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CNC development history and processing principles

CNC machine tools are also called Computerized Numerical Control (CNC for short). They are mechatronics products that use digital information to control machine tools. They record the relative position between the tool and the workpiece, the start and stop of the machine tool, the spindle speed change, the workpiece loosening and clamping, the tool selection, the start and stop of the cooling pump and other operations and sequence actions on the control medium with digital codes, and then send the digital information to the CNC device or computer, which will decode and calculate, issue instructions to control the machine tool servo system or other actuators, so that the machine tool can process the required workpiece.

‌1. The evolution of CNC technology: from mechanical gears to digital codes

The Beginning of Mechanical Control (late 19th century - 1940s)

The prototype of CNC technology can be traced back to the invention of mechanical automatic machine tools in the 19th century. In 1887, the cam-controlled lathe invented by American engineer Herman realized "programmed" processing for the first time by rotating cams to drive tool movement. Although this mechanical programming method is inefficient, it provides a key idea for subsequent CNC technology. During World War II, the surge in demand for military equipment accelerated the innovation of processing technology, but the processing capacity of traditional machine tools for complex parts had reached a bottleneck.

The electronic revolution (1950s-1970s)

After World War II, manufacturing industries mostly relied on manual operations. After workers understood the drawings, they manually operated machine tools to process parts. This way of producing products was costly, inefficient, and the quality was not guaranteed. In 1952, John Parsons' team at the Massachusetts Institute of Technology (MIT) developed the world's first CNC milling machine, which input instructions through punched paper tape, marking the official birth of CNC technology. The core breakthrough of this stage was "digital signals replacing mechanical transmission" - servo motors replaced gears and connecting rods, and code instructions replaced manual adjustments. In the 1960s, the popularity of integrated circuits reduced the size and cost of CNC systems. Japanese companies such as Fanuc launched commercial CNC equipment, and the automotive and aviation industries took the lead in introducing CNC production lines. 

Integration of computer technology (1980s-2000s)

With the maturity of microprocessor and graphical interface technology, CNC entered the PC control era. In 1982, Siemens of Germany launched the first microprocessor-based CNC system Sinumerik 800, whose programming efficiency was 100 times higher than that of paper tape. The integration of CAD (computer-aided design) and CAM (computer-aided manufacturing) software allows engineers to directly convert 3D models into machining codes, and the machining accuracy of complex surfaces reaches the micron level. During this period, equipment such as five-axis linkage machining centers came into being, promoting the rapid development of mold manufacturing and medical device industries.

Intelligence and networking (21st century to present)

The Internet of Things and artificial intelligence technologies have given CNC machine tools new vitality. Modern CNC systems use sensors to monitor parameters such as cutting force and temperature in real time, and use machine learning to optimize processing paths. For example, the iSMART Factory solution of Japan's Mazak Company achieves intelligent scheduling of hundreds of machine tools through cloud collaboration. In 2023, the global CNC machine tool market size has exceeded US$80 billion, and China has become the largest manufacturing country with a production share of 31%.

2. CNC machining principles: How code drives steel

The essence of CNC technology is to convert the physical machining process into a control closed loop of digital signals. Its operation logic can be divided into three stages:

Geometric Modeling and Programming

After building a 3D model using CAD software such as UG and SolidWorks, CAM software “deconstructs” the model: automatically calculating parameters such as tool path, feed rate, spindle speed, and generating G code (such as G01 X100 Y200 F500 for linear interpolation to coordinates (100,200) and feed rate 500mm/min). Modern software can even simulate the material removal process and predict machining errors.

Numerical control system analysis and implementation

The "brain" of CNC machine tools - the numerical control system (such as Fanuc 30i, Siemens 840D) converts G codes into electrical pulse signals. Taking a three-axis milling machine as an example, the servo motors of the X/Y/Z axes receive pulse commands and convert rotary motion into linear displacement through ball screws, with a positioning accuracy of up to ±0.002mm. The closed-loop control system uses a grating ruler to feedback position errors in real time, forming a dynamic correction mechanism.

