When creating a new product, most forging manufacturers agree that solidifying a bulletproof design and choosing the right But did you know that choosing the right machining method for your material. But did you know that choosing the right machining method for your material can impact time to market, cost and overall product quality? Next, the forging supplier will share with you.
From initial customer involvement to first-hand parts, CNC casting steel parts are delivered in shorter lead times than molded parts. However, if the tool has already been manufactured and you are scheduling delivery of other parts, molded parts will be faster. To give you an idea of the tool creation schedule, the fastest, simplest tool made of rigid foam may take about 40 to 120 hours to create (from design to first pour). However, more complex tools will take at least 200 hours to produce, and should take even longer as the level of design complexity increases.
CNC Milling Casting Steel Parts
There are some differences to be noted in the finished parts produced by machining and molding. On the one hand, parts fresh from the machine have a smooth, uniform surface, as it is difficult to obtain detailed textures through machining. Machined parts also have a porous foam surface, so further sealing and painting may be required.
On the other hand, a molded part has a better finish because it comes off the tool with a smooth or textured skin that has been sealed. The coating can even be pre-applied in the mold. For post-processing, you simply wipe off the release agent and remove the parting line and you are ready to start using the product. If the durability and water resistance of the product is important to your application, casting may be the better choice.
As for tolerances, both types of processes have their advantages and limitations. Typically, higher tolerances can be achieved with machining compared to molding. However, with machining there will be more variability from part to part and from part to lot than with molding. When machining, it is common to set up a program on one machine and then delete it in order to use that machine for another project. When you need to load the program again, the location may not be exactly the same, resulting in slight problems with part consistency from batch to batch (although all within tolerance). The casting process causes minimal wear on the tool, so the molded parts are nearly identical from batch to batch.
Depending on the properties you are looking for, there are many different types of polyurethane foams: open and closed cell, density and strength, impact and thermal insulation, self-crusting, buoyancy, etc. Depending on the combination of parameters, certain processing methods may be more suitable than others. Usually, rigid foams can be processed by both machining and casting methods, as they are hard enough to withstand the cutting and grinding used in machining.
However, some flexible foams may be too soft to withstand machining, so for such materials, casting would be the only option. Flexible foam applications with simpler design specifications (e.g., bedding and packaging materials) can be machined.
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