What Are The Causes & Effects of Built-Up Edge (BUE) in CNC Machining

by Norm Grimberg | Aug 10, 2021 | CNC Machining

During the CNC machining process, there are chances of errors. They can come up in any shape. When the machinists are manufacturing high-precision parts, then there is no chance of any error developing. One such error is BUE (built-up edge).

BUE can lead to poor surface finish, increased tool wear, and decreased productivity, affecting the quality and efficiency of the manufacturing process. Understanding the causes and effects of BUE is crucial for CNC machining operators and manufacturers to develop effective strategies to mitigate the problem.

Therefore removing BUE is necessary from the machining process. In this article, we will explore the causes and effects of BUE in CNC machining, providing insights into how manufacturers can overcome this challenge to optimize their production processes.

What is BUE (built-up edge) in machining?

The accumulation of workpiece material on the tool’s rake face is known as a built-up edge (BUE). This material separates from the chip and welds under pressure.

Many different factors can cause it, and it can impact the outcome of a precision CNC project. Too much build-up on the chip’s edge can cause the tool to separate from the chip.

The workpiece materials are deposited at the cutting edge during the turning process, resulting in the formation of a build-up edge. As a result, the deposits alter the cutting edge’s geometry, reducing the cutting edge’s ability to make clean, sharp cuts.

Rapid turning essentially combines the properties of the cutting tool and the workpiece material.

As a result, CNC machine shops and their clients must be aware of the precautions that one should take to avoid this.

Importance of understanding the causes and effects of BUE

Understanding the causes and effects of built-up edge (BUE) is essential for improving the efficiency and quality of CNC machining operations. BUE occurs when a small amount of material adheres to the cutting tool and accumulates over time, leading to poor surface finish, increased tool wear, and decreased productivity.

Here are some reasons why it is crucial to understand the causes and effects of BUE:

Minimizing Tool Wear: By understanding the causes of BUE formation, operators and manufacturers can implement measures to reduce wear and tear on cutting tools. BUE can cause significant damage to cutting tools, leading to a shortened lifespan and increased costs. By minimizing BUE formation, the lifespan of cutting tools can be extended, reducing costs and improving overall efficiency.

Enhancing Surface Finish: BUE can cause uneven surface finish, decreasing product quality and performance. By understanding the effects of BUE, manufacturers can develop strategies to minimize its impact on surface finish. This, in turn, can improve product quality and increase customer satisfaction.

Improving Productivity: BUE can lead to a decrease in productivity due to the need for frequent tool changes and adjustments. By understanding the causes of BUE, operators can implement measures to minimize its formation, reducing the need for frequent tool changes and increasing productivity.

Increasing Profitability: By minimizing BUE formation and improving efficiency, manufacturers can reduce costs and increase profitability. This can be achieved by optimizing tool selection and implementing process control systems.

Understanding the causes and effects of built-up edge (BUE) is critical for improving the efficiency, quality, and profitability of CNC machining operations. Manufacturers can optimize their production processes by minimizing BUE formation, enhancing surface finish, increasing productivity, and reducing costs, improving overall competitiveness and success in the marketplace.

What causes the formation of BUE?

The geometry of the cutting tool gets altered as the material builds up. The rake angle gets included. This shift in geometry occurs regularly. As a result, the metal removal process loses dimensional control.
A work-hardened and abrasive material makes up a built-up edge. When pieces break free from the cutting tool, they stick to the workpiece and scratch the surface.
The higher the BUE, the rougher the surface will be.
The cut with a built-up edge is usually deeper than it would be with just the cutting instrument’s tip.
When a piece of the cutting tool breaks off, it can take some of the tools with it. As a result, tool wear is premature.
Reduce friction – If you want to use low cutting speeds, use the ideal cutting lubricant. The cutting fluid will carry away the heat generated during machining. When there is less heat, there is less build-up.

BUE effects on the cutting process

In short, too much build-up edge can lead to dimensional inaccuracies and even the complete scrapping of a part or component.

It also results in a poor surface finish, which can drive up the cost of any machining project. For a skilled machinist, a build-up edge is one of the easiest things to spot and manage.

Problems BUE creates for CNC machine shops:

Cutting tools have a short lifespan.
Lead times are longer.
Variations in component uniformity.
Surface finishes that are not up to par.
Reduced quality in part.

