Production and manufacturing have considerably evolved over the years. Everything from production strategies and practices to machines has changed.

Things have gotten much more specialized, streamlined, and efficient. One such development in the manufacturing industry is automation. A lot of the work no longer requires to be done by hand. You do not need a factory full of workers to operate machinery; all of that can be done through computers. This is where CNC comes in.

CNC (Computer Numerical Control) machines use computer systems and software programs to operate machinery and carry out complex processes. A CNC cutting machine or burn table uses CNC processes to cut and engrave different materials like wood, steel, and aluminum.

Do you want cost-effective mold-building solutions? CAV Tools provides manufacturing solutions for high quality and fully customized close tolerance products in Fort Worth, TX, and all over the US. Click here to get a free custom quote now.

Many people who previously did most of the work by hand aren’t that proficient in cutting with CNC. So below are a few tips to help them perform this task effectively.

Select The Perfect Cutting Tool

Using the right tools is very important to maximize efficiency and finesse. If you want to engrave an intricate pattern, you need small cutting tools to achieve a precise and clear result. To engrave larger text patterns, use cutting tools that have wider angles. And if you are carving hard materials, then use tools with the largest tip and cutting angle.

Pay Heed To Your Spindle Speed

Use small shank tools with low-power spindle motors for optimal results, make sure the cutting speed isn’t set too fast, or minimize resistance in high-speed milling. For increased speed, use high-power motors with large shank diameter engraving tools.

Use The Tool With The Appropriate Length

For carving knives, the recommended blade length should be 2-3mm more than the measured thickness of the processing sheet. When the motor speed is between 18000 and 24000 RPM, or you are cutting acrylic, use a shorter blade length.

Save Your Tools From Breaking

If you have high-quality tools that, for some reason, are frequently breaking, then your carving settings are the issue, like the plate material hardness, fixture issues, and motor and rail precision.

Consider Using An Engraving Attachment

Consider using the optional engraving attachment with CNC Jr, Supra, or Baron. The 3D machining capabilities with the attachment will give you more creative opportunities.

Using a CNC machine for cutting will make your work neater and save you both money and time. So follow the tips and get a better grip on CNC.

Do you want to elevate your manufacturing process and improve your results? CAV Tools offers premium manufacturing solutions and tools that can be customized to suit your needs. Click here to get a free custom quote now for Fort Worth, TX and all over the US.

Posted in Cav Tool Blog | No Comments »

Surface grinding is an age-old manufacturing technology that has been around for 100 years or so. The process involves grinding down metal surfaces of different heights and leveling them using a grinding wheel.

At Cav Tool Inc., we specialize in surface grinding to create custom dies and molds for companies in Grand Rapids, MI. Click here to learn more about what we do.

In this article, we will give you a snapshot of how surface grinders work.

What is Surface Grinding?

Surface grinding is the most common grinding process used to refine various kinds of metal and non-metal objects. The concept is simple: the surface grinding operator holds the workpiece (usually metal) to make it perfectly flat. It is an abrasive machining process to grind away varying heights and leveling the workpiece.

Surface Grinding Applications

Surface grinding is used in several industries in Grand Rapids, mostly in the manufacturing sector. You can use a variety of metals and plastics as workpieces to create integrated parts and components with perfect shape and measurements. These include:

• Punches and dies
• Windmills
• Machine frames
• Clutch and gears
• Automobiles
• Railways
• Washers
• Ceramics
• Piston rings

Surfacing grinders also used for power generation.

Anatomy Of A Surface Grinder

A surface grinder comprises of two basic components:

1. Grinding Wheel
2. Rotary Table (or Reciprocating Table)

The grinding wheel is usually made of composite material, like rough or coarse aggregate bonded with a cementing matrix. The wheels spin at high speeds to grind metals into a flat surface.

Grinding wheels don’t always need to be straight. Surface grinding operators also use custom grinding wheel profiles in some instances to create a specific pattern on the surface of the metal. But patterns can be machined with straight grinding wheels as well, depending on the operator’s skill.

There is also a relationship between the workpiece and the grinding wheel.

