CNC processing and traditional processing comprehensive comparison

There are many ways of manufacturing to make all kinds of products come to life. But not every method is suitable for all projects. It's like choosing a tool, where you need to consider different techniques to find the best fit for your project. Today, we are going to talk about two kinds of change the manufacturing technology —— CNC machining and traditional machining. They have their own advantages and limitations, and have a profound impact on modern modes of production.

CNC machining realizes the automation of the manufacturing process, before these work require human operation. This technology uses precise computer control to carve the raw materials into sophisticated designs. Traditional processing relies on manual operation, and skilled craftsmen manually operate the tools to complete the manufacturing.

In this comprehensive guide, we will deeply analyze CNC machining and traditional machining, introducing their principles, advantages and limitations. Our goal is to help you wisely choose the right process for your project. Before discussing their differences in depth, let's understand their underlying principles.

What is CNC machining?

CNC (computer CNC) processing is a reduced material manufacturing process. It uses computer control and machine tools to remove material layers from stock parts to produce custom-designed parts. This CNC processing technology combines traditional machining with numerical control technology, computer-aided design and auxiliary manufacturing process.

Numerical control processing technology

The designer first uses the computer-aided design (CAD) software to create a digital 3D model of the desired parts. The skilled programmers then convert the CAD model into a series of instructions that the CNC machine tool can understand, often referred to as the G code. After loading the program, the CNC machine tool will firmly clamp a piece of raw material (workpiece) and move the cutting tool along the precise path by using the computer-controlled motor. The cutting tool gradually removes the material from the workpiece and transforms it into its final shape, a process called CNC machining. Due to the precision of this method enables the production of high quality CNC machining parts with precise dimensions and complex details.

Advantage of CNC processing

1.Accuracy and repeatability

CNC machines can accurately copy CAD drawings and output near-perfect results, with an accuracy typically between 0.0002 and 0.0005 inches. The accuracy of the results is ensured by converting the CAD model into programmable code (such as G code and N code) to controlling the movement of the cutting tool.

2.Precision machining parts

The CNC process reduces the chance of manual manipulation, minimizes errors and improves reproducibility. This is critical for both bulk and mass production. Industrial CNC machines such as laser cutting machines can provide about ± 0.0005 inches to produce accurate replicas.

3.Production of complex shapes and high-complexity parts

The CNC machine tool provides up to 6 machining shafts with high manufacturing complexity capability. Modern CNC technology can realize multi-axis rotation and translation, helping to process the highly complex features. This capability makes it possible to manufacture highly complex CNC machining parts.

4.Reduce human error and enhance security

The CNC machine tool accurately follows the pre-programmed instructions, eliminating the possibility of human error. At the same time, equipped with a closed working area and automatic closing mechanism and other safety functions, to minimize the risk of accidents.

5.Efficient mass production

Automated CNC processing methods reduce manual intervention and achieve faster and more consistent production. CNC machine tools can duplicate the same parts to ensure product quality and reduce possible waste.

6.Flexibility in production capacity

As production requirements change, manufacturers can easily expand CNC processing processes to provide flexibility for mass manufacturing and maximize the use of resources and budgets.

Disadvantages of CNC processing

1.Higher initial investment and maintenance costs

CNC machine tools consists of various components, such as computer systems, CNC controllers, advanced software, cutting tools, etc., resulting in its high initial cost. For small businesses, this can be an overwhelming burden. As complexity increases, maintenance costs increase accordingly, so CNC machine tools are more suitable for projects with large production scale and efficiency significantly affecting processing costs.

2.Requirements for skilled operators and programmers

Running CNC machine tools requires experts with a deep knowledge of programmable code and machine operation. Unlike traditional machining, which relies on manual labor, CNC machine tools require the technical expertise of the technicians, which increases the operating costs per part. Nevertheless, CNC machine tools can provide cost-saving benefits by providing cost-effective production operations.

