Tag: <span>FABRICATION AND MACHINING</span>

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The process of cutting and then bending steel into a product that is usable and functional is called stainless fabrication. The procedure of strengthening and hardening steel is costly when considered next to other metals. But the metal is very malleable. It can be readily:

1. Bent
2. Spun
3. Folded
4. Welded
5. Machined
6. Deep drawn

Welding Vs. Stainless-Steel Fabrication

The technique is often confused with welding, but the two are very different. While fabrication is the creation of a product from raw material, welding is a process done on the completed item. At times, the steel fabrication process incorporates welding. The welding method is generally applied in fabrication when a product needs to look aesthetically pleasing while being efficient. A simple example of welding is the joining of two fabricated stainless-steel items through heat and pressure.

Two Stainless Steel Fabricating Processes

1. Work Hardening:

The method is utilised to strengthen steel by deforming it. The slower the speed of forming, the higher the deformation and strength. For this reason, some forming techniques are deliberately slowed down to improve their hardening capability.

Generally, for most stainless-steel alloys, the speed of hardening is rapid but the exact rate is specific to each grade. Fabrication techniques mostly use the austenitic variety of steel as it has a faster hardening rate when compared to carbon steel family.

The type of steel grade employed is dependent upon kind of hardening treatment being appropriated. The prerequisite for cold working is austenitic steel. When thermal treatment is the need of the hour, then steel grades from the martensitic family are put to work.

Benefits of work hardening rate

• A project that needs corrosion resistance and extreme strength can leverage stainless steel because of its hardening rate. A few places that Stainless-Steel is used due to its work hardening property is in machine components, hospital equipment such as cryogenic machines and nuts and bolts.

The martensitic family has shown special defence against corrosion as compared to other SS groups. It is why people prefer the alloy for the production of:

1. Tools
2. Cutlery
3. Bearings
4. Valve Parts

• Another advantage that works hardening accrues to stainless steel is magnetism. SS itself has a very slight magnetic quality, but those alloys which are known for speedier hardening tend to show more magnetism.

2. Welding Stainless Steel

One more technique in the steel works of stainless steel is welding. Usually, stainless steel alloys are easy to weld, but the grades define the efficiency of it.

• Austenitic Family:

This group is straightforward to weld barring the free-machining grade. Austenitic steel is also vulnerable to sensitization and inter-granular corrosion when utilised for thicker items.

• Martensitic Family:

Though the grade is known to crack during welding, the issue can be solved by simply pre and post-heating the metal. Another method to prevent fractures is to employ additional filler rods of austenitic.

• Ferritic Family:

In comparison, it is the least suitable group for welding. There are a few grades like 409 that can still be employed in specific projects. To solve problems like high grain growth, sensitization and low ductility, the family can be post-heated or austenitic fillers utilised.

• Duplex Family:

Known for its low thermal expansion, the group is perfect for welding. There are some grades, e.g., 2205, that show better resistance to corrosion, strength and ductility due to greater nickel content.

5 Rewards of Using Stainless-Steel Products

Ask any stainless-steel railing supplier, and they will say that like every other metal SS also has some cons. The initial investment is high, superb quality equipment is needed to handle it, and welding can be hard. Even still, it is the most preferred metal for fabrications because of the advantages overshadow the demerits by far.

1. The most apparent benefit of working with stainless steel is the ease of fabrication. As long as the latest equipment and machinery is used, everything from cutting to welding can be done on stainless steel. The issues occur when outdated paraphernalia is employed.
2. With the awareness of the environment and the products we appropriate affecting the planet, the need of the hour is to have sustainable practices. The second pro of SS is that it is entirely recyclable and therefore doesn’t adversely affect the community. Did you know that more than half of stainless steel is made by melting previously used metal and scraps?
3. Corrosion can significantly impact the long-term value of any metal. Because of steel has chromium in it, the metal is resistant to corrosion which makes it a valuable investment. Moreover, different SS alloys have different corrosion strengths. A lower grade metal is apt for a wet element. A project that uses acids or alkaline solutions would better benefit for higher grade alloys.
4. Besides being protected against corrosion, stainless steel is also heat and fire resilient. Alloys of the metal that have higher amounts of chromium and nickel in them can be used for water heaters, boilers and valves in any extreme temperature machines.
5. Yes, the starting phase of working with stainless steel necessitates a high financial input but its long-term returns offset the cost. It is virtually a maintenance -free metal which translates to better savings. Furthermore, it fabricates the most exceptional products.