Ways to reduce BUE in CNC machining

1. Opt for free-cutting tools with sharp geometries and highly polished surfaces when choosing an instrument. Picking an ideal CNC tool with chip breaker geometry will aid in the division of chips, making it easier to remove them from the part and cutting surface.

2. Increase the cutting speeds, especially when using carbide inserts, because chips will have less time to adhere to the tool.

3. Be sure of your application strategy and running parameters. It is always a good idea to double-check your running parameters to ensure they are ideal for your turning application.

4. Cutting fluids can help reduce the amount of built-up edge. It accumulates on tooling components by reducing the amount of heat produced during machining.

5. Choose a coated insert because coatings get designed to prevent common machining issues. It gets engineered for a given set of part materials.

6. Select free-cutting tools with precise geometries and smooth surfaces that get meticulously maintained. Keep in mind that the geometry of the chip breaker may help to reduce chip adherence even more.

Looking for an experienced machinist who can overcome BUE in CNC machining? Contact Us! We can help.

How Does Machine Design Associated Help to Overcome Built-up Edge Problems?

We only use best practices to ensure that our work for our customers gets done in the most efficient, precise, and cost-effective way possible, with a strong focus on continuous improvement.

Here are the reasons to choose us for your BUE that are below:

Quality Standards

Our expectations for the quality and performance of our products are high. We are proud of our ability to design and manufacture products and services that consistently deliver exceptional results, and we stand behind them completely.

Expertise

Our worker’s abilities, talents, and expertise have earned us a reputation as technical experts in the industry. We invest in and continue to develop a highly-skilled workforce eager to share their knowledge with our clients.

Our Machinery

We have a variation of CNC machinery at MDA, including our CNC milling machine in Canada, among other things. Our experts keep up with the latest advancements in CNC machinery, so our equipment, such as our CNC milling machine in Canada and throughout North America, is always top-of-the-line and serviced to ensure it is running at its peak.

Selection of Cutting Tools

MDA’s machine design team selects cutting tools based on their geometry, material, and coating. Cutting tool geometry plays a crucial role in preventing BUE. By selecting the proper geometry and rake angle, the cutting tool can reduce the tendency of the material to adhere to its surface, thereby reducing the formation of BUE.

Benefits Of Precision CNC Machining To Custom Parts For Low – Mid Volume Production

by Norm Grimberg | Jul 14, 2021 | CNC Machining, Custom Machined Parts

Every machinist knows about precision machining or has used it to manufacture ideal machined parts. Precision machining has changed the way industries are working, and it is the right choice for high-volume requirements.

Precision machining helps the machine shops to stay competitive in the market despite the high demand from the customer. If your machine shop is yet to include precision CNC machining in the manufacturing process, then you are missing out a lot.

Our experts at MDA will share the benefits of using precision CNC machining that will help to manufacture your next machined part.

Why is precision machining necessary?

Precision CNC machining is a process where large pieces of materials or parts are shaped into precise forms to meet the specific demands of various industries. Precision CNC machining is finding more relevance in business. In aerospace, it manufactures landing gear parts, manifolds, etc. The medical industry manufactures implants, orthotic devices and other precision instruments via precision machining. So, if a product contains equipment, then it requires precision CNC machining. Here are some reasons why precision machining is necessary:

It improves smooth functionality and operation.
Accurate measurement of precise parts.
Precision machining provides durability.
Conforming to industry standards.

Benefits of precision CNC machining

#1. Fast production of materials and parts

Precision machining is fast and one of the best manufacturing methods available right now. It reduces the manual work by relying on specialized software to create the custom part you need.

It is better than the conventional CNC machining method, which takes around weeks or months to finalize a custom part. In precision machining, you can manufacture a part in days. See the difference? It saves you time, in the long run, helping you to meet the deadlines. Our experts follow the precision machining techniques reducing the human intervention making the parts consistent for low – mid-volume production.

#2. It is cost effective

Fast production of the machined parts leads to a reduction in overall costs. That’s not all. Precision CNC machining helps to reduce the price you need for raw materials and supply chain management. The machine shops now can produce the machined parts in saving on costs and other factors like:

Reduction in labour
Increased manufacturing
Meeting with the delivery rates

Investing in precision machining allows for maximizing the company’s business. When you choose us for the precision CNC machining needs, you will save a lot on your manufacturing costs.