3. Less cost-effective for very small batches

Due to the high setting investment, CNC machining may not be the most effective option for small-scale production. These machines require substantial upfront costs of equipment, tools, and programming expertise. Furthermore, each artifact needs to create and optimize specific CNC processing procedures for it, which increases the time and cost required to set up the processing process. For small-scale production requiring frequent changes or small batches, traditional manual processing methods may be more cost-effective and time-efficient.

What is traditional processing?

Traditional processing involves the molding of materials using manual tools and machines (such as milling machines, grinders, lathes, and drill machines). These devices enable the operator to cut small pieces from the workpiece to achieve the desired shape. The mechanic selects the appropriate cutting tool based on the material and the desired results. They then fix the workpiece in a vise or fixture on the machine tool (lathe, milling machine, drill machine, etc.).

What is conventional processing?

Traditional processing is one of the pillars of mechanical manufacturing, and the mechanic manually controls the machine, operating the lever and handle to move the cutting tool to the workpiece. They rely on experience to determine factors such as cutting speed, feed rate and cutting depth. In this process, the cutting tool comes into contact with the workpiece to removes the material by shear while the mechanic constantly observes and adjusts the cutting conditions to ensure that the desired shape is achieved.

Although the traditional processing method is more manual, it still has important advantages in many cases. This processing procedure usually proceeds in the order of initial processing, measurement, and possible reprocessing, relying mainly on the operator experience and skills.

The advantages of traditional processing

1.Lower initial investment

Compared with CNC machine tools, the upfront cost of traditional machining tools is lower. They provide more affordable entry points for small studios, startups or anyone starting a project. Lower initial costs will facilitate the smooth start of the manufacturing process without causing heavy financial stress.

2. Flexibility in small batch production and prototypes

Traditional processing stands out for its adaptability in small-scale production and prototyping. Its machines can be easily adjusted or modified without complex reprogramming. Therefore, it is ideal for making unique items or limited edition items with regularly updated designs. This feature is particularly valuable for prototyping or new design trials prior to large-scale manufacturing.

3. It is easier to change or adjust in the process

The operator using traditional processing can directly observe and adjust the process in real-time. This enables immediate changes based on observed or unforeseen circumstances. Unlike CNC machine tools that require program modifications, these adjustments can be made quickly. Thus, conventional processing is a better choice for situations where adaptability and rapid decision making is critical.

4. Suitable for simple parts and operations

Traditional machining is good at creating parts with basic shapes and simple machining requirements. The machine efficiently performs basic operations such as turning, milling, and drilling. Therefore, they are well suited for projects that do not require complex CNC processing functions. This method effectively produces simple parts without adopting high-tech solutions that the project may not need.

The disadvantages of traditional processing

1.Lower precision and reproducibility compared to CNC

Traditional processing technology has lower precision and consistency than CNC processing. The process relies heavily on the operator skills and the manual control of the tools and adjustments. This manual participation may lead to differences in the size, surface quality and uniformity of parts, especially for parts with complex shapes.

2. Higher potential for human error

As mentioned earlier, conventional processing relies heavily on the skill and judgment of the operator. This reliance on human control can be errors due to factors such as fatigue, misreading, miscalculation and so on. These errors may lead to inconsistencies and scrapped parts, ultimately increasing CNC processing costs

3. Low productivity and efficiency

However, manual intervention includes adjusting, knife change, and operator-controlled procedures. This reduced speed reduces the efficiency, making these methods less suitable for mass production at a consistent speed.

Moreover, the time intensity of these methods requires companies to anticipate longer waiting times for the finished product. This affects the rapid response to customer demand or market changes. Furthermore, the processing process provides limited design flexibility. Once the design is determined, making modifications can be challenging and costly. This rigidity limits the ability to innovate and the ability to tailor products to changing consumer preferences.

4. Need for highly skilled operators

Operating traditional machines requires extensive skills and experience, including a comprehensive understanding of processing techniques, equipment functions, and material characteristics. This requirement poses challenges for companies to find qualified people, and training new employees can be costly and time-consuming.

Now that we have reviewed each process one by one, let's compare the major differences between CNC processing and conventional processing.