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Source by Uma Nathan

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What is a hot wire cnc foam cutter used for?

Hot wire foam cutters will cut different types of foam, from insulation to fabrication, from logos, surfboards and signs to crown moldings and concrete molds

Hot wire foam cutters are designed to cut different types of foam

1. EPS – expanded polystyrene

2. XPS – extruded polystyrene

3. EPP – expanded polypropylene

Not to be used for cutting polyurethane – will result in toxic fumes

What are the main components that a foam cutter is made of?

1. The software is divided into two sections – design software to design the shapes to be cut, and the cutting software that controls the machine

2. The hot wire tensioning mechanism

3. Effective cutting sizes for the horizontal, vertical and the wire length

4. Number of axis – a 4 axis machine will be able to cut tapered shapes (like a cone or a jet wing)

Here are some features to look for in a hot wire foam cutting machine:

For production of crown molding:

1. Multiple wires – from 3 to 8 wires will increase the cutting capacity from 2 to 7 times

2. 8 foot effective wire length – don’t settle for a 4′ machine

3. If primary use of the machine is to cut logos and signs – a smaller machine will do the job

4. Cutting speed – mostly material dependent – as a rule of thumb: the higher the foam density – the slower the cutting speed

Hot Wire CNC Foam Cutter prices:

CNC foam cutters will range from $1500 to $50,000. The price is a factor of the machine size, the number of wires, the way the wires are kept under tension.

Other foam cutting machines:

Another way to cut foam is with a CNC router – this is mainly for machining the foam and not for cutting.

CNC routers for foam are mostly used for 3D shapes seen in Las Vegas, theme parts and even signs

Foam coating: EPS and XPS will melt if painted with oil-based paint. Painting is composed of two steps:

1. Preparing the foam for coating – a primer should be used to prevent the coating material to penetrate the EPS beads

2. Coating – Coating is usually Epoxy (usually brushed) or Polyurethane (brushed or sprayed)

Once the foam is coated – it can be painted with any type of paint.

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Source by Sigal Barnea

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In the industrial mechanical business industry, Computer Numerical Control (CNC) milling machines are widely used to fabricate components from different materials, which have succeeded the traditional milling methods; and these machines would be able to get things done effectively with the assistance of human operators.

Hence, here are a few important things that an operator should know before operating such CNC machining center:

1. You must be proficient in G programming language (also known as G-code) – Most CNC milling machines are controlled by integrated control software, which single movement of the cutting tool is derived from G-codes. Therefore, as an operator, you need to familiar with Computer-aided manufacturing (CAM) software as it is a compulsory skill needed to perform high precision machining operations. Since it is getting easier to use CAM software as it has several features that requires less programming, most companies offer training for their employees – particularly for those who are just getting started as a CNC machine operator.

2. Preparing and handling the cutting tools – As a CNC machining center operator, you will have a routine of operating CNC milling machine including start-up and shutdown operations. For instance, you need to make sure that the cutting tools are properly placed before the milling operation starts. In addition, you need to load raw materials into the work cube and make appropriate adjustments to machine. Besides that, you need to monitor the performance of the machining center to ensure that the components are produced precisely. If the components are not manufactured within the precision range, you need to check the conditions of the cutting tools before sending them for maintenance.

3. Troubleshoot and rectify minor errors – Being a CNC milling machine operator, you are expected to perform basic maintenance tasks including replacing necessary tools including drills, tapers, knobs and etc. If you have come across any major problems which affect your workload, you need to seek assistance from set-up machinists and supervisor to resolve such problems immediately.