#3. Precision machining is ideal for prototyping

Prototyping is crucial in the manufacturing process. Prototyping allows the machine shop owners to overcome the mistakes in the long run. Precision CNC machining offers rapid prototyping capabilities and helps businesses to tap the smaller markets. The precision CNC machining allows the prototypes to have more functional parts rather than design prototypes.

| Also Read: Why Precision Machining Is The Right Choice For High-Volume Requirements

#4. Compatible with a wide range of materials

Different materials present challenges for manufacturers during the machining process. We all know that to manufacture machined parts for various industries, machine shop owners need to use a range of materials, from titanium to steel to aluminum or copper.

Precision CNC machining is compatible with a lot of materials. There would be no need for the machinist to choose a different manufacturing process as precision machining can do it all. At MDA, our professional experts keep this in mind and manufacture the machined parts in the specific material selected by the client.

#5. Maximizes efficiency

Precision machining is helpful for fast production, as mentioned in point 1. It also allows the machine shop owners to scale up the production needs. The reason is precision machining can create thousands of precision machined parts in no time. Professional machine shop owners can use the manual workforce in other tasks which require more human touch as customer service or post-production.

#6. Safer production

Because the industry is transitioning from manual to automated technology machinery, making it difficult for humans to participate in the manufacturing process. Even though the workforce on the shop floor gets reduced, CNC machine shops will still require skilled employees to be present at the time of production and provide the correct inputs to the machines.

It benefits a business because it reduces the amount of machinery that needs to be maintained and the number of labourers required to run operations. The overall cost of manufacturing a unit will be lower, and profit margins will increase.

Why choose MDA for precision CNC machining?

We are a leading precision company located in Canada. Using advanced manufacturing equipment, our expert engineers and technicians assist businesses in producing high-quality and precise parts. Our production facilities are ISO 9001:2015 certified for quality, and we have a team of quality control experts on staff.

Contact our professionals to get a quote for precision CNC machining parts.

Why Precision Machining Is The Right Choice For High-Volume Requirements

by admin | May 20, 2021 | CNC Machine Shop, CNC Machining, Machine Shop

Precision machining is a growing trend among machine shops and experienced machinists, and it’s not a lost manufacturing process. We know the importance of precision machining in manufacturing precision parts; components of many tools and applications in various industries.

Precision machining has overcome the traditional methods and is estimated to surpass $94.42 billion by approx 2026. Every industry relies on machined parts using precision machining to:

● Create custom machined parts from raw materials
● Helps to fabricate metals into individual components
● Machine cast parts straight from the mould

But what is the reason precision machining is so effective? How does it help you to make better-machined parts?

This article helps to identify how precision machining is better for creating the products, and how your company can use it for high volume requirements.

Let’s Begin With The Benefits Of Precision Machining:

#1. Fast turnaround time

The turnaround time gets reduced during precision machining because of the use of advanced software capabilities. Now, it’s easier for the machinists to go from a design to the finished product in an easy way.

Using a precision manufacturing process reduces the manual work. It helps to reduce the design time, which use to take months now can be completed within weeks.

Our experts understand our clients and works towards their specifications. Our team offers turnaround services and delivers quality machined parts according to the client’s deadline. That is why our service adds value to our clients in various industries.

We produce accurately machined parts with high tolerances by leveraging precision machining that helps us to perform repetitive tasks. We ensure that our components remain consistent even during the larger runs.

Another advantage of precision machining is that it requires little or no supervision and works non-stop with the same accuracy in replicating the same machined part.

#2. Ideal for prototype designs

The prototype design is necessary before finalizing the manufacturing of the machined parts. Prototypes are designed with the product specifications.

Our team provides prototype machining services for smaller and independent manufacturers where the companies are developing new products. Our experts believe in high-quality parts, made right the first time. We deliver prototypes that match the design intent.

No company wants to take the risk when they are producing a high volume of machined parts. Therefore prototype design testing is an ideal thing to do.

At Machining Design Association, we produce parts with our subtractive manufacturing process. With us providing parts from prototype to high production it becomes a seamless transition. We make manufacturing simplified with cost-effective options aligned to the customer’s needs.

