As a product manufacturer or a component developer, one of the most important decisions you will make concerns which type of machining operation to use.
This decision is critical for several reasons – including finding the perfect balance between cost efficiency and operational reliability. And in many cases, the decision tends to lie between CNC machining and manual machining.
So, which option do you pick? Let’s find out the nuances in this article:
Understanding CNC Machining
Short for Computer Numerical Control machining, CNC machining is a process of manufacturing tools and products that makes use of both machines and computerized controls to extract a material from a specific workpiece.
In CNC machining, you have an automated precision operation that ensures that whatever is being done is being carried out with optimal efficiency and accuracy. There are several types of CNC machining available, but they tend to have the same working principle and goal – making use of special tools and computer designs to remove a material from a workpiece as accurately as possible.
The Role of Computer Programs and Automation
With CNC machining, one of the most important aspects of the entire equation is the computer. Whether it’s with a CNC mill vs lathe, computers play a role in everything, ensuring that you can easily feed the machine a set of instructions that it will act upon.
In general, computers play extensive roles in how these machines work. Some of their functions include:
- Generating CNC programs, which will contain the instructions for the entire machine to follow
- Executing said program, ensuring that the machine acts as instructed as precisely as possible.
- Examining the entire program to ensure that there are no errors in sight – and if they crop up, recommending fixes
- Providing feedback to help with improving the process on the next go around.
- Storing all data and information about the machining operation to ensure that it can always be recalled.
With this round function, computers play a major role in ensuring that CNC machining operations run as smoothly as possible. And even when you check your CNC manual, you’ll find that they are especially critical
CNC Machine Components and Operation
When you see a regular CNC machining system, you’ll find that it doesn’t just work alone. Different components come together to make these machines work, with some of the major ones being the following:
A Controller: Here, you have the central unit that takes a CNC program and interprets it into something that the computer will be able to understand.
The Machine Itself: Next, you have the machine tool, which is the main equipment used in carrying out the entire CNC operation. There are different components here, and they all move in tandem to make the tool work.
Drives & Motors: These ones are used to move the axes of the machine, while also controlling their speed and position. Primarily, their job is to convert any electrical signals from the CNC controller to the motion of the machine.
Feedback Components: As their name suggests, you have things like sensors and encoders that offer real-time information about the performance of the components in general.
The Human-Machine Link: You have a human-machine interface that makes it possible for operators to use the CNC system. With the interface, they will be able to send commands, keep an eye on the entire process, and conduct troubleshooting operations if they notice any issues.
Toolholders & Operational Tools: Depending on the machining operation you’re handling, some tools make it happen. At the same time, you have tool holders that keep the tools in place and help them operate.
An Introduction To Manual Machining
Next, let’s take a look at manual machining and how it works.
With manual machining, you’re operating cutting and shaping materials using tools that operate on manual technology. There is no CNC technology available here, and instead, operators use hand-operated tools to perform different operations on workpieces.
Interestingly, a manual machinist will be able to handle the same operations as a CNC machine operator. Some of these include:
- Turning, where you rotate a workpiece as a c-cutting tool removes materials slowly to create the piece you want
- Milling, where you use a spinning multi-point cutting tool to handle the material removal on the sorkpiece’s surface
- Drilling, where you make holes in a workpiece with a cutting tool – what we call a drill bit.
- Grinding; a process where you use abrasives to take out any excess material from the workpiece directly
- Sawing, where you cut workpieces into specific shapes and lengths with a manual saw machine – it could be a hacksaw, a bandsaw, a circular saw, what have you
- Shaping and planning, which involves removing materials to create shapes that are either flat or contoured
- Broaching – a specialized process where you make internal or external profiles with the use of a broaching tool
Because these processes are manual, It’s important to have skilled people handling them. Operators need to understand the machining principles, how to choose tools, and much more to ensure that they have the best outcomes overall.
What Are The Differences Between CNC Machining & Traditional Machining?
Now, let’s get into the manual CNC debate to understand where the two processes differ and what the lines between them are.
The Ease Of Control & Automation
With CNC machining, you have computer-controlled machines that take programs and execute them based on the instructions given in these programs. There are computer-aided design (CAD) software options available that help to create part designs and convert them into codes that can be read by computers.
This automation is the major difference between CNC machining and manual milling or any other form of machining. Here, you need to use manually operated tools that are controlled by humans. A manual machinist will have to use hand tools to perform whatever task.
Which Option Is More Accurate?
In this comparison, CNC machining easily takes the prize. CNC machines are capable of making parts that have tight tolerances, and they do so with optimal precision. Thanks to computer control, you can ensure that processes are consistent and can even be repeated as many times as you want.