4. Take note of the preventive measures – Be sure to understand the preventive measures of your working environment before you start performing any CNC milling operations. The most important thing that most operators would concern is to stop the machine immediately when things fall out of place. Thus, most CNC milling machines has a true interrupt program button that stops cutting and retracts the tool.

5. Must have knowledge of using the precision inspection equipments – You need to ensure that the components need to be produced within the precision range. Therefore, you need to make use of precision inspection equipments such as calipers, micrometers and optical comparators; to track the performance of the CNC milling machine so as to confirm that the component fabrication process are effectively done.

By knowing the important things mentioned above, hope that you are capable to handle CNC milling machines productively.

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Source by Jimmy Dales

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Do you know what actually CNC machining is all about? CNC, an acronym for Computer Numerical Control is a process used especially in the manufacturing industries that involves the computer use for handling machine tools. CNC machining is the practice of milling and spinning of ferrous and non-ferrous metals. There are online machining services for brass, iron, copper, plastic, steel, aluminum or other metal. Fine metals including silver, gold and platinum are also handled by the service providers. They have an in-depth precision of sheet metal.

Today, CNC turning machines are the most efficient tools available for manufacturing industries using which manufacturers can expand their business. Using this technology in manufacturing can give lots of advantages.

Keep ahead of the competition- In the everyday competitive market, manufacturing business is quite challenging for both a new and old one. CNC machining is commonly popular as computer controlled, since they’re extremely expert at producing than outdated common systems. If you have a manufacturing business and looking for large agreements or contracts with other organizations, remember you have the innovative technology to fulfill the demand and need.

In a CNC machine, there are CNC machining parts which are used for different purposes like drilling, cutting, milling, routing, or anything that works on materials like metal and wood. CNC machines can be used to build accurate forms and shapes using the automatic system from the computer. Using CNC machining parts, raw materials in the machine are processed, and are given different forms by shaping them through cutting tools. Cutting tools, control panel, axis, coolant supply tube, table, and spindle are a few of the CNC machined parts. The CNC processes help in saving lots of time, money and efforts of the business as they are automated.

Manufacture with accuracy- Manual turners and millers can use CNC turning machines to do extremely better. The turning and milling process can vastly grow your business prospects when handled by computer. The industries such as healthcare sector that have extremely complex and precise designs need parts that are perfect. Using this new technology, one doesn’t have to worry about the possibility of individual flaw.

Increase profit and reduce efforts- CNC turning machines are a bit expensive, but getting it is very beneficial. This machine will not only reduce the production cost, but also time and effort. CNC is actually quite time-consuming and thrift technology through the edges. If you’re planning to buy the machine, make sure the device is right and works error-free. It can be indeed a real selection for boosting the production.

Cut down the expenditure cost- Dropping the consuming cost is surely one of the major benefits. Manufacturing engineering companies fritter away huge amounts of money annually on wastage, because of the individual error. This way expenditure can be reduced and thus increasing the benefits.

Improved Efficiency- Without any doubt, CNC machines are one of the most efficient means of producing an element due to the fact that most include internal quality assurance detectors. With the great speed of production and best raw material usage, along with its efficiency, it’s obvious to see why CNC machining is a remarkable standard of metalworking and part fabrication.

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Source by Mikal Smith

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CNC router machines can be used to create a variety of different projects. If you are looking for the perfect machinery addition to your business to help boost it, then definitely look at the CNC router machine. From sign making, furniture building, sheet plastic fabrication, non-ferrous sheet metal machining, cabinet making, etc, the CNC router machines can pretty much offer you a whole other level to add to your current business.

The CNC router machines operate off of computer numerical controlled and robotic technology. This means that upon downloading a software program to the machine which tells the machine what exactly to do and to what specifications to do it, basically all the operator has to do is hit the start button once the machine is loaded with the materials. Very little human intervention is required. One employee can oversee the operations of several machines at one time.

Once started, the machine will continue to operate until the program tells it to stop. The CNC router machines come in variety of different sizes which allows you more design possibilities in terms of the size of materials that you can use and what you can create. Very little waste will be created as the machine will use one sheet to cut out all the specific parts that are necessary (unless the project is extremely large and more materials are required).