#3. Less labor and it lowers costs

Since precision machining provides a fast turnaround time and most of the work is done by the CNC machine, there is less need for manual work. It improves the reliability that is crucial in the manufacturing process.

It’s common sense that there would be less chance of human error during the process when there is less human input in the process. But you cannot neglect the human presence during the precision machining process. The machine shops require skilled employees during high volume production.

It helps the company to reduce the number of laborers that are necessary to work on the machinery. It reduces the overall cost of the parts that is manufactured.

Most industries require tight tolerances for their precision machined parts, and it is a costly manufacturing process depending on the machines used. With the implementation of precision machining, manufacturing machined parts with high tolerances has become affordable.

#4. Precision machining can handle most complex projects

Precision machining takes care of complex projects that are of high volume. Most of our clients know that at MDA, we work on complex projects that allow our clients to have access to
Low-cost production.

Precision machining helps to deliver 3-D dimensional shapes that are complex and not possible with traditional machining methods. Plus the precision machining has the repeatability capability allowing companies to produce the material with no defects and variation. These companies include medical industries, aerospace industries and oil and gas industries.

Reasons highlighting the importance of precision machining in the machine shops

● Ideal for qualitative and quantitative production: This is possible with the help of precision machining. The machine shop’s machinists can produce components in high volume while maintaining the quality.

● Helps to stay ahead of the competition: There is competition across all areas in machining. A machine shop must do everything possible to differentiate oneself from their competition. Making sure that the latest equipment is used, the most up to date software and having qualified personal. Not all machine shops are the same.

Summing It Up

Precision machining is a very important aspect in any machine shop. In providing quality parts at very competitive prices; our customers, have a competitive advantage. Knowing that parts will arrive on-time and without defect, assures that their end user will be happy. It takes so many parts to keep the gears turning. If one part is defective or not available, the wheel will stop turning. Machining Design will partner with you to assure that the precision machine parts that you order will be to your satisfaction. You can contact us at MDA.

Why CNC Machining Will Transform the Medical Industry’s Future

by admin | Apr 30, 2021 | CNC Machining, Medical Industry

CNC machining as an industry will grow rapidly in future. The growth of CNC machining is fueled by various industries like construction, automotive, aerospace and medical. And the demand for CNC parts is increasing day by day.

One such industry is the medical industry with the demand for increasing medical components, efficient production is necessary for the medical sector.

The precise components are necessary for the medical industry, without the proper innovation and progress of medical CNC machining, we would not have the necessary medical devices. And during this pandemic, the need for medical equipment is important more than ever.

The medical machined parts require precision and cleanliness that can be achieved by CNC machining.

We at MDA know the unprecedented situation and work while closely monitoring the situation, manufacturing quality machined parts to keep up with the demand.

“When it comes to machining, the medical industry requires the combination of precision and consistency that is suited for multi-axis CNC machining.”

CNC machining role in manufacturing next-gen medical components

Medical machined parts are used directly for patient treatment. And these are critical in the medical industry.

It combines surgical tools, devices, sensors, and implants that need to be constructed with proper care and precision. The medical industry uses tools that don’t have direct contact with the patients.

The MRI system is one such tool. It requires complex pieces of equipment. It comprises hundreds of individual parts and many of these parts are fabricated with CNC machines.

Some of the other medical parts include are:

Part	Application
Rotor	Blood Gas Analyzer
Stator	Blood Gas Analyzer
Alignment screw	CT Scanner
Gear plate	Laser Eye Keratome
Barrier	CT Scanner
Micro-tip	Instrument Cap
Impeller	Fluid Flow

MDA manufacturers are efficient to produce medical parts without the need to incur costs associated with medical-related certifications and clean rooms.

The CNC machining process allows us to reduce the manufacturing costs for the medical machined parts. Healthcare professionals still rely on MRIs, and medical equipment, therefore demanding the highest quality in all the components.

| Also Read: How CNC Machined Parts Can Be Used In The Medical Industry

How CNC machining will disrupt the future of the medical industry?

CNC machining is nothing new and is apt for the medical industry because it requires equipment to be precise. Here are some more reasons why CNC machining is ideal for the medical industry:

CNC machining can work with many materials
Offer more axes for cost-savings
Complex designs can be manufactured on a large scale

MDA experts use different tools to manufacture complex shapes with tight tolerances. It is possible with the ability of the equipment and material to rotate on various axes. CNC processes work with several materials like steel that are suited for medical applications.

