CNC machining time explained

Unlocking efficiency: In-depth study of CNC machining time

In a world of precision manufacturing, time is not just money, but the heartbeat of efficiency, cost and ultimately successful project success. As a professional five-axis CNC machining manufacturer, Greatlight always knows this. Whether you are an engineer designing complex prototypes or a purchasing manager to source production parts, it is crucial to master the nuances of CNC machining time. This blog will dissect the need for machining time, the factors that affect it, and how advanced technologies like ours can optimize this critical metric.

What is the CNC processing time?

In short, CNC machining time refers to the total duration of the CNC machine tool that actively spends performing operations to convert raw material blocks (metals, plastics, etc.) into finished components based on CAD models. This is the sum of all cutting, drilling, milling, turning and other subtraction processes commanded by the Pre-Programmed Instructions (G-CODE). This does not include peripheral time such as settings, tool changes, artifact processing, or quality checks, although these settings can also result in overall project schedule and costs.

Key factors indicating processing time: complex interactions

Understanding processing time requires appreciating the complex interactions of many variables. Here is what significantly affects how long your parts take on the machine:

1. Partial geometry and complexity:

   • complex: Complex geometry with tight tolerances (<0.025mm), deep cavity, thin wall, undercut or complex surface profiles essentially require more operation, thinner tool paths, slower feed rates, and potentially multiple settings. A simple flat plate will be much faster than a complex turbine blade mold.
   • size: Larger parts naturally require the tool to travel longer distances and remove more materials, thereby increasing cycle time.
   • Tolerances and surface surfaces: Maintaining very tight tolerances or achieving ultrafine finishes (e.g., RA <0.4μm) requires slow finishes and potential multiple operations (rough, semi-fixed, finishing).

2. Material processability:

   • Hardness and toughness: Harder materials (e.g. hardened steel, content, titanium) require significantly slower cutting speeds and feeding speeds compared to softer materials (e.g. aluminum or brass). Harder materials also allow faster use of tools, sometimes requiring more careful parameter or other tool changes.
   • Thermal characteristics: Rapid heat (copper, aluminum) or materials that are prone to hardening or distortion (certain stainless steel, titanium alloys) often require adjustments to cut strategies to avoid damage, which affects speed.

3. Tool routing strategy and CAM programming:

   • Best tool path: The efficient CAM software generates tool paths to minimize air cutting (non-cut motion), safely remove material deletion rates during roughing, and use the best tool engagement angle. Optimized paths waste time.
   • Tool selection: Using the largest diameter tool may increase material removal (MRR) during roughing. High-performance tools (e.g., diamond coatings for carbon fibers, variable helixes for titanium) can cut faster and more aggressively. Advanced geometry and coatings reduce wear and provide longer cutting performance.
   • Processing operation: The sequence and type of operations (oriented, bagging, analysis, drilling, tapping, contour) adds layers to the time equation. Five-axis functions (Part 2) can be combined. High-speed machining (HSM) technology utilizes faster spindle speeds and feed speeds, which are shallower and sometimes reduce the entire cycle time.

4. Machine tool performance:

   • Spindle power and torque: Higher power allows heavier cutting and maintaining the speed of hard material without stagnation.
   • Fast travel rate: Faster machine movement between cutting positions minimizes non-production time.
   • Acceleration/deceleration: Higher dynamics ensure that the machine quickly reaches the target feed rate.
   • Five-axis function (critical to Greatlight): This is a game-changer. Simultaneous 5-axis machining allows the tool to be orientated by almost any angle, done in a single setting (eliminate fixtures and redefine time) with a single setting (eliminate fixtures and redefine time). It enables:

     • Accessibility: Machining complex features on multiple faces without repositioning the parts.
     • efficiency: By tilting the head/workpiece, use shorter and harder tools, allowing for higher speed/feeding.
     • merge: Combining multiple operations performed on a 3-axis machine into a continuous cycle.
     • Improved finish: Optimal tool orientation maintains ideal cutting conditions and surface contact.

5. Batch size:

   And each part Processing The time may be the same, with larger batches benefiting from amortization setup and programming time for multiple units, reducing the effective time for each part. For small batches or prototypes, setup and programming become a larger relative percentage of total project time.

How to estimate or calculate CNC machining time?

1. Cam simulation: The most accurate method. Modern Cam software simulates the entire machining process based on the CAD model, selected tools, tool paths and specific feed/speed parameters. It provides a detailed cycle time estimate considering all movements (cutting and fast movement).
2. Theoretical calculation (manual estimation):

   • Material Removal Rate (MRR): The core of time estimation. MRR (cube inches/min or CM³/min) depends on the feed rate (IPM or mm/min), cutting depth and cutting width. MRR = Feed Rate * Depth of Cut * Width of Cut
   • Cutting time for each operation: For milling pass: Time = (Length of Cut) / (Feed Rate). For drilling: Time = Hole Depth / (Feed Rate * (Peck Depth / Hole Depth)) (Considering the pecking cycle). Turn: Time = (Part Length + Approach) / Feed Rate Per pass/per diameter.
   • Sum operation: Summarize personal operation time, including allowance for rapid movement between positions. Based on machine data, estimate tool changes and real-world factors such as acceleration/deceleration.
   • Turning time: Sharp corners inherently require a slowing handle; high-end CAM software can accurately model this slowdown.