To get the machine to do different projects, software programs for each project will need to be written. You can save the program that has been written by the programmer and use it at any time in the future where you may need to duplicate a project. If this happens, there is no fear that the project will not turn out the exact same. With computer numerical controlled technology, you can guarantee that each time the program is used; you will receive the exact same finished product. Replication is an easy process.

There are many different options when it comes to CNC router machines. Depending upon the brand that you buy, you can features such as larger cutting spaces, vacuum tables, different spindle options, automatic tool change spindles, gang drills for in line boring, and much more. It does not matter whether you are a small business or a large corporation; there is a CNC router machine that is right for you.

Expand your business by expanding your creativity, design capabilities and service options to your customers. Create those one of a kind designs that is sure to please anyone. Make beautiful furniture, beautiful cabinets for any home, help businesses advertise with sophistication and class. These are just some of the ways in which you can use your CNC router machine to expand your business opportunities.

If you have any questions about CNC router machines just contact any dealer or supplier of the CNC technology. They will be able to answer any other questions that you may have and will be able to point you in the right direction to ensure that you purchase the right machine for your business.

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Source by Ivan Irons

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In line with agricultural and industrial businesses, bulldozers are a prerequisite for a faster and less complicated load of works. Throughout the tall establishments that are situated in the busy cities and reputable business industry, behind those are the raw blocks and soil that were toiled by bulldozers. Now, let us appreciate how this helpful machine is manufactured and undergo complete machining, fabrication, and sub-assembly in aid of computer-aided drafting program which assembles and integrate the different metals and parts together to form the final product of a bulldozer.

First off, the process of manufacturing a bulldozer undergoes 10 steps which will be discussed in a simple manner for public to understand how this machine is made from raw materials into a loud, humongous and destructive or constructive engine. The complex system and intricate assemblies starts it manufacturing process on an assembly line. An outline from engineering prints and drawings taken from a computer-aided drafting (CAD) is prepared that will serve as a blueprint for the assembly of the parts. Components will undergo heat treating, annealing, or painting beforehand in preparation of submission to the main assembly line.

1. Main core, which forms the rigid inner body, is then accountable for the next assembly. It cuts and molds the steel plate in order to complement with the structural shape. The main purpose behind this is it avoids high impact shock loads and torsional forces that will pull down the dozer down because of its massive weight. In this process the components go through welding of steels (as for the structural skeleton); fabrication in which plates are mounted in fixtures and manually or robotically welded to the stationary central casting; and cross members are also welded for support of the other component of bulldozer. The frame then is rotary sanded on all plated surfaces which in turn will be passed to booth and the main assembly line.

2. At assembly line diesel engine which is located at the front, and the transmission which is located at the rear part (the two is connected by long shaft and supported by couplings and bearings) is are assembled, thus power train is formed because of the long connected line of the two, with series of gears and differentials. This is bolted directly to the base on the main assembly line.

3. At the front of bulldozer sits the radiator and hydraulic lifting cylinders, other than that, connections are made to attach water lines from the engine. Other additional assemblies like hydraulic, lubrication, cooling, and fuel systems are also constructed and thus assembly will be ready to be fastened directly to the engine.

4. The cab, which in array with electronic controls, is mounted on steel blocks or pads located on dozer frame.

5. The undercarriage is mounted on the frame and is assembled to the drive train.

6. Cab controls are connected to the engine and hydraulic systems.

7. The front blade is attached to hydraulic cylinders, which are attached at one end to engine casting in front of the bulldozer.

8. Once the assembly of the primary components is already outfitted, more hoses, electrical lines and fluid lines are attached at fitted connections.