CNC machining has enabled several medical innovations to take shape. These innovations rely on precision parts getting manufactured to exact specifications and tolerances to work as required in the medical industry.

Benefits of CNC machining in the medical industry

The health and well-being of patients rely on the components and equipment used in the medical industry. CNC machining proved to be efficient in the medical field, therefore it is not a surprise why they are considered as standard. Here are the benefits:

#1. CNC machining is ideal for custom medical part requirements

CNC machines are programmed to manufacture exactly what’s required to match the needs of the medical industry. Plus the CNC machine also requires an experienced machinist to operate on it.

We are perfectly aware that healthcare has different requirements for different equipment and CNC machining services by our experts create devices for different needs. We are capable of producing the parts quickly even during this pandemic situation. Our sophisticated programming method allows us to execute complicated designs.

#2. Useful for manufacturing medical implants

CNC machining provides great certainty to deliver the final result. Implants and surgical equipment that aren’t manufactured according to the right standard can have consequences. Therefore, implants need to be manufactured under special guidance and with the right machining process i.e. CNC machining.

CNC wire EDM manufacturing helps to deliver finished medical equipment. It provides inch-perfect accuracy that is necessary for medical parts.

#3. Broader material suitability

In the medical industry, equipment is exposed to harsh conditions that include chemicals and high temperatures. Therefore, the medical equipment needs to be manufactured with special materials. Almost every CNC machine is capable of working with rigid materials for surgical equipment. It includes stainless steel, titanium, aluminum and plastics.

#4. Maximum production capacity

CNC machining operations efficiently produce medical components in both small and large quantities. It is a great advantage when manufacturing custom parts which is the case of specialized medical appliances, surgical products and prosthetics.

Choose the right CNC machine shop for medical parts

Crafting parts to the level of precision necessary for medical equipment needs a machine shop that is equipped with state-of-the-art technology and committed enough to provide high-quality products.

From its use in implants and replacement parts to medical devices and laboratory equipment. Plus the machine shop workflow must include using CAD data and customer drawings to build parts exactly to the specifications.

MDA is an ISO:9001:2015 certified company dedicated to providing high-quality CNC medical machined and custom parts according to customer specifications. We utilize only the best practices to ensure the work we do for our customers is done most efficiently. Call us on tel:18884404435 or mail machiningdesign@mdaltd.ca.

A Quick Guide To Understanding 5-Axis CNC Machining

by admin | Nov 30, 2020 | 5-Axis CNC Machining, CNC Machining

Ages ago, hammer and chisel were the perfect tools for creating different objects. Centuries later, handheld machines were invented, which made machining easier. But that was too time consuming and needed excessive manual labour. But don’t worry, you have our 5-axis CNC machining guide to help you understand.

Soon, computerized technology infused with machining to offer advanced computer numerical control machines (CNC machines). A program would control the tools’ movements on the blocks. It took care of the rotation of the cutter as well as the turning of the block of material.

Initially, they had just one or two axes moving along the X and Y-axis. But soon, 3-Axis CNC machines came forward that allowed the cutter to move even longitudinally along the Z-axis. And as technology advanced, machines came with five axes to cover all the five sides of a product for building all types of parts, be it simple or complex, without any additional setup.

Understanding 5-Axis CNC Machining

In the simplest terms, 5-Axis CNC machining means using machines controlled by computer numerical programs to build machined parts. These machines have cutting tools closer to the surface of the block that needs to be machined and move along five axes. In addition to the manipulation along three regular axes, five-axis machining chooses from the three rotational axes and offers a more robust mechanism for crafting specific angles and complex parts. The intricacy and precision obtained with 5-axis machining are unmatched, which makes it great for industries requiring to build complex machine parts.

Advantages Of 5-Axis CNC Machining

Most CNC machine shops now have 5-Axis CNC machines to deliver error-free products at a quicker pace. Installing these machines may be expensive, but the endless benefits they offer compel people to utilize them for producing new CNC machined parts. Here are some of the advantages of using 5-Axis CNC machining over the earlier way of machining.

Unmatched Accuracy & Precision For All Parts

One of the most significant advantages of five-axis CNC machining is the precision it can offer for all types of parts. Whether it is a complicated part, tilted surface, or a specific angle, machinists vow on 5-axis CNC machine type to get the precision and accuracy they desire. It reduces the chances of error and offers higher quality workpieces with precision accuracies.