Multi-physics collaborative control

During the machining process, the machine tool needs to coordinate multiple parameters synchronously: the spindle motor drives the tool to rotate at a high speed of 20,000 rpm, the cooling system sprays atomized cutting fluid to reduce the temperature, and the tool changing robot completes the tool change within 0.5 seconds. For example, when machining titanium alloy blades, the system needs to dynamically adjust the cutting depth according to the hardness of the material to avoid tool chipping.

‌3. The future of CNC technology: cross-dimensional breakthroughs and industrial transformation

Currently, CNC technology is facing three major trends:

‌Combined‌: Turning and milling machine tools can complete turning, milling, grinding and other processes on one device, reducing clamping time by 90%;

Additive-subtractive integration: Germany's DMG MORI's LASERTEC series machine tools combine 3D printing and CNC finishing to directly manufacture aerospace engine combustion chambers;

‌Digital Twin‌: By using a virtual machine tool to simulate the actual machining process, China's Shenyang Machine Tool's i5 system has increased debugging efficiency by 70%.

From the meshing of mechanical gears to the flow of digital signals, CNC technology has rewritten the underlying logic of the manufacturing industry in 70 years. It is not only an upgrade of machine tools, but also a leap in the ability of humans to transform abstract thinking into physical entities. In the new track of intelligent manufacturing, CNC technology will continue to break through the limits of materials, precision and efficiency, and write a new chapter for industrial civilization.

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Discussion on thin-walled parts processing technology in CNC parts processing

In the field of CNC parts processing, thin-walled parts processing technology is a key technology used to process parts that require lightweight structures and reduced weight. Thin-walled parts processing requires consideration of factors such as material selection, tool path planning, and processing parameters to ensure accuracy and stability during processing. The use of advanced CNC equipment and precision tools, combined with reasonable processing technology, can effectively improve the quality and efficiency of thin-walled parts processing.

CNC thin-wall parts processing technology and tooling design points

1. Core of tooling technology ‌1）Combined tooling design‌

Adopt modular combined structure (such as base, sleeve, stopper and fixing parts), reduce local stress concentration through multi-point uniform clamping, realize precise positioning of thin-walled shell parts, and reduce clamping deformation‌. The support ring and the annular shell can enhance the rigidity of the parts and avoid vibration deformation caused by cutting force during processing. ‌ 2）Flexible tooling application‌

Through electromechanical and hydraulic integration technology and multi-sensor control, the clamping force can be adjusted in real time to adapt to the dynamic rigidity changes of parts. For example, the aerospace field uses adjustable positioning clamping elements to meet the clamping needs of thin-walled parts of different sizes and specifications‌.

‌3）Auxiliary support technology‌

Add multi-point auxiliary support (such as hydraulic or mechanical ejector) to the weak rigidity area to improve the local rigidity of the processing part. For example, when the aerospace field uses honeycomb grid wall panels for processing, auxiliary support is used to reduce warping deformation.

4）‌Special mandrel and positioning structure‌

For thin-walled tube parts, use mandrel positioning with equal-height positioning blocks to avoid clamping force acting directly on thin-walled areas and reduce the risk of elliptical deformation‌

2. Processing technology optimization 1）‌Phase-based processing strategy‌

Use a progressive process of roughing → semi-finishing → finishing to gradually release the internal stress of the material. After roughing to remove the excess, semi-finishing is used to correct the deformation, and the final finishing is done to achieve the required accuracy‌.

2)‌Tool parameter and path optimization‌

Improve tool rigidity (such as increasing the cross-sectional area of ​​the tool holder) and optimize the tool angle to reduce radial cutting force; use small cutting depth and high speed cutting parameters to reduce thermal deformation‌. Use five-axis linkage milling or dynamic milling path for complex surfaces to avoid local deformation caused by repeated cutting of the same area by the tool‌.

3)‌Cooling and vibration control‌

Make full use of coolant to reduce cutting temperature, and combine dynamic cooling technology to control thermal deformation; reduce cutting force transmission and suppress vibration through high-speed cutting (above 15,000 RPM)‌.

3. Industry Application Cases 1)‌Aerospace field‌

Parts such as turbine blades and cabin panels are processed using five-axis milling combined with flexible tooling to achieve an accuracy of ±0.01 mm. The materials are mainly titanium alloy and Inconel 718‌.

