Optimizing Manufacturing Efficiency: A Guide to Computerized Numerical Control (CNC) Machining Surface Finishes

Why we Need Surface Finishing in CNC Machining

When it comes to CNC machining, surface finishing plays an essential role in boosting corrosion resistance, promoting cleanliness and hygiene, boosting productivity, preserving quality control, and improving appearance. It assists in converting rough machined parts into polished, useful, and aesthetically pleasing parts that satisfy the required standards and client expectations. To be specific, surface finish has a big impact on a product's aesthetic appeal. A polished and smooth surface improves the product's overall appearance and increases its visual appeal to consumers. It may influence how valuable and high people think the product is.

Also, component performance can be impacted by surface finish, particularly in applications where tolerances are tight. Irregularities on the surface, such as tool marks or roughness, can influence the fit, alignment, and operation of mating parts. A smoother surface contributes to excellent performance, accurate assembly, and correct operation of the final product.

CNC Machining Surface Finishing Techniques:

As Machined

AS machining refers to the surface condition of a part or component immediately after being machined using CNC processes. When a part is designated as "AS machined," it means that no additional surface finishing or post-processing operations were performed on the part after the machining process.

Bead Blasting

Sandblasting is blasting microscopic abrasive particles onto a part's surface using high-pressure air or water. This method leaves a textured or matte finish by eliminating burrs, coatings, and surface imperfections. On metal surfaces, bead blasting can also be used to provide a uniform satin or matte finish.

Brushing

The process of applying a brushed finish imparts a distinct visual appeal to a part's surface by employing an abrasive substance or brush to create a pattern of tiny, circular scratches or parallel lines. This coating may cover up little surface flaws and has a distinctive visual appeal.

Anodizing

An electrochemical process called anodizing coats a metal object, usually an aluminum one, with a coating of protective oxide. Anodizing creates a consistent, glossy, or matte surface that is resistant to corrosion. The method involves adding dyes to the anodized layer, which improves corrosion resistance, hardens the surface, and creates attractive finishes. Anodizing allows parts to take on a variety of colors; the most popular ones are black, red, and gold.

Hard Coat Anodizing

Hard coat anodizing, sometimes referred to as hard anodizing or Type III anodizing, is an electrochemical surface treatment that coats aluminum or aluminum alloy surfaces with a thick, long-lasting oxide coating. The reason it's termed "hard coat" is that, in comparison to traditional anodizing, the resulting anodized coating is substantially harder and more wear-resistant.During the anodizing process, a controlled oxidation occurs at the surface of the aluminum part. This forms a layer of aluminum oxide that is integral to the surface and provides enhanced hardness and wear resistance. The hard coat anodizing process typically results in a coating thickness ranging from 25 to 100 microns (0.001 to 0.004 inches), although thicker coatings can be achieved.

Conductive Anodizing

Conductive anodizing is an electrochemical surface treatment done to aluminum or aluminum alloys. We often refer it to as Type II anodizing or "architectural" anodizing. Because it improves the anodized aluminum surface's electrical conductivity, it is referred to as "conductive". Normally, conductive oxide layer-forming anodizing is employed for electrical grounding or EMI/RFI shielding applications.

In particular, the conductive anodizing procedure is comparable to Type II conventional anodizing, but it usually calls for lower voltages and shorter anodizing duration. The aluminum components that are going to be anodized serve as the anode (positive electrode) and are submerged in an electrolyte solution that typically contains sulfuric acid. The bath also contains a cathode or negative electrode. Through a regulated oxidation process, an oxide layer forms on the aluminum surface when direct current (DC) is applied.

The conductive anodizing process produces a relatively thin and porous anodize coating, usually 5 to 25 microns (0.0002 to 0.001 inches) thick in the meantime. The coating's porosity results in a greater surface area and improved conductivity.

Silkscreen

Screen printing, also known as screen printing or screen printing, is a printing technology that can be used in conjunction with a CNC process to apply ink to a surface using a fine mesh screen to print designs, logos, or graphics onto parts or components on the surface.The application of silk screening in CNC processes has various benefits. For instance, CNC-machined items with a variety of flat or curved surfaces can have elaborate, multicolored motifs and graphics applied to them via silk screening.

Moreover, it optimizes product identification and aesthetics by allowing parts to be customized with logos, branding, serial numbers, or other markings. A thing needs to be noted that pieces with comparatively flat or slightly curved surfaces work best for silk screen printing. To achieve accurate and consistent results, parts with complicated geometries or irregular surfaces might need to be printed using different techniques like digital printing or pad printing. Compatibility with part materials, intended look, and desired performance characteristics can also be ensured by carefully selecting inks, screen sizes, and printing conditions.

Laser Marking

To apply precise and long-lasting markings to a part or component's surface, laser marking is a popular technique that works in tandem with the CNC software. It makes use of a laser beam to produce robust, high-contrast markings without making direct contact with the material. We use a laser in laser marking to permanently label or code a part's surface. This technique is typically applied for branding, traceability, serialization, and product identification. Materials such as metals, polymers, ceramics, and others can be marked using a laser.

Acid Etching

Acid etching is a chemical procedure where the material is selectively removed from a part's surface using an acid solution. A substance that is applied to a substrate to remove specific materials, leaving behind a permanent, regulated pattern or design. It is frequently applied to a range of materials, including metals, glass, ceramics, and even some polymers, to create intricate patterns with precisely regulated depth.

Other CNC Surface Finishing Techniques

Hand polishing

Vapor polishing

Mirror polishing

Electropolishing

VD and CVD Coatings

Passivation

Antimicrobial Coatings

Burnishing

Laser Ablation

Conclusion

In conclusion, achieving the desired surface finish is an essential aspect of Computerized Numerical Control (CNC) machining. The surface finish not only affects the aesthetics but also plays a significant role in the functionality and performance of the machined parts. In this guide, we have explored several common surface finishing methods used in CNC machining.

When choosing the proper surface finishing technique, it's critical to take the material, design specifications, intended application, and desired finish into account. To achieve the intended results while preserving the integrity of the CNC machined parts, it is essential to adhere to manufacturer instructions, and best practices, and make sure that the surface is properly prepared.