Great Advantage: Optimize time with five-axis expertise

At Greatlight, our core expertise Five-axis CNC machining It’s not just about dealing with complex geometry; it’s a basic strategy Reduce overall processing time At the same time, it enhances accuracy. Here is how we use it:

• Lower aggressive settings: Compared to multiple 3-axis operations, machined complex parts in one fixture can be cut and aligned for a large amount of time.
• Best tool performance: Continuous optimal tool orientation prevents tool deflection, enables the use of shorter tools, maintains the ideal chip load and allows for higher effective feed rates – accelerates cutting without sacrificing mass.
• No fine complexity: In general, complex designs can be processed more efficiently in a single 5-axis cycle than through a laboriously set 3-axis process. Complexity is processed by programming.
• Reduce manual completion: Directly from the machine, minimizing the time spent on secondary finishing can make transitions and better surface quality even more degraded.
• Advanced technology stack: We combine 5-axis machines with high-performance cutting tools, powerful CAM software optimized for multi-axis machining with complex collision avoidance and tool path smoothing, and material-specific expertise to safely push efficiency boundaries.

Practical Tips for Reducing CNC Processing Time (and Cost)

Your design choice is important even before the parts hit our machine. Consider these time-saving strategies:

1. Manufacturing Design (DFM): Simplify geometry where possible, avoid unnecessary deep pockets or thin walls, minimize tight corner radii of can be used, and specify tolerances only where critical. Work with your mechanic (we!) as early as possible.
2. Material selection: Choose the easiest material to meet functional requirements. If high strength/heat resistance is not critical, aluminum alloys (such as 6061-T6) are usually much faster than steel or titanium.
3. Optimize wall thickness and characteristics: Uniform wall thickness promotes consistent processing and avoids slow and delicate operation. Merge functions when feasible.
4. Take advantage of standard functions: Specify standard hole sizes and thread types where possible to avoid custom tools.
5. Benefits of utilizing five axes: When complexity is inherent, the design that takes full advantage of simultaneous use of 5-axis machining from the outset.

Conclusion: Time is the essence of precise manufacturing

CNC machining time is much more than a simple stopwatch reading. It is the product of exquisite dance between design, materials, tools, software and cutting-edge machinery. Understanding the factors in the game allows you to make informed decisions, optimize designs for efficiency, and have a more accurate grasp of project schedules and costs.

exist Greatwe transform this understanding into a tangible result. As an expert Five-axis CNC machiningWe leverage world-class equipment, advanced programming and deep technical expertise to minimize your machining time without compromising the accuracy and quality of your part requirements. We go beyond processing to provide seamless One-stop post-processing and completion service Provides truly finished components. Whether you are using common aluminum alloys or challenging aerospace materials, we can quickly customize and Quickly bring your design to life – all of which are the best prices.

Ready to experience the efficiency of expert five-axis CNC machining? Contact Greatlight today for a quote and see how we can simplify your precision metal parts production!

FAQ: CNC machining time explained

Q1: Why is CNC processing time so important?

Answer: Processing time is directly related to cost (machine hourly rate, labor, power consumption). Accurate estimates it are crucial to referencing, scheduling, and managing project budgets. This also affects the delivery time and delivery schedule. Optimization time reduces cost and speed time to market.

Q2: How fast is the five-axis CNC machining faster than the three-axis?

A: There is no percentage because it depends entirely on the complexity of the part. For simpler parts, there are some face functions, and the time difference can be small. For highly complex parts that require multiple settings and orientations on a 3-axis machine, five-axis machining can often reduce total machining time by eliminating settings, using faster strategies and enabling better tool access.

Question 3: Can you guarantee the estimated processing time?

A: Detailed cam simulations and historical data for well-known manufacturers are priced above design stability. In actual processing, small unforeseen complexity can lead to slight changes. Open communication about tolerances and geometry is the key to minimizing surprises.

Q4: Does using the fastest speed/feed always reduce processing time?

Answer: Not sure. Pushing speed and feeding are too aggressive to cause tool breakage, poor surface effect, inaccurate dimensions or excessive tool wear that requires frequent changes, which can be a waste of time. Optimal parameters balance with tool life, quality and machine stability.

Q5: How much will material selection affect processing time?

A: It has a huge impact. Hard, strong, sticky or abrasive materials (e.g., stainless steel 316L, Inconel 718, hardened tool steel) require slower cutting speeds, lower feed speeds and special tools, with significantly increased processing time compared to easily machining materials such as aluminum 6061 or brass. The thermal conductivity of the material will also affect the parameters.

Question 6: How does part size affect processing time?

A: Larger parts usually take more time because cutting tools need to travel larger distances and remove more materials. However, when equipped with large tools and high power spindles, Relative The time of each feature may be optimized. Setting and processing times usually also increase with part size.

Q7: Will surface finishing increase processing time?

Answer: Absolute. Achieve fine finishes (low RA values) requires additional slow speed, precise completion rates, and small steps. Mirror finishes or textures often involve specific tool paths or dedicated completions, adding a lot of time compared to simplicity "The original" surface. Let Greatlight effectively meet your completion needs.

Question 8: Can Greatlight Machines have faster parts than competitors that use only 3 axes?

A: Yes, usually used in moderate to highly complex parts, we Five-axis CNC machining Features provide obvious speed advantages. Compared to the traditional multi-step three-axis approach, using shorter/similar tools on optimization angles eliminates multiple settings and machining complex profiles in a single continuous operation greatly reduces the entire cycle time. This is the core of our value proposition on Greatlight.