communication between the stakeholders, and the information collected can be used to reassess and adjust the project. It is quite easy to get lost, if you want to draw up a good progress report. So, how can you make this task more fluid?

The range of CAD, CAM and PDM TopSolid solutions

How collaborative 3D design helps to produce progress reports

In the design phase of a project, you do not necessarily need a rendering in real time. You have not reached the end of the project, and many elements can still vary. Nevertheless, you may want the communicate the project as is to an external party. The customer, for example, who can ask for a progress report at any time.  You must be capable of proposing a 3D model, which you can do to in two ways: just the visual, or the visual with the tree structure of the parts. How?

You have three possibilities:

  • Produce a view outside the project in its current state in the form of a 3D view that is not necessarily realistic. We call this TopSolid Viewer: we supply the data, then the partner loads it and can see the same thing as on our workstation.
  • Authorizing a user to log into a Product Data Manager (PDM). They can then see their machine in a simple web interface, on a mobile phone or on a mobile tablet. In concrete terms, we send them a link that grants access.
  • The last method consists of sending a simple link by email. The user then logs into a web site, where we have shared the 3D data with them.

 

When should the progress report of a 3D CAD project be sent?

The process described above can take place several times in the product design cycle. The idea is to iterate with the customer, who can make amendments, adjustments, corrections, etc.

The history must keep track of all these interactions, which is where the PDM comes into play. Thanks to the PDM, we know everything that has happened. We know if and the date when we sent a prototype to the customer, their response and any action that was taken as a consequence, etc. Everything is tracked in the management environment.

When you reach the end of your project, after numerous exchanges and discussions, you can start the review in virtual reality. This is still an iterative process, and you may want to backtrack on certain design choices.

If you backtrack through the design steps “by hand”, then the process can become so complex that it is unmanageable. It is better to have a system that is smart enough to rebuild everything on its own, otherwise it could take a very long time.

 

The Product Data Manager: the cornerstone of a good progress report

As you may have already observed in your projects, every person and every company may have its own definition of what a progress report should be. There are infinite variations, from no formalism at all (the customer knows nothing or, on the contrary, has full access in real time, but no explanations), to a complex and sometimes totally unusable document.

See also “The benefits and selection criteria of the PDM for CAD-CAM”.

 

They key consists of the combination of collaborative 3D CAD techniques and an efficient PDM (Product Data Manager). They save time and allow for simplicity. They also standardize exchanges, reduce the risk of errors, build on knowledge and secure data. Want to find out more? Then get in touch!

Why should SMEs consider tailor made configuration?

Why should SMEs consider tailor made configuration?

In the collective imagination, cost-effective production means standardization to mass-produce at a low cost. However, the constant production of new products and consumers’ desire for hyper-personalization challenge this idea. To address these challenges, custom configuration proves to be a significant solution for small and medium-sized industrial entities. This meets both the consumer’s desire for personalization with the company’s economic viability. Here’s how it works.

Customized configuration is a key component of digital engineering

With the integration of digital technologies and the automation of information systems, engineering 4.0 (or digital engineering) has revolutionized object design, manufacturing, and production processes. This is how tailor-made configuration has emerged. Digital tools empower users to hyper-personalize their products by playing with various combinations. For that, the customer can adjust his modifications on a 3D simulation to achieve the desired result. In an increasingly competitive production environment, hyper-personalized configuration answers to the growing trend towards mass customization. It is also a solution to the consumers’ desire for personalization and the resulting need for production flexibility. Nowadays, industries wishing to remain competitive must be able to rapidly modify their production lines without losing quality. Therefore, it is essential for them to invest in a high-performance tool capable of multiplying configurations.  

Hyper-personalized configuration: a tool beneficial to all levels of a business

Hyper-personalized configuration is primarily seen as a sales support tool, but its benefits go way beyond the sales department alone – particularly in industry. Customized configuration provides numerous advantages at various levels of the business, including:

  • A tenfold increase in production reliability: 3D visualization and details of modifications, made by the design office, during the design phase, enable the manufacturing of error-free complex products.
  • Offering consistent prices with real-time updates: with customized configuration, you can monitor real-time price adjustments based on changes made during the design phase. This allows you to sell and produce at the best price without reducing profit margins.
  • Expanding your market reach: the number of configurations enables access to a broader customer base. Moreover, customized configurations create a seamless connection between the design and the final product. Consequently, the production begins only after an order is place by the customer.
  • Empowering customers: as decision-makers from start to finish of the design process, users can hyper-personalize their products. Customized configuration reduces the discussions between the customer and the design office and significantly reduces the time spent on the project by the latter.
  • Improving the competitiveness of all businesses: large corporations, SMEs, SMIs… This technology is accessible to all types of industry. Indeed, in the context of a mass production strategy, small businesses may struggle to remain profitable if they are unable to expand to produce more. Thanks to customized configuration, small and medium-sized businesses can get more profitable without significantly increasing their production.