For manual machining, processes tend to rely on human control, which, as we all know, can be a bit unreliable.
Understanding Complexity Standings
When you have complex parts with complicated shapes to create, CNC machining is the best bet. And, the fact that you can handle different operations means that the machines are also quite versatile.
For manual machining, you probably have to deal more with simple parts and basic geometries.
Setting The Machines Up & Switching Them
For every CNC machining operation, you will need to handle an initial setup and programming step. This is where you create the program for the computer and interpret it before the computer starts to work.
At the same time, a CNC machine will be able to glide through different programs if the need arises – as long as the setup step is done right.
You can set up manual machines as well, but the process usually involves a lot of manual steps – tool changes, fixture setups, and more. As a result, you’re mostly left with a time-consuming process that also requires a great deal of labor to be achieved.
All in all, it’s pretty obvious that CNC machining especially excels when you have complex parts and need to make them with optimal accuracy. On the flip side, manual machining allows you to be more flexible and creative – especially if you’re working on a small-scale operation.
CNC Machining vs Manual Machining: Which Is More Expensive?
Considering the many tools and components you will need for CNC machining, you can understand that the upfront costs alone will be incredibly high. Besides just the tools, you also need to pay for the software, and you need to ensure that anyone handling the machine is skilled enough – something which will also require its investment.
That said, you should also consider what you’ll be getting from these CNC machines – better accuracy, lower waste, improved efficiency, and a higher chance of being productive with your machining.
At the end of the day, it’s a case of prioritizing what you want based on a cost perspective.
CNC Machining Advantages vs Manual Machining
With all that’s been said, what are the benefits that CNC machining has over manual machining operations?
CNC Machines Are More Accurate: Easily the biggest benefit you stand to gain from these machines is the fact that they are considerably more accurate. You can also repeat them several times and still rest assured that they will come out with accurate parts across the board, so there’s no issue here.
Complex Parts Aren’t An Issue: No matter how complex or intricate the part you’re trying to create is, you can rest assured that CNC machining will be able to handle it. Just load the instructions into the machine, and you’re good to go.
Expand Your Production Scale Easily: For large-scale production tasks, CNC machines will also come in handy. The repeatability involved, as well as the entire benefit of optimal accuracy, means that large-scale manufacturing tasks will be able to benefit significantly more with CNC machines.
Manual Machining Advantages vs CNC Machining
The Initial Cost Is Lower: In most cases, you’d find that the upfront cost associated with manual machining tends to be lower than the CNC manual. For cost-conscious users and manufacturers, this is a major stipulation that shouldn’t be ignored. Per usual, remember to think about costs carefully and with the long game in view.
They’re Usually Easier To Work With: When it comes to manual machining, you usually don’t have to spend so much resources to work with them, there’s no need for programming or CAD designs, so ease is a major benefit here.
Turnaround Can Be Shorter: There’s a significant chance that you’ll be dealing with a short turnaround time when working with a manual mill machine, for instance. However, this might come at the expense of the accuracy you so seek.
CNC Machining vs Manual Machining: Applications and Industries
In most cases, it can help to understand the spaces where both CNC machining and a manual milling machine, for instance, will operate better.
Industries Where CNC Machining Excels:
If you’re working in any of the following fields, then you might want to consider using CNC machining instead:
Aerospace, automotive, and medical sectors
We see CNC machining being used in industries like medical, automotive, and aerospace. For all of these spaces, it is beyond important to have parts that are created with optimal levels of accuracy and efficiency. And with CNC machining, you can ensure that you have the right processes and operations to create these highly intricate parts.
Mass production and high-volume manufacturing
CNC machining is also perfect in cases when you need to create products in large numbers. These machines work based on automation, and their processes are incredibly repeatable. So, you can create as many products as possible while also being incredibly accurate across the board.
Situations Where Manual Machining is Preferred
On the flip side, consider using manual machining if you find yourself in any of these situations:
Prototyping and small-batch production
If you’re starting your production process by developing simple prototypes that aren’t so complex, then manual machining is probably what you want to employ instead. These are just prototypes
Artisanal and custom fabrication
These days, artists are also turning to manual machining if they want to work. Because you still get optimal control over how the process works, you’re considerably freer to express your creativity across the board. The machining tools just help to improve your process flow overall.
Repair and maintenance tasks
Because maintenance tends to be pretty fluid, you need a bit of human action to handle them too. So, it should come as no surprise that manual machining is usually what works here too.
Conclusion
At the end of the day, CNC machining and manual machining primarily vary in how they work – and this spills into the benefits that they provide as well. That said, knowing what to use – and when to use it – will be incredibly vital going forward.
If you’d like to learn more about these processes, feel free to reach out to us at HM.