2)‌Medical equipment‌

Orthopedic implants are precision turned and electropolished to a surface roughness of Ra 0.1 μm. The material used is stainless steel 316L or PEEK with good biocompatibility‌.

‌3)Automobile manufacturing‌

The gearbox housing is made of aluminum alloy 6061 high-speed milling, combined with heat treatment strengthening process, the accuracy is controlled within ±0.02 mm, and the lightweight goal is achieved at the same time‌.

4.Challenges and solutions for machining thin-walled parts

There are many challenges in machining thin-walled parts, such as vibration and deformation, which affect machining accuracy and surface quality. To solve these problems, a series of measures can be taken, such as optimizing tool selection and tool path design, reasonably controlling cutting parameters, reducing cutting speed and feed speed, etc. The machining quality of thin-walled parts can also be improved by pre-processing the workpiece before machining and heat treatment after machining.

Difficulty in clamping and deformation control 1)Thin-walled parts have poor rigidity, and traditional clamps can easily cause indentations or local deformation on the clamping surface (for example, the clamping deformation of aluminum alloy parts can reach 0.1 mm). 2)Special-purpose fixtures need to be frequently replaced for special-shaped parts, and the changeover takes more than 20 minutes, which is inefficient. 3)Dimensional deviations due to cutting forces, residual stresses and thermal deformation during machining (scrap rate can reach 30%). 4)Thin-walled parts are easily affected by cutting forces and vibrate and deform, and insufficient tool rigidity leads to poor surface roughness. 5)Cutting heat causes local expansion of the material, and insufficient cooling causes dimensional fluctuations.

‌Solution‌: 1)Use hydraulic combination vises or modular tooling to evenly distribute clamping force at multiple points, expand processing space and improve changeover efficiency. 2)Use mandrel positioning or slotted sleeve clamps to avoid radial clamping forces acting directly on thin-walled areas and reduce the risk of elliptical deformation. 3)Processing in stages (rough machining → semi-finishing → finishing), combined with aging treatment to release internal stress, control the deformation within 0.03 mm.Adopt vertical clamping axial compression instead of radial compression, and use micrometer to monitor deformation in real time. 4)Use a large cross-sectional toolholder and a positive-edge-angle turning tool to optimize chip removal direction and improve rigidity.Use small cutting depth (0.1-0.3 mm) + high speed (above 15,000 RPM) to reduce cutting force and thermal deformation. 5)Fully pour cutting fluid and use dynamic cooling technology to control the cutting temperature within 50℃ to reduce thermal deformation.

Development Trend and Prospect of Thin-wall Parts Processing With the continuous development of the manufacturing industry and the advancement of technology, thin-walled parts are increasingly used in aerospace, automotive, electronics and other fields. With the continuous innovation of CNC technology, materials science and other fields, thin-walled parts processing technology will be further improved, and processing accuracy and efficiency will be further improved, providing better support and guarantee for the development of various industries.

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The impact of 3D printing on social development

3D printing technology is a rapid manufacturing technology that can transform virtual objects into physical objects by stacking materials layer by layer based on digital models. With the continuous development and innovation of technology, the 3D printing industry has gradually emerged and demonstrated great potential in various fields.Since its birth in the 1980s, 3D printing technology has experienced a leapfrog development from a prototype manufacturing tool to an industrialized production method. According to the Wohlers Report 2023, the global 3D printing industry has exceeded US$20 billion, with an average annual growth rate of 17.5%. This technology breaks the physical limitations of traditional subtractive manufacturing by stacking materials layer by layer, and its "design is production" feature is reshaping the production organization model of human society.

1. The Reconstruction of Industrial Economy by 3D Printing Technology

‌1）Decentralization of production processes‌ Traditional manufacturing relies on centralized factories and complex supply chains, while 3D printing makes distributed manufacturing possible. For example, Siemens Energy deployed a mobile printing center at the Antarctic research station to manufacture repair parts on site, reducing equipment downtime by 80%. This "on-demand production, nearby delivery" model has reduced global logistics costs by about 12% (McKinsey, 2022).