The range of CAD, CAM, ERP and PDM TopSolid solutions

Top Solid’Design: custom configuration for manufacturers

TopSolid’Design is CAD software designed to optimize the work of the design office at every stage of the design process. With this in mind the Product Configuration module enables designers to propose customized configurations. The process is straightforward: parts are configured from the 3D model and its possible variants. Everything is designed using native design office data. With just a few clicks, users can customize the product’s appearance to match their wishes and budget, with real-time adaptability. At the end of the configuration process, the design office takes the reconfigured file, makes the modifications required by the user, and sends it to manufacturing. Our Product Configuration module is suitable for both B2B (for industrial customers, resellers, or partners) and B2C. This module meets the user’s demand for customization while streamlining the design office’s workflow. As a modular solution, TopSolid’Design is compatible with most market formats, including our TopSolid’Cam manufacturing software – without any loss of data. Our flexible solution is adapted to the needs of industry designers. It offers:

  • full traceability throughout the design process,
  • time-saving benefits for the design office through collaborative work,
  • sharing of native CAD files,
  • …and robust data security and access control.

Try TopSolid’Design: Contact us now!

CAD/CAM for grinding on your machine tools

CAD/CAM for grinding on your machine tools

More precise than traditional machining operations, grinding enables the surface of a product to be finely modified thanks to the abrasive machining technique. Nevertheless, investing in the right machine tools to perform this type of operation represents a significant cost for companies, more so as their piloting can prove difficult for programmers. To facilitate grinding on these machine tools, some manufacturers are exploring the possibilities offered by CAD/CAM. But what additional advantages does CAD/CAM offer this activity? Here’s how.

The challenges of rectification

By employing the principle of abrasive machining, grinding achieves exceptionally high dimensional accuracy on parts, enabling us to meet customer requirements better. Whereas traditional machining operations involve the removal of a swarf, grinding acts more finely on the material, polishing it with a grinding wheel.

While the effectiveness of this method is not in doubt, it nevertheless represents a significant investment for companies: they must purchase the machine tools required for these operations. The challenge for organizations is to measure the profitability of the proposed solutions. To carry out grinding operations, they can:

  • Either invest in grinding machines dedicated exclusively to honing.
  • Or to invest in combined machines for both machining and grinding.

The limits of “foot-in-the-machine” programming

In the first case, i.e., with a solution that combines machining and grinding, companies can adapt and create grinding programs for the machine.

The disadvantages of this approach are manifold:

  • Lack of flexibility: unlike CAM, this programming does not allow machine simulation and collision checks.
  • High cost: this type of programming requires the purchase of a grinding machine in addition to the machine tool, plus handling costs.
  • Risk of inaccuracy: Moving parts from the machine tool to the grinding machine amplifies the risk of inaccuracy.
  • Considerable programming time: programming machine tools and setting up grinding machines can be time-consuming for the teams in charge.

The range of CAD, CAM, ERP and PDM TopSolid solutions

CAD/CAM to optimize grinding on machine tools

Faced with these limitations, some manufacturers have developed combined machines which, thanks to CAD/CAM, allow:

  • First, machine a part by milling and turning.
  • Grind the same part in a second step.

The part does not need to be moved, as all handling is done on the same machine. This eliminates repositioning errors caused by moving the part from the machining center to the grinding machine and saves valuable handling time.

Point of attention: the need for a dedicated grinding CAD/CAM tool

For companies equipped with machines that combine machining and grinding, choosing the right CAD/CAM software is crucial. Only some CAD/CAM solutions contain dedicated grinding operations; some propose diverting machining operations into grinding operations. This is not a very relevant approach, as the method used to pilot a grinding wheel differs significantly from that used in milling or turning.

This type of solution offers no added value to the programmer, who is forced to manually adjust the ISO code to obtain the correct surface finish on the part. This is why companies are strongly advised to opt for a CAD/CAM tool that has specifically designed the grinding operation.

