Tech Tips | MACHINING | 87
You may wonder whether this thin material is real. It is.
Here are the secrets to machining
a thin workpiece like this.
to Better Machining of Thin Materials
Machining thin materials is not a tough job, as long as you have a good machine and the right techniques
BY LEO CHANG
Leo Chang is senior application
engineer with Hartford.
1. Small needle machining: First,
recognize that needles may break
due to the height of the needles ( 30
mm) and to cutting overload. Under
this condition, use special cutting
methods to overcome this problem.
2. Thin plate machining: We designed
a special tool for this machining,
one that will not generate vibrations
when cutting rest layers.
A high precision machining centre
is key to success when machining
thin materials, but you must employ
advanced machining techniques and
skill to ensure that success. SMT
1. Success depends on having a high
precision and stable machining
centre. Your machine must not allow
tool marks during machining. You
must have a machine that achieves
positional accuracy and repetitive
2. You need a high precision spindle
with a spindle balancing level of
G0.4 (low vibration spindle) with
spindle runout of 0.005/300 mm for
better dynamic accuracy.
3. You need the right tool designed with
a sintered shank that will provide
better precision of yaw and avoid
breaking the needle bar.
4. Lubrication is important. Use
a MQL(Minimum Quantity
There are problems you may encounter
when attempting to machine thin
workpieces. If positional accuracy on
your machine is not precise, if the
rigidity of your machine is not strong
enough, if the spindle and tool are not
good, they will generate tool marks,
break the needles and lead to further
machining problems. As well, high
pressure coolant may slant the needle
bar. If the needle bar is not rigid
enough, it may cause the needle to
break when machining. You cannot cut
thin plate in one setup, and repetitive
cutting may lead to tool marks and
impact the quality of surface ;nish.
• It’s a NAK- 80 tetragonal body
machined in one setup.
• The diameter of the needle
bottom is 0.5 mm, top is 0.005
mm and height is 30 mm.
• No damage after machining nine
• The thickness of thin plate is 0.3
mm, height is 30 mm.
• The width and depth ratio
is 1: 60; no tool marks after
Machining a thin workpiece like
this requires two conditions:
a high precision and stable
machining centre and excellent