2)Promoting innovative development of manufacturing industry

The product development cycle of traditional manufacturing is long, but 3D printing technology can achieve rapid customization and rapid prototyping, greatly shortening the product development cycle. Enterprises can quickly verify design solutions through 3D printing technology, reduce trial and error costs and time, and improve product competitiveness.Products that require multiple processes to produce in traditional manufacturing can be formed in one go with the application of 3D printing technology, reducing process and labor costs. At the same time, 3D printing technology can also achieve mass customization production, meet personalized needs, and improve production efficiency.

‌3）Liberalization breakthrough in product design‌ Additive manufacturing has gotten rid of mold restrictions, making complex structures (such as topologically optimized components) possible. Boeing integrated 20 components into a single component through 3D-printed fuel nozzles, reducing weight by 25%, increasing strength by 300%, and significantly improving aircraft engine performance.

3）Reshaping the resilience of supply chains

The COVID-19 pandemic exposed the fragility of the global supply chain, and 3D printing technology has alleviated this problem through localized production. In 2020, an Italian company used 3D printers to produce breathing valve accessories within 48 hours, breaking through the difficulties of traditional supply chain disruptions. This capability has reduced the company's inventory costs by 30%-50%, while shortening the launch cycle of new products by 60% (Deloitte, 2021).

4)additive manufacturing deconstructs traditional industries

3D printing technology breaks through the limitations of traditional processes such as mold forming and cutting by stacking materials layer by layer. This change enables the lightweight design of topologically optimized components in the aerospace field. For example, the C919 passenger aircraft of COMAC uses 3D printed titanium alloy door hinges, which reduces weight by 38% while improving fatigue resistance.

2.Disruptive innovation in the social and people's livelihood fields

1‌）Realization of precision medicine‌

3D printing technology has been successfully applied to orthopedic implants, crown customization and other fields. Invisible braces from Align Technology in the United States are directly printed through patient oral scan data, shortening the correction cycle by 40%. Bioprinting technology has made breakthroughs in the regeneration of skin, cartilage and other tissues. In 2023, Israeli scientists successfully printed a prototype of an artificial heart with a vascular network.

‌2）Promotion of inclusive medicine‌

Developing countries have used low-cost 3D printed prostheses (such as the open source prosthetic hands of the e-NABLE community) to reduce the cost of rehabilitation for disabled people from tens of thousands of dollars to less than $50, benefiting more than 100,000 patients worldwide.

3）Practical transformation of educational innovation

Primary and secondary schools use 3D printing laboratories to visualize STEM education (science, technology, engineering, and mathematics). For example, students can print molecular structure models to study chemical reactions, or make water conservancy engineering sand tables to simulate flood control designs. This "from virtual to physical" transformation increases the efficiency of understanding abstract concepts by 45% (UNESCO, 2022).

3.Deeper challenges caused by technology diffusion

1‌）Labor market polarization grows

The automated nature of 3D printing may lead to a reduction in traditional manufacturing jobs. 3D printing has reduced the demand for traditional jobs such as mold technicians by 40%, while the job gap for digital modelers has reached 1.2 million. The average cost of training for blue-collar workers in the manufacturing industry will rise to 82,000 yuan per person in 2024.The International Labor Organization (ILO) predicts that by 2030, about 5% of the world's manufacturing jobs will be replaced by 3D printing.

2)The ethical dilemma of bioprinting

Clinical trials of human cell-printed organs have sparked controversy over the "commercialization of life". In 2024, 23 countries around the world will legislate to restrict the types of human tissues that can be printed.

3D printing technology is evolving from a manufacturing tool to a catalyst for social change. It triggers not only innovation in production methods, but also a comprehensive reconstruction of the operating rules of human society.3D printing technology is not only a revolution in manufacturing tools, but also a profound change in human thinking and social operation logic. It has shown great potential in improving production efficiency, promoting social equity, and promoting sustainable development, but we must also be vigilant against the risk of technology getting out of control. Only through the coordinated evolution of technological innovation and institutional innovation can the social development vision of "technology for good" be realized.

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