 

TopSolid’Cam: a software designed to optimize grinding on machine tools

TopSolid’Cam is a complete, high-performance CAD/CAM software package that supports and facilitates the design work of programmers thanks to:

  • Easy and complete solution integration.
  • Interoperability with all CAD software.
  • A self-managed working environment.
  • Production optimization thanks to a duplication process.
  • Different simulation levels.
  • Change management and tracking.
  • An answer to a wide range of milling and machining needs.

More specifically, TopSolid’Cam’s “grinding on machining center” functionality enables customers equipped with machine tools to combine machining and grinding to optimize the management of this operation. Indeed, the solution offers the possibility of programming the grinding process directly from the software, even before the part is mounted on the machine. Designed explicitly for on-machine grinding, this functionality adapts to the characteristics of each operation and facilitates the programmer’s work.

Would you like to learn more about TopSolid’s machining center grinding functionality? Ask our team for a demonstration.

Success Story: TopSolid by Rabumeca

Success Story: TopSolid by Rabumeca

Based in the Ain region of France, Rabumeca designs and manufactures welded assemblies in steel, stainless steel, and aluminum for various sectors. Founded in 1989, the company boasts many years of experience in its field, which earned it the “quality, cost, delivery” award from ArcelorMittal in 2013. Since 2020, Rabumeca has been integrating TopSolid’Design software into its design process—interview with Sébastien Bridet, Rabumeca’s Managing Director.

Experience, know-how, and commitment: the recipe for a successful company

Backed by over twenty years of experience, Rabumeca has gradually expanded into the food, pharmaceutical, steel, and environmental sectors. Today, it employs 20 people and expects sales of 2.7 million euros in 2021. At the heart of the company’s project is the determination to offer quality services within set deadlines and the desire to establish a relationship of trust with its customers and business partners.

Rabumeca’s deployment in various industrial sectors has enabled the company’s employees to develop a wide range of technical skills. Over the years, the company managed by Sébastien Bridet has also expanded its expertise through a policy of investment aimed at improving equipment reliability and performance. The collaboration with TOPSOLID came naturally.

Rabumeca and TOPSOLID: A Recent History

In need of new CAD software to boost productivity, Rabumeca launched a call for tenders in 2020. For the company, the choice of TOPSOLID was obvious: “We chose TopSolid because they were the only ones who understood us and listened to our needs. The people we spoke to were experts in their field, and they knew how to adapt their design software to our manufacturing process“, says Sébastien Bridet.

In application, employees use TopSolid’Design to launch manufacturing and design products for special machines. Nicolas Laibe, project manager at Rabumeca, describes the process in detail: “I use TopSolid’Design to retrieve 3D files from customers and provide the technical information required for the project. I use the sheet metal and tube recognition modules to obtain the documents required for manufacturing. In this way, the software enables him to construct “everything from laser flattening to bending sheets, assembly drawings for sub-assemblies, and assembly drawings with all the corresponding bills of materials.”

TopSolid’Design supports Rabumeca’s development.

Specialized CAD/CAM software, TopSolid’Design efficiently supports Rabumeca’s projects. An accurate productivity tool, the teams particularly appreciate its ease of use.

Support throughout the entire process

In TOPSOLID, Rabumeca found a pedagogical partner who was able to guide the company’s employees through the software: “We had a 6-day TopSolid’Design training course at TOPSOLID headquarters, and we had a specific training course on our premises, adapted to our needs“, explains Sébastien Bridget. In his opinion, the quality of the support staff made the difference: “We found people who were able to respond to our needs and questions daily and who were able to support us throughout the implementation of the software.

Ease of use

For project managers, TopSolid’Design represents an added value to design, mainly ease of use. Nicolas Laibe explains: “I find TopSolid’Design very easy to use; it helps us have the right documents. It’s logical and clear, with the right icons and functions. It’s very similar to what we use in the workshop.

Productivity gains

More generally, TopSolid’Design has given the company a real boost in productivity. With over a year’s hindsight, Rabumeca’s managing director comments: “TopSolid has enabled us to automate all the tasks we used to do manually. The working documents saved us enormous time when we launched our processes. According to him, the productivity gains achieved by the company thanks to the software are far from negligible: “We estimate that we have gained around 30% in productivity in the methods department“, he asserts.

The range of CAD, CAM, ERP and PDM TopSolid solutions

Development prospects are closely linked to TOPSOLID.

Rabumeca’s objective for the near future is to develop its functionalities to meet its customers’ needs even more effectively. Sébastien Bridget wishes to integrate TopSolid’s quotation module into his organization. By setting up facilitating systems, this module makes obtaining a result close to workshop reality possible via a 2D or 3D part drawing. Proud of their achievements, TOPSOLID will again be delighted to support them in this process!