Sometimes, the material becomes extremely heated, starts to erode, or becomes embedded within the wheel, slowing down the process. This usually occurs with materials like plastic, brass, stainless steel, and aluminum. On the other hand, materials like steel and cast iron usually grind well without any complications.

Talking about the other component of a surface grinder, the table includes the work bed where you place the workpiece for grinding. The material is either clamped down or held tightly with an electromagnet.

The workpiece is placed directly beneath the grinding wheel, which is set at the required speed. The work bed moves in and out while the workpiece is elevated slightly until the whole material is ground. Many surface grinders have hand adjusted dials, while others use hydraulics or electric power to move the work bed.

Of course, modern surface grinders are programmable and require almost no input from the operator once they are set up.

Types of Surface Grinders

There are three basic types of surface grinders:

1. Horizontal-spindle grinders
2. Vertical-spindle grinders
3. Disc grinders

At Cav Tool Inc., we use a variety of surface grinders to create custom molds and dies. Click here to get a free quotation.

Posted in Cav Tool Blog | No Comments »

No matter what business you’re in, you will require some quantities of metal or plastic components. When it comes to metal fabrication, CNC machining is one of the most effective and reliable methods out there.

Components produced by CNC machining are found everywhere, from the car you drive to the device you are using to read this article. And while the technology isn’t new, CNC machining is still widely sought for a range of metal fabrication applications.

CNC machining is one of our specialties at Cav Tool Inc. Companies in Grand Rapids, Michigan, may click here to learn more about the process. Today, we will discuss the business benefits of CNC machining.

Defining Terms

First things first; Computer-numerical control machining, or CNC machining, refers to the process when lathes, routers, grinders, and mills are controlled by a computer as compared to human operators.

There are special computers and programming languages for CNC operations that automate speed, position, coordination, and feed rate. The process also uses several axes at once to produce large quantities of accurate and consistent parts faster than other methods. 

CNC Machining Applications

With computer-controlled machining, the applications are endless. You can work with any quantity of any metal, be it aluminum, carbon, stainless steel, titanium, brass, etc. CNC machining can also be applied to other materials like wood, silver, plastic, etc.

You can use this technique to produce large quantities of fittings, shafts, manifolds, dies, fixtures, and other parts. Other CNC applications include:

• Punching
• Shearing
• Shaping
• Stamping
• Tapping
• Texturing
• Threading
• Turning
• Welding
• Boring
• Contouring
• Cutting
• Drilling
• Engraving
• Facing
• Grooving
• Knurling

In short, you can get any component or product for your business with CNC machining. Industries where CNC machining is used include aerospace, agriculture, automotive, construction, dental, electronics, food and beverage, jewelry, military, printing, and transportation.

Many times, different businesses require the same components, such as valves, panels, and plates. Once again, you can use CNC machining to make the same component for unique usage across different industries.

Benefits of CNC Machining 

Now that you know what computer-controlled machining is and where it is used, here are some of the major benefits of this method:

• Achieve consistency in large orders
• Expedite production orders when you are running short on time
• Produce accurate and consistently matched parts
• Increase your design capabilities
• Enjoy automatic updates
• Works with compatible software programs

Overall, CNC machining benefits your bottom-line by doing the job faster and with greater precision than other methods.

Of course, CNC machines require heavy investment. But they prove cost-effective in the long run. For one thing, these machines require little maintenance, even when used continuously. Moreover, computer-controlled machining reduces the need for human operators, thus saving labor costs.

Want to learn more about the benefits of CNC machining? Click here to talk to our experts at Cav Tool Inc. We use CNC to help companies in Grand Rapids, Michigan, produce custom components, and can do the same for you as well.

Posted in Cav Tool Blog | No Comments »

Jig grinding is one of the best mold manufacturing processes, offering high accuracy and repeatable results. At Cav Tool Inc., we provide high-quality jig grinding services in Detroit, Michigan. Click here to learn more about our competencies, or get a free quote.

An increasing number of manufacturers rely on jig grinding for higher accuracy and repeatability of molds.

