Why is Manual casting machine for small batches Better?

CNC machining has become the central pillar of modern manufacturing processes. Most industries rely on this technology to handle the needs of multiple stages of production. From prototyping to mass production, CNC machining can do it all.

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However, many professionals wonder how this technology fares against other alternatives. One of the most queried comparisons is the performance of CNC machining vs manual machining process. This article will have a side-by-side overview of these two technologies and see how they perform on every parameter that matters.

What is the Difference Between CNC Machining and Manual Machining?

While Computer Numerical Control (CNC) machining and manual machining do the same thing, the way they do it and the quality of the final product are quite different. Let us have a brief overview of these two technologies before going into the details of each:

What is CNC Machining?

Computer Numerical Control machining, or CNC machining, is the manufacturing process where a cutting tool is controlled by an automated system to remove material from a workpiece. It is a scalable process that can do everything from prototyping to mass production. It was introduced in the middle of the 20th century and the technology pickup up speed with the development of computer science.

What is Manual Machining?

Manual machine, as the name suggests, uses human labor to control the cutting tool and remove material from the workpiece. The cutting tool in this process can be simple or complex, but the relative movement is done by an operator.

CNC Machining vs Manual Machining- Advantages and Disadvantages

Computer Numerical Control machined parts and manual machined parts have quite a difference among them. These differences can be often spotted in visual inspection of the completed parts or by comparing their production numbers. Here are the advantages and disadvantages of each process to make it clear what you should expect:

Advantages of CNC Machining

CNC machines provide benefits such as:

• CNