CNC Planing and Shaping

Applications of CNC Planning and Shaping for Castings and Forgings

1. Surface Planing:

• Large Surface Flattening: Planing is ideal for creating smooth, flat surfaces on large and heavy castings and forgings (e.g., machine beds, plates, and frames).

• High-Precision Flatness: Critical for parts where high flatness tolerance is essential for assembly or further machining operations.

2. Profile Shaping:

• Complex Contours and Geometries: Shaping creates irregular, concave, or convex profiles and features on castings and forgings.

• Keyway and Slot Cutting: Produces grooves, keyways, or slots for assembly and functional purposes.

3. Dimensional Adjustments:

• Critical Dimensioning: Planing and shaping correct dimensional errors or achieve exact tolerances on large components after rough casting/forging.

4. Finishing of Large Castings and Forgings:

• Often used as a secondary finishing operation to refine large and intricate surfaces that other processes like milling or turning cannot easily reach.

5. Squaring:

• Ensures parts are square, which is critical for assembly, where perpendicularity and true alignment are necessary.

Recommended Machines for CNC Planning and Shaping

1. CNC Planers:

• Fermat CNC Planers: These machines are known for their stability and precision, ideal for large castings and forgings.

• Schneider CNC Planers: Offers high-performance machining for large and heavy-duty components. Schneider planers are commonly used in the heavy machinery industry.

• Mazak CNC Planers: Mazak offers flexible solutions with advanced features, enabling planing of complex surfaces and profiles.

2. CNC Shapers:

• Shibaura CNC Shapers: Known for high precision in shaping large castings and forgings, especially for aerospace and automotive industries.

• Bhurji CNC Shaping Machines: High-performance shapers for automotive and manufacturing components where quality and precision are paramount.

• Doosan CNC Shapers: Doosan's CNC shaping machines are designed for efficiency and precision, particularly for industries like energy and defense.

3. Bridge-Type CNC Planing Machines:

• Okuma Bridge Planers: These machines are great for working with large and heavy workpieces, with high accuracy and stability.

• Keller CNC Planing Machines: Offers reliable solutions for rough and fine planing operations on heavy parts, widely used in industries like steel and foundries.

4. Universal CNC Machines with Planing and Shaping Capabilities:

• DMG Mori CNC Milling/Planing Combination Machines: These machines allow for both planing and milling capabilities, providing flexibility for various types of machining operations on castings and forgings.

• Haas CNC Universal Machines: Suitable for both planing and shaping tasks, these machines offer high versatility with large work envelope capabilities.

Dimensional Inspection Measures

1. Coordinate Measuring Machines (CMM):

• Used for measuring precise dimensions and geometric characteristics of planed or shaped surfaces. CMM ensures the correct placement of features and checks flatness and profile.

2. Surface Roughness Testers:

• Measures the smoothness of the machined surfaces, ensuring they meet the required surface finish parameters (Ra, Rz values).

3. Straightness and Flatness Gauges:

• Ensures the machined surfaces are within specified tolerances for flatness and straightness.

4. Feeler Gauges and Dial Indicators:

• Checks flatness and parallelism across surfaces. Dial indicators are also used to check surface irregularities.

5. Optical Comparators:

• Helps in checking contours, keyways, and other complex shapes that are hard to measure directly.

6. Laser Scanning Systems:

• Non-contact measurement system used to ensure accuracy, especially in measuring complex profiles and large surfaces.

Inspection Reports

1. First Article Inspection (FAI):

• Details the verification of the first part produced in a batch, ensuring that the dimensions and features are within specified tolerances.

2. Geometric Dimensioning and Tolerancing (GD&T) Reports:

• Includes a detailed report of the dimensional and geometric tolerances for flatness, parallelism, perpendicularity, and profile.

3. Surface Finish Reports:

• Documents the roughness of the planed or shaped surface, comparing it to the required specifications.

4. Dimensional Inspection Reports:

• Provides detailed measurements of all critical features, including flatness, dimensions, and alignment.

5. Material Test Reports (MTR):

• Ensures the material properties (strength, hardness) of castings and forgings are consistent with the specifications.

6. Runout and Parallelism Reports:

• Confirms the alignment of surfaces and features, especially for parts requiring assembly into larger systems.

Quality Control Measures

1. Pre-Machining Inspection:

• Evaluate raw castings or forgings for defects like cracks, porosity, or alignment issues, as these can affect the planing or shaping operation.

2. Tool Condition Monitoring:

• Regular checks on the condition of cutting tools, ensuring they remain sharp and perform at optimum levels for precise machining.

3. In-Process Monitoring:

• Monitors parameters like feed rate, depth of cut, and cutting speed to ensure stable machining and to prevent dimensional drift or tool wear.

4. Post-Machining Inspection:

• Verifies all critical dimensions after machining, ensuring flatness, straightness, and profile meet design specifications.

5. Non-Destructive Testing (NDT):

• Methods like ultrasonic testing, magnetic particle testing, or dye penetrant testing can be used to detect any internal or surface defects in castings or forgings.

6. Traceability:

• Ensures that all data, from the raw material inspection to final inspection and reports, is logged and traceable to each part for accountability and future reference.

7. Compliance with Industry Standards:

• Ensures adherence to international standards like ISO 9001, AS9100, or IATF 16949, ensuring that the products meet quality and performance standards required by the industry.

Advantages of CNC Planing and Shaping for Castings and Forgings

1. High Precision:

• Ensures flatness, parallelism, and smoothness within tight tolerances, especially on large, heavy parts.

2. Cost-Effective for Large Parts:

• More economical for machining large surfaces than other methods like milling or turning, particularly for heavy components.

3. Versatility:

• Capable of handling both rough and fine machining, making it suitable for complex geometries and large-scale production.

4. Reduced Lead Time:

• Automated CNC planing and shaping can handle complex tasks quickly, reducing cycle times for high-volume production.

5. Consistency and Repeatability:

• CNC systems provide highly consistent results, ensuring that every part meets the required specifications for large production runs.