In today’s blog post, we will provide an overview of jig grinding and why it excels as a mold manufacturing process.

Jig Grinding vs. EDM

As a parts manufacturing process, jig grinding has always enjoyed a favored position. However, in the 1980s, EDM emerged as a new technology, and mold makers across the country were quick to adopt it. EDM became popular because it offered speed and cost benefits over other mold manufacturing techniques.

Jig grinding operations were considered not only costly (as they required heavy investment), but also labor-intensive. Add to this the fact that jig grinding operators were hard to find. But despite the cost-effectiveness and time-efficiency, EDM could not match the surface finish results and profile tolerances offered by jig grinding. And over the years, jig grinding has sped up, thanks to specialized software.

Nowadays, milling is hailed as an alternative to jig grinding, precisely because of the same reasons that made EDM popular initially.

However, milling also presents challenges as mold manufacturers want to expand their operations, especially when seeking high-quality molds. Overall, jig grinding offers the desired surface finishes and tolerances that manufacturers require.

Modern Jig Grinding

Today, jig grinding operations are faster due to the introduction of specialized hardware and software. The benefits are obvious.

For starters, the software reduces and sometimes even eliminates the need to input data manually, even when calculating detailed geometries. Macros drive start/stop points for cutting, minimizing setup and changeover, speeding up the entire process significantly.

On the hardware end, you have periphery equipment to ensure sub-micron positioning and grinding, as wheel measurement follows each wheel dressing. On the other hand, one can ensure accurate reversal points as scraped and linear guideways provide smooth and consistent dampening points. In turn, this allows for fast grinding action without the risk of bottoming out in blind holes.

Modern jig grinding machines are also capable of high speeds and feed rates that were previously unheard of. This is achieved by optimizing specialized software and the electron-mechanical structure.

Automated Jig Grinding 

Despite all these benefits, the cost is still an issue for manufacturers when considering jig grinding over other processes. Along with hefty installation costs, skilled machine operators are hard to employ as well.

However, both these challenges have been resolved mainly by automating jig grinding with the use of more powerful CNC controllers. Once again, specialized macros take care of various grinding requirements without geometric calculations and hard tooling settings.

Moreover, various patented improvements have practically doubled modern jig grinding machines’ efficiency while reducing wasted movements. This is why machine tool manufacturers prefer jig grinding.

Companies in Detroit can always reach out to Cav Tool Inc. to leverage our jig grinding capabilities for mold making. Click here to get a free quote.

Posted in Cav Tool Blog | No Comments »

Planning to order stamped metal parts in Detroit? Get started on the right foot and find a vendor who can deliver metal parts fast, accurately, and within your budget.

However, before moving on, you should consider how the tool and die design process will influence your parts. And think how in-house metal part design can help your company.

At Cav Tool Inc., we specialize in tool and die design and manufacturing. And today, we will outline the benefits of in-house tool and die design and the various stages of the process. This information will come in handy when you want high-quality parts at the best prices.

Quotation

The first stage of the process is getting a quotation. Pricing stamped metal parts is not easy, as dies are usually customized according to unique designs. A lot goes in quoting the price of dies. These include:

• The type of tool required
• Delivery date
• Quantities/volumes to be produced by the die
• Payment terms
• Location, capacity, and expertise of the vendor

These are some factors to consider when pricing tools and dies. Your vendor must possess a solid understanding of what goes into the design and building process and a firm understanding of sheet metal processing techniques.

Moreover, modern tooling and die making also incorporates intricate die design software. Among these, 3D CAD (computer-aided design) is the most well-known.

To cut a long story short, the design and build can begin once the vendor provides the quote, and you approve it. You may click here to get accurate quotes on our tool and die services.

Designing the Tool

Production begins with designing the progressive die, and the designer optimizes each punch, bend, and hole in the metal intricately. Stock strip design also incorporates CAD techniques. These are used to establish dimensions, feed direction, tolerances, and other key characteristics.

Producing the Tool

The die design begins once the stock strip is complete. The design stage involves detailing each component. Tool materials are also ordered at this stage. 3D CAD is used to machine, ground, and EDM cut die blocks.

This is where you realize the benefits of working with a single, full-service tool designer and manufacturer in Detroit (Cav Tool Inc.). Keeping all the processes in-house helps to avoid delays and quality issues.

Moreover, in-house tool and die design are also cost-effective when you want to get parts to production. Along with helping you save money, it also enables you to save valuable business time. Further cost savings come in the form of reduced material and labor expenses.

In any case, not all companies can invest in die tooling equipment and hiring licensed technicians. That is why it is feasible to work with a die designer and manufacturer who handles all processes in-house.

That’s about it. If you want to learn more in-house tool and die processes, click here to talk to our experts.

Posted in Cav Tool Blog | No Comments »

The punching press is one of the most advanced technologies in metal fabrication. Its wide-ranging applications have made it the Swiss army knife of manufacturing. Thanks to the latest tooling and machinery, you can use a punch press to:

• Punch holes in a thick perforation
• Cut large panels
• Bend high flanges
• Form complex shapes like embosses and louvers

But with so many applications, sheet metal punching is a widely misunderstood technology. As experienced punching specialists in Detroit, Michigan, we often get many questions from our clients about sheet metal punching.

And that is why today, we have assembled a blog post to answer these FAQs. You may also click here to learn more about our metal punching services at Cav Tool Inc. or get a free quote.

Q1. What is Sheet Metal Punching?

Punching is one of the most common processes in sheet metal processing and fabrication. Modern punching processes employ CNC machines and punching presses to create holes of any shape and size.

Q2. How Does It Work?

The metal piece is inserted in a punching press. One the one hand, you have the punch that passes through the sheet metal. On the other side of the sheet is the die that ensures accurate holes without breaking the metal.

Q3. What Materials Can Be Used For Punching?

Modern sheet metal punching techniques allow you to punch all kinds of metals, including:

• Iron
• Stainless Steel
• Aluminum
• Copper
• Brass
• Special Alloys

And since the punching press has enough force to fabricate metals, it can also be used to punch other materials, such as plastic.

Q4. Which Industries Can Use Punching Technology?

Metal punching is applicable to a wide range of industries, including:

• Engineering
• Pharmaceutical
• Automotive
• Manufacturing
• Electronics
• Textile
• Aviation

The more specific the application, the more customized the punches. Click here to place an order for custom punches in Detroit, Michigan.

Q5. Are Different Punches Required for Different Shapes?

 Not necessarily. Modern tooling technology allows you to create custom dies and molds to create shapes and holes of all sizes and designs. But you can also punch holes of your desired shape and size by using a combination of existing dies. If a combination doesn’t give you the desired results, you can order a specific mold. The possibilities are endless.

Q6. Are Punching Tools Durable?

Punching tools are durable as they are made from high-strength materials like tungsten carbide. On average, punching tools are useful for up to 600,000 strokes. A stroke refers to the punching action in a press. Of course, regular lubrication and cleaning will ensure an even longer life for dies and punching tools. Sharpening may also be required to provide power and precision when punching holes.

At Cav Tool Inc., we use state-of-the-art equipment for high-quality punching and tooling solutions. We also employ CNC punching machines that allow automated punching operations while making the process even more efficient.

Posted in Cav Tool Blog | No Comments »

Want to know how ‘punching’ works in the manufacturing industry? You have come to the right place! Punching is one of our specialties at Cav Tool Inc., and you may click here to place a punch manufacturing order in Detroit, Michigan.

Today, we give our readers an overview of what industrial punching is all about. Learning more about the process will help you place accurate punch-making orders, among other benefits.

What is Punching?

To begin with, punching refers to a metalworking process where holes are punched through a workpiece, usually a metal sheet. This is different from ‘blanking,’ a process where a metal sheet or any other workpiece is separated from the primary metal strip or sheet.

Punching can be done by hand or a machine. The latter is, of course, the preferred method as machine punching can create holes in the thickest and hardest of materials.

Why Punch Metal?

Manufacturing companies may perform punching when they want to create holes in metal workpieces. Punching is a popular metalworking process that offers several benefits.

