What Is Machining? A Beginner’s Guide to Its Features and Benefits

What Is Machining ?

Machining is the process of shaping resin or metal with precision tools, removing material to create parts that meet design specifications with high accuracy.

Machining generally falls into two main categories:

Turning (Lathe Machining): In turning, the workpiece spins at high speed while a stationary cutting tool removes material. This method is ideal for creating round or cylindrical shapes.

Milling (Milling Machining): With milling, a rotating cutting tool is applied to a stationary workpiece to remove material. Milling is best suited for producing block-like or complex shapes.

Both processes involve two fundamental movements: cutting (the action of removing material) and feeding (the movement of the tool or workpiece to expose new surfaces for cutting). These movements are repeated to progressively shape the material.

Yumoto Electric is a company specializing in the machining of both resin and metal. We produce prototype development parts, jigs, and components for custom-ordered equipment. Feel free to contact us for any machining inquiries.

Features of Machining

A significant advantage of machining is its short lead time to production and high processing accuracy. While there are many ways to manufacture parts, such as 3D printing, injection molding, and casting, machining often provides superior precision.

If you have 3D-CAD data, machining can even begin on the same day you make the request. Plus, since it doesn't require pre-preparation like molds, it's highly adaptable, making it ideal for high-mix, low-volume production.

The cost of machining largely depends on the material's hardness, the part's shape, and the amount of material to be removed. Be aware that for very complex shapes, machining might be challenging or result in significantly higher costs.

Benefits of Machining

Machining offers several significant advantages:

High Processing Accuracy

This method allows for extremely precise machining, often achieving tolerances down to the order of 1/1000th of a millimeter. Beyond dimensional accuracy, the surface roughness can also be adjusted to suit your specific application. This high level of precision even makes it possible to produce parts for fit-checks with other components.

Wide Range of Compatible Materials

While machining difficulty can vary, a wide range of resins and metals can be precisely cut. Many materials are well-suited for machining, so you can almost always find one that meets your specific requirements.

Ideal for High-Mix, Low-Volume Production

Because machining doesn’t require costly upfront investments like molds, it’s ideal for small-batch production and prototyping. Here at Yumoto Electric, we can even handle orders for a single piece.

Disadvantages of Machining

While machining offers many benefits, it also has some limitations:

Limited by Tool Reach: Machining can only create shapes that the cutting tool can physically access. Any areas the tool cannot reach cannot be machined.

Potential for Material Waste: Raw materials are often cut to rough sizes before machining. However, material suppliers have standard thicknesses, and you often start with a piece larger than your final product. Since the cost of the raw material is based on its initial volume, a greater amount of waste material directly translates to higher material costs and more machining time.

Types of Machining

Machining is broadly divided into two types: milling and turning.

Milling

Milling is a machining method where a rotating cutting tool removes material from a stationary workpiece, typically using universal milling machines, NC milling machines, or machining centers.

Milling is ideal for creating flat surfaces, sides, steps, grooves, and holes, and uses tools such as face mills, end mills, and slotting cutters. It is typically applied to block-shaped workpieces.

Universal Milling Machine

This is a manually operated machine. The operator adjusts tool position, feed rate, speed, and depth of cut.

NC Milling Machine

This type of milling is computer-controlled using programs from 3D CAD/CAM software, allowing precise machining of complex shapes.

Machining Center

This is an NC-controlled, multi-axis machine capable of holding multiple tools. By combining linear and rotary movements, it can perform complex machining operations in a single setup.

Turning

Turning is a machining method where a fixed cutting tool removes material from a rotating workpiece, typically using universal lathes or NC lathes.

Universal Lathe

This is a manually operated machine, which allows for highly precise machining when handled by a skilled individual.

NC Lathe

This type of lathe machining is computer-controlled, with stepless speed changes, allowing the spindle's rotation speed to be specified by a program. NC lathes can perform various operations such as drilling, grooving, and thread cutting by adjusting the cutting tool and feed motion.

Important Considerations for Machining

When performing machining, several factors require careful attention to ensure optimal results and tool longevity.

Machining and Resistance

During machining, friction between the cutting tool and the workpiece generates resistance. The level of this resistance depends on the material, contact area, rotation speed, and the type of tool used, with the cutting area having the greatest impact. This resistance directly affects tool life, so it’s important to optimize machining conditions to maintain the right balance.

Machining and Speed

Meeting strict delivery times makes operational efficiency critical. In machining, increasing tool speed can improve productivity, but higher speeds also increase resistance between the tool and workpiece, potentially causing thermal deformation. Since the optimal speed depends on the material, tool, and machining operation, it’s important to adjust speeds carefully for both efficiency and precision.

Machining and Temperature

Friction between the tool and workpiece generates heat, which can affect accuracy and cause deformation. Faster speeds and larger cutting areas produce more heat, making temperature management essential. Cutting fluids are commonly used to reduce friction, remove heat, and clear chips, helping maintain precision and tool life.

Products Made by Machining

Yumoto Electric specializes in producing precision machined components and jigs by machining material from solid blocks. We excel at manufacturing small, precise parts, often smaller than the palm of your hand, and can handle items up to shoulder-width in size.

If you need quick turnaround time for product development, or manufacturing jigs for your production line, please feel free to send us your machining requests.

Step Up Your Project with Yumoto Electric

Yumoto Electric delivers high-quality components fast, worldwide. We provide precision machining for a wide range of metals and engineering plastics. We have experience with over 200 materials including metals such as aluminum alloys, stainless steel, molybdenum, and titanium, and engineering plastics including PEEK, PPS, MC Nylon, and POM.

If you’re unsure about material selection or machining methods, we offer complimentary consultations to help optimize your design and production. For any questions, please feel free to contact us.