CNC machining process and Cost of copper parts
Copper processing is generally carried out through CNC machining technology widely used in manufacturing. Copper is a common, commonly used material. Usually, we use various products containing copper inside. Several unique characteristics of copper make it a more desirable material for CNC machining processes when copper parts are machined using CNC technology. In this article, we will discuss the different CNC machining processes that can be used to machine copper, compare the differences between each cycle, and calculate the Cost of general-purpose CNC machining of copper.
Different CNC machining processes are suitable for machining different types of copper parts. For example, CNC turning is ideal for producing cylindrical parts, while CNC milling is generally used to create complex shapes. Wire cutting is usually used for cutting intricate shapes of copper, while laser cutting is generally used for processing thin copper sheets.
The CNC machining process of copper parts is mainly as follows
1. CNC turning and milling of copper parts
CNC turning is one of the CNC machining processes; turning is a CNC lathe rotating the copper workpiece while guiding the cutting tool along the surface, removing material as it moves. This process is repeated until the desired shape and size of the copper part are achieved. This process is optimal for producing cylindrical parts such as shafts, sleeves, and bushings. It is typically used to create copper parts that require tight tolerances and a smooth surface finish. The process offers high accuracy and repeatability, making it the preferred method for producing complex geometries.
CNC milling is another machining process in CNC machining technology. Milling is a CNC milling machine that rotates cutting tools along multiple axes, allowing for the production of more complex shapes and geometries. Repeat this process over and over until the desired shape and size of the copper part are achieved. This process is suitable for producing complex conditions such as gears, brackets, and housings. Copper parts that require intricate designs and tight tolerances are typically made using CNC milling. This process is preferred for producing complex functions in the market today.
(1) Advantages of CNC-turned and milled copper parts include
ability to produce complex geometries
high precision and accuracy
efficient material removal and faster production times
Consistent quality and repeatability
Reduced labor costs and human error
(2) Limitations of CNC Turning and Milling of Copper Parts
The hardness of copper causes rapid tool wear and shortens tool life. The process may require multiple tool changes for complex geometries, increasing machining time and costs. Copper is an excellent conductor of heat, which can cause thermal distortion or warpage of the workpiece if not adequately controlled. But generally, with a certain level of CNC machining technology and experience. CNC machining technology efficiently produces high-precision copper parts and is the leading choice of parts processing technology in the aerospace, automotive, and electronics industries.
(3) copper parts of the CNC machining cost calculation method
The Cost of CNC machining copper parts depends on the sum of various project factors, such as the complexity of the design, the amount of material used, the time required to manufacture the part, and the overhead costs of the machining process. You can refer to the following formula used to estimate the Cost (only you need to know the specific values to substitute for calculating the approximate Cost as a basis for judgment):
Total Cost = material Cost + labor cost + administrative Cost
Material Cost = Quantity of material used x material cost per unit
Labor cost = time required to manufacture the part x labor cost per hour
Overhead Cost = (Machine cost per hour + Tool cost per hour) x Time required to make the part.
Please note that labor cost per hour and machine cost per hour will vary depending on the location and the specific machine used. In addition, tooling costs will depend on the number of tools used and their life span.
You can use the above formula to estimate the Cost of CNC milling copper parts, but remember that this is only an estimate, and the actual Cost may vary depending on the above factors. In addition, milling copper parts may cost more than turning due to the hardness of the copper, which may require more cutting tools and slower cutting speeds.
2. Wire cutting of copper parts
Wire cutting, also known as electrical discharge machining (EDM), is a process that uses electrically charged thin wires to cut copper material. The electrically charged fine wire is guided by a computer-controlled machine that moves the wire along a desired path to cut the copper workpiece into the desired shape. This process cuts copper parts with complex shapes and contours, offering high precision and accuracy. Wire cutting is often used to produce copper parts for the aerospace and automotive industries. Wire cutting is often used to make high-precision and correct copper parts, such as those used in medical and electronics. The process offers an excellent surface finish and the ability to produce intricate shapes.