Easier Machining Of Complex Shapes

Even the most experienced machinists cannot cut intricate shapes with just three axes of the earlier machines. To get undercutting or to reach specific angles of a workpiece, one needed additional setups or complete casting earlier. With the five axes machining in the 5-Axis machines, it becomes easier to reach any specific angle, machine arcs, and cut complicated shapes with ease.

Minimized Need For Setup Change

Several machine parts are impossible to cut with just three axes movement. They require additional setup. A 5-Axis CNC machine already has the five axes that are necessary to cut all five sides of the material to create the piece without the need to change the setup. It even helps in reducing the errors otherwise caused due to working on multiple arrangements.

Increased Life Of Tool

The length of the cutting tool is shorter in 5-axis machining as the machine head can be much closer to the cutter’s surface. With higher proximity, the speed issue gets resolved, and one can achieve more cutting speed. This process also minimizes the vibrations and helps the tool last much longer without breaking. It even controls the chip load, which leads to fewer collisions.

Decreased Collisions

Another advantage of a 5-Axis CNC machine is that it decreases the chances of collisions. With this CNC machine, one can easily tilt the cutting tool to reach specific angles. This tilting mechanism prevents any risk of collision between the surface and the cutting tool.

Reduced Lead Time

Efficiency is the reason why most people prefer 5-Axis CNC machining now. It lowers the overall lead time due to many reasons. One does not need to change the setup repeatedly. There are minimum manual changes and very few fixtures. With a single push setup or a Done-In-One setup, this reduces the overall time in finishing.

| Also Read: 5 Best Benefits Of Using 5-axis CNC Machining

When To Use Of 5-Axis CNC Machining

CNC machining is used to cut different machined products used across various industry verticals like military, aerospace, electronics, construction, transportation, and many more. But with 3-Axis CNC machining already assisting in making many parts, why and when should one use 5-Axis machines for machining. Let’s find out.

To Machine Complicated 3D Shapes

Machining complex 3D shapes aren’t easy. One needed separated casting to machine such parts. And such casting might take months to finalize. But with the CNC machining tool, one can efficiently build these parts in a short time. The movement of the machine along the five axes allows precision on all sides without additional fixtures. No matter how complex the part, CNC machining can perfect it quickly.

To Machine Tilted Surfaces

CNC machining is perfect for machining parts that have tilted surfaces. With a movement along the five axes, 5-axis CNC machining allows drilling of surfaces with impossible geometry. The axes can reach the irregular surfaces that are tilted to offer perfection on the surface. Tapping, boring, milling, reaming, drilling, and other operations of machining on titled surfaces is much more convenient with a machine with five axes.

To Machine All Sides With Specific Angles

Industries like automotive, aerospace, medical, etc., have many parts with unusual shapes that need a specialized casting to get specific angles. Reaching the complex surfaces having distinct angles is impossible with a 3-axis CNC machining. A five-axis CNC machining tool can access all five faces of the part to machine any specific angle of the machined part.

To Machine Flexible Outputs Quickly

When it comes to machining the different types of outputs, five-axis CNC machining offers the flexibility of diverse engineering solutions without consuming much time. While most of the manufacturers show interest in low volume machining of repeated pieces, manufacturers with five-axis machining can take up high volume orders and even change the fast changes in the products. One can reprogram the machine to create a different product within a few hours.

Need And Experienced Company Providing 5-Axis CNC Machining Services? Contact Us We Can Help!

Choosing The Right 5-Axis CNC Machining Company

CNC machining can help all industries like aerospace, defence, marine, medical, etc., find high-quality products in no time. It can also reduce the overall cost of getting these products.

Now that you know the benefits of 5-Axis CNC machining and in what type of machining this technology should be used, the only thing that remains is a company that offers these services. You can look for a one-stop-shop for your machining needs, and MDA is one of the leading players you can get in touch with us. The CNC programmers working at MDA have years of experience and hands-on knowledge of the technology to offer quality 5-Axis CNC machining services.

The company is known for its accuracy and precision in delivering products using this latest technology. No matter what industry, the company can machine parts with any specific angle and complexity. Moreover, it can also offer custom finishes to the machined parts.