CNC processing with conventional processing

1. Precision and complexity of the parts

The key difference between CNC processing and traditional processing lies in computer control and manual control. CNC processing relies on computer control and thri, thus greatly improving the accuracy of accuracy and consistency. In contrast, conventional processing relies on the skill and experience of the operator, which partly limits the precision and complexity.

The CNC machine tool follows pre-programmed computer instructions to achieve the finest details, eliminating the possibility of human error. This allows CNC precision machining to achieve more stringent tolerances, thus ensuring that the finished parts meet strict size specifications. Especially in areas such as the aerospace, medical equipment and electronics industries, this precision is critical to ensuring product functionality and safety.

Traditional processing, although relying on the skill and experience of the operator, is susceptible to fatigue and slight inconsistencies, leading to changes in part size and surface finish. Furthermore, conventional processing of complex parts is more challenging and time consuming and often requires expertise and multiple settings.

Overall, computer control by CNC precision machining allows for higher precision and complexity, creating complex geometries, precise details and complex tool paths, providing the possibilities for creating innovative and powerful products in various industries.

2. Material type

Although both CNC processing and conventional processing can handle a variety of materials, they differ significantly in handling different material types. CNC processing provides a greater flexibility in terms of material versatility. Unlike conventional processing methods, it is not limited by the tool hardness as a wider range of tools and processing techniques can be utilized. This includes using advanced cutting tools such as diamond coated tools or carbide blades.

In addition, CNC machining can also use discharge machining (EDM) or water jet cutting technologies, which are not limited by the hardness of the material. This versatility allows CNC processing to handle a wider range of materials, including hard and brittle materials that are difficult or impossible to handle by conventional processing methods. This offers the possibility of processing materials such as titanium, stainless steel, nickel, ceramics and even plastics with complex features and high precision.

In contrast, conventional processing is usually limited to the handling of softer materials. The technique relies on knives made of materials with specific hardness levels. If the workpiece material is harder than the tool, it will lead to tool damage, which may cause surface quality decline, tool wear and safety risks. Therefore, traditional processing is more suitable for softer materials, such as aluminum 6061, lead, low carbon steel, tin and brass. The hardness range of these materials allows conventional tools to efficiently remove the materials without compromising their integrity.

3. Production capacity and efficiency

Numerical machine tools perform well in mass production. Their automated operations include pre-programmed CNC tool paths, automatic knife changes, and continuous operation. This significantly reduces the production time compared to the conventional methods. The manufacturer can use the same program to create multiple identical parts without manual intervention. This improves the efficiency of mass production. Moreover, unlike human operators which need rest and rest, CNC machine tools can run continuously. It maximizes resource utilization and increases overall productivity.

4. Metal CNC production parts

Traditional processing relies more on the skills and experience of the operator and therefore is more suitable for producing small batches of parts. Although the simplified process may improve the efficiency, it cannot be compared with the automation and consistency of CNC processing. Furthermore, the quality of traditionally processed products directly depends on the ability of the operator, and thus there may be potential changes and inconsistencies, especially for complex parts.

5. Cost-effective

CNC processing has a significant disadvantage in terms of the initial setting costs. Significant investment in mechanical equipment, programming and tools can be a challenge for small-scale production because the initial investment may outweigh direct gains. However, CNC machining has a significant long-term cost advantage when considering larger-scale yields. It improves production efficiency, reduces waste, and reduces labor costs.

In contrast, the initial investment in conventional processing is low, but larger-scale production operations may generate higher labor costs. The time and effort required for manual manipulation and potential errors and rework may increase costs.

6. Operating skill requirements

CNC processing has significant advantages in terms of operator experience dependence. Computer control ensures consistent and precise processing, regardless of the level of operator experience. Pre-programmed instructions determine the entire CNC process, eliminating the inconsistencies associated with human errors and manual operations. Therefore, even less experienced operators can produce high-quality and consistent parts.

Instead, conventional processing relies heavily on the operator skill and experience to achieve the desired outcome. Although skilled operators can produce high-quality parts, their level of experience directly affects consistency, especially for complex geometries. This may lead to rework, part scrapping, and increased production time. Furthermore, training skilled operators requires time and resources, increasing the overall cost burden.