For starters, punching is the most effective method for creating holes in metal workpieces. Moreover, you can get holes punched in any number of shapes by using different die pieces. Not to mention, it is a fast process, and holes are punched with great force and accuracy within seconds.

Punches are used in a wide range of industries, including construction, food, hygiene, and pharmaceuticals. In the past few years, punching has also been gaining relevance in the aerospace and electronics industries to process metal foils.

Another application of punching is waste removal during the manufacturing process.

As you can see, this process has several applications across a wide range of industries.

How Punching Works

The punching tool is made from high-strength material, such as tungsten carbide. Holes are punched by aligning the workpiece between the punching tool and the die. Once the metal workpiece is aligned, the punching tool is pressed upon it and creates a hole of the same shape as the die.

Along with high-strength metal, the punching machine is also powered by hydraulic pressure, which allows for greater punching force. Overall, punching is a simple and effective way of punching holes of any size and shape on metal sheets.

Industrial punching techniques have improved over the years. Previously, punching was only performed by hand with specialist tools. But machine punching is the norm nowadays. In fact, CNC punching machines allow automated punching operations while making the process even more efficient.

Also remember that while punching is mostly performed on metal workpieces, the same process can also be applied to plastic. This is usually done at the final stages of assembly to remove excess plastic from workpieces. You can also perform punching on packing materials, compounds, leather, and metal sheets.

This concludes our overview of industrial punching, and we hope you now have an idea of the process works. Companies in Detroit regularly reach out to us for their punch manufacturing needs. Click here to talk to our punching experts at Cav Tool Inc. 

Posted in Cav Tool Blog | No Comments »

Tool and die technology is still the backbone of industry all over the world. However, most businesses are unaware of how the technology works and how it can benefit their operations.

Learning the basics of tool and die making will help you order the best tools, dies, molds, etc. for your unique production needs. At CAV Tool, we offer the best tool and die manufacturing services in Detroit. Click here to get a quote.

And today, we provide our readers with an overview of the tool and die technology.

Definition of Terms

As per the Department of Labor, ‘tool-making’ refers to the production of tools, dies, and special guiding and holding devices to enable machines to manufacture specific products. These products include everything from clothing to heavy machinery, and from phones to aircraft. 

‘Stamping dies’ refers to dies that stamp, coin, emboss or form material in a press. The three major types of dies are Single Hit, Transfer, and Progressive dies. Stamping dies can fabricate sheet metal in a press to create parts and products for various industries, such as automotive,

agriculture, telecommunications, construction, appliance, and HVAC, etc.

The hydraulic or metal press consists of two sections, called punch and die. They are also referred to as ‘male’ and ‘female.’ The punch is mounted on the press ram, and it is pressed into the fixed die section. The metal sheet that is placed in between is then cut or shaped into a specific form. 

Like the dies, the presses also come in a variety of sizes, depending on the application. Presses in automotive industries can be as high as three stories. They are capable of pressing with substantial force to stamp the roof of vehicles. 

Tool and die technology also involve creating molds for plastic products and other materials. The main difference between die casting and molding is that the latter doesn’t require force. 

Tools and die-makers undergo specialist training and are employed to create prototypes of products, produce specialized machine tools, and modify and repair existing tools.

Benefits of Die and Tool Technology

While investing in die tooling requires a substantial investment, it offers several benefits to businesses. These include:

• Increasing production quantities significantly. 
• Ensuring repeatability, i.e., all parts will be the same.
• Reducing material costs
• Lower labor costs as less time is spent fabricating parts.

Of course, investing in die tooling equipment and technicians is not feasible for all companies. Which is why you can consider partnering with a manufacturing company. 

How To Choose a Tool and Die Builder

The choice of a tool and die building company depends on several factors. You need to consider your budget as well as production estimates.

Safety concerns are also significant. Your tool and die builder should have excellent references and experience. They should also offer suggestions and help you mitigate potential problems.

For companies in Detroit, CAV Tool is a one-stop-shop for all die and tooling needs. Click here to get in touch.

Posted in Cav Tool Blog | No Comments »