(1) Some of the advantages of wire-cutting copper parts include
- high precision and accuracy
- Ability to produce intricate geometries
- superior surface finish
- Minimal tool wear
- Reduced labor costs and human error
(2) Wire-cutting costing for copper parts
The Cost of wire-cut copper parts also depends on the design’s complexity, the amount of material used, the time required to manufacture the region, and the overhead costs of the machining process. You can estimate the fee using the following formula provided below:
Total Cost = material Cost + labor cost + administrative Cost
Material Cost = Quantity of material used x Cost of material per unit
Labor cost = time required to make the part x labor cost per hour
Indirect Cost = (Machine Cost per hour + Wire Cost per hour + Electrode Cost per hour) x Time required to make the part
Please note that labor cost per hour and machine cost per hour will vary depending on the location and the specific machine used. In addition, the wire and electrode costs will depend on the type of wire and electrodes used and how long they last.
You can use the above formula to estimate the Cost of wire-cutting copper parts, but remember that this is only an estimate, and the actual Cost may vary depending on the above factors. In addition, wire-cut copper parts may be more expensive than turning or milling due to the slower cutting speeds required and the Cost of the wire and electrodes used.
3. Laser cutting of copper parts
Laser cutting is a process that uses a high-power laser beam to cut copper material. This process is suitable for cutting thin copper sheets and plates with high precision and accuracy. Laser cutting is often used to produce copper parts for the electronics industry.
Laser cutting of copper parts is possible, but it requires some special considerations due to the characteristics of copper. Here are some things to keep in mind:
1. Copper is highly reflective of visible and infrared light, which may make it difficult to cut with a laser. A CO2 laser with a wavelength of about 10.6 microns is unsuitable for cutting copper because most of the laser energy will be reflected away from the material.
2. Fiber lasers, which operate at a wavelength of about 1 micron, are more suitable for cutting copper because of their lower reflectivity. However, even with a fiber laser, some laser energy will still be reflected off the material, which can cause problems in the cutting process.
Copper is a good conductor of heat, which can cause severe problems with laser cutting. The heat generated by the laser can quickly dissipate into the surrounding material, making it challenging to maintain a consistent cutting temperature. This can lead to uneven cuts and rough edge finishes.
To solve the heat conduction problem, some laser cutting machines designed to process copper may use “flying cut,” where the laser moves quickly along the material’s surface rather than staying in one place for too long. This helps minimize heat buildup and produces a cleaner cut.
It is important to note that copper is highly conductive; it can conduct current from the laser beam, potentially damaging the laser and cutter. Therefore, special precautions may be taken to protect the laser and cutter during the cutting process.
In general, laser cutting of copper parts is possible, but it requires specialized equipment and careful attention to the unique properties of copper. Working with experienced professionals with the expertise and equipment needed to perform high-quality cutting of copper materials is essential.
(1) How laser cutting of copper parts is costed
The Cost of laser cutting copper parts is also dependent on the complexity of the design, the amount of material used, the time required to manufacture the region, and the overhead costs of the process. You can use the following formula to estimate the Cost:
Total Cost = material Cost + labor cost + administrative Cost
Material Cost = Quantity of material used x Cost per unit of material
Labor cost = time required to make the part x labor cost per hour
Indirect Cost = (Machine cost per hour + Laser cost per hour) x Time required to make the part
Please note that the labor and machine costs per hour will vary depending on the location and the specific machine used. In addition, the laser cost will depend on the particular type of laser used and its lifetime.
You can use the above formula to estimate the Cost of laser cutting copper parts, but keep in mind that this is only an estimate, and the actual Cost may vary depending on the above factors. In addition, laser cutting of copper parts may be more expensive than other methods due to the high power requirements of the laser and the maintenance and replacement costs of the laser equipment.
Summing up
CNC machining technology provides a precise and efficient method for producing copper parts with high accuracy and repeatability. The appropriate CNC machining process selection depends on the type and complexity of the copper part being made. If you want to know more about the CNC machining of copper materials or if you need to machine copper parts, please get in touch with Anpllocnc.