9. The bulldozer then is painted after completion of the assembly of the necessary parts.

10. There will be additional fluids to be put and bulldozer is now set for testing station.

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Source by Bianca Gianni

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The concept for modern numerical control (NC)- the forerunner to today’s computerized numerical control (CNC)- was originally conceived c.1947 by John T. Parsons (1913-2007) and Frank L. Stulen (1921-2010) at the Rotary Wing Branch of the Propeller Lab at Wright-Patterson Air Force Base, in Dayton, Ohio as a result of the US Air Force’s (USAF’s) search for a system to design and manufacture more accurate and complex airplane parts (Source: History of CNC Machining: How the CNC Concept Was Born,” CMS North America, Inc.). Early on, Parsons and Stulen developed a helicopter-blade template fabrication system using an IBM 602A multiplier to calculate airfoil coordinates and feed data points directly into a Swiss jig-borer, which impressed their USAF research colleagues. Shortly thereafter, Parsons and Stulen developed a unique, computerized, punch-card program to render complex 3-D shapes, leading Parsons to start his own company, Parson Corp., operating out of Traverse City, Michigan.

In 1948, representatives of the US Air Force (USAF) visited the Parsons Corp. headquarters and Parsons was awarded a contract to make new and innovative wing designs for military applications. This, in turn, led to a series of USAF research projects at the Massachusetts Institute of Technology (MIT) Servomechanisms Laboratory, culminating in the construction of the very first numerically-controlled, albeit awkward, machine prototype. To accomplish this, Parsons purchased a Cincinnati DK Series, 28-inch Hydro-tel verticle-spindle contour milling machine consisting of a table and spindle that moved along X, Y and Z-axes. Over the next two years, the Cincinnati was disassembled, significantly modified, retrofitted, and reassembled. As application studies proceeded, the prototype was augmented to produce a motion of the head, table, or cross-slide to within 0.0005″ for each electrical impulse fed by the director. To ensure the prototype was functioning as instructed, a feedback system was added. In response to movement, synchronous motors geared to each motion produced voltage. This voltage was sent back to the detector for comparison to the original command voltage.

By 1953, enough data had been culled to suggest practical, aeronautic applications, and the Cincinnati prototype, which employed a Friden Flexowriter with its 8-column paper tape, tape reader, and vacuum-tube control system, became the de facto prototype for all successive developments. To this day all CNC controlled machines, even the most sophisticated still require three basic systems to operate: a command function system, a drive/motion system, and a feedback system.

Although CNC gained slow acceptance throughout the ’50s, in 1958 MIT Servomechanisms Laboratory developed g-code, which has become the most universally used operating language for CNC devices.

In the early ’60’s the Electronic Industry Alliance (EIA) standardized g-code and computer-aided design (CAD) became a nascent technology providing a firmer technology foundation. As a result, CNC soared and began steadily supplanting older technologies.

By the ’70s, minicomputers such as the DEC PDP-8 and the Data General Nova made CNC machines more powerful and cost-effective. US companies responsible for the CNC revolution, focused on high-end equipment. German and Japanese companies sensing the need, began producing smaller, less expensive CNCs, and since 1979 they have been outselling the United States.

Finally, PCs have now made CNC controls even cheaper, making way for the use CNC-controlled machines for the hobby and general purpose markets. CNC control language now known as LinuxCNC (formerly known as Enhanced Machine Controller, or EMC2) continues to thrive, as are many other CNC technologies.

Work Cited:

“History of CNC Machining: How the CNC Concept Was Born,” CMS North America, Inc., http://www.cmsna.com/blog/2013/01/history-of-cnc-machining-how-the-cnc-concept-was-born/

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Source by Adrian K Thomas

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Metal fabrication welding is integral to avail the best fabricated products for any industry sector. So, in order to achieve perfection in this arena, it is always essential to have trained and skilled professionals that are thoroughly equipped for the profession. The job of a fabricator and welder involve laying out, shaping, forming and welding of various metals into the required shapes and sizes. These fabrication welding structures are used for machinery, ovens, tanks, pipes, stacks and parts for buildings.

An expert fabrication welding professional should be able to fabricate and assemble structural metal products and also prepare blueprints whenever required. And only a trained personal can do such things as layout using triangulation and parallel and radial line development. Only a skilled professional can perform for intricate work production of sheet metal cabinets, shelving, pipes, ducts, fire truck builders, garden equipment, snow blowers and equipment for material transfer etc.

Another prerogative of a professional dealing in fabrication welding is to understand the physical properties of metal and accordingly figure the stock that is required for the thickness when setting up a machine for metal fabrication of parts.

He/she should be able to handle such fabrication machines as shears, press brakes, rollers, lasers and abrasive water jet cutting machines and automatic welding machines. As welding involves cutting, shearing and sawing, forming, rolling and bending for welding of metals, these are things that a good fabricator and welder should have for achieving quality. Apart from that fabricators are also expected to have sufficient knowledge about the nuances of trade mathematics such as basic geometry and trigonometry.

Reading and understanding blueprints and welding symbols, and having a basic understanding of blueprint reading, sketching and basic welding metallurgy are other requisites. Only a metal fabrication welding professional having the above requisites qualifications can claim to get the best metal fabrication and welding including structural metal arc welding, steel welding, and cutting etc.

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Source by Kyle Arthur

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The lathe machine tool shapes an object by cutting, sanding, drilling or formation with tool by rotating the object on its axis. Generally a lathe machine is used to give shape to workpieces and has many parts. Most of them are feed service lever, back gear level, head stock, face plate, tool post, compound rest, saddle, clutch knob and half nut lever. Each and every part of the machine is very important and performs very complicated functions. The person who operates the machine is called turner. It fully depends on the experienced turner to do a great job which demands huge level of attention.

There are different types of lathe machines which are used for wood working, metal working, glass working, metal spinning, ornamental turning, shaping, rotary & watchmaking. Every type of lathe is used for specific function. For example, a steel workshop uses metal working lathes & a carpentry workshop uses wood working ones. A Lathe machine can be used to shape different objects. Besides, a solid round bar can be shaped to a bolt by making specific thread. It can be used for complicated drilling where it’s hard in the general drilling machine and can drill at specific angles by setting degrees.

Boring is the another function of lathe machine which is used to make holes inside an object. It can cut 6 inches of hole easily by using sharp tools. There are two types of tools mostly used for cutting solid material like M.S. cutting tool & diamond cutting tool. These two kinds of tools are used for fine tuning an object. The lathe object is used to sharpen is an alloy which is formed by adding some materials to harden it. Lathing concept has been formed since 1300(B.C) to the present. During this time it had evolved for different functions especially in mechanical works, carpentry works, glass works and steel fabrication where it’s contribution has been very essential.

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Source by Sam Mathews

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CNC Machining relies on computer technology to help control the actions of the machine tools. This significantly helps with work efficiency and simplifies a wide range of functions. This type of machinery is now featured in most industries, from the simple factory to the large-scale set up. Popular industries include those involved with wood, electrical discharge machining, metal fabrication and metal removing.

Here are a few of the benefits of using this type of hardware:

Low production costs

CNC machining is appreciated for speeding up and making the entire production process that much more efficient. A notable benefit is the ability to minimize waste of the raw materials being cut. Plus, these types of machines are mostly operated by a single person, which can help to lower the number of workers on the shop floor.

Greater automation

The process of using CNC Machining is mostly automated. It can be loaded with several types of tools and can automatically choose the right one to match the specific application. A standard NC machine can only be operated by the skilled engineers, but the computer assisted hardware is less dependent on human input, and easier to control by the least skilled person.

Increased efficiency

The highly efficient nature of CNC Machining makes it a practical choice for the factory involved in mass production. Once the computer has been input with the precise design requirements, the tool has the ability to produce the same result time after time. But, if a discrepancy or error is noticed in the product, the tool is easily stopped to make the required adjustments and avoid wasting too much raw material.

Plus, there is less likelihood of encountering operating issues from human error because most of the setup is automated and controlled by computerized programs.

Highly flexibility

The CNC Machining is highly flexible to work with because its commands are easily input using a specific computer program. Any changes in the operation are quick and easy to perform which is great for not only saving time, but also to keep manufacturing costs at a minimum.

Continuous operation

This machinery is designed and built to continuously operate and can be left running 24 hours a day. There is no need to switch off at the end of the working day, and will have no problem running throughout the night. With the proper ongoing maintenance, they have the ability to continue to run for years without much trouble.

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Source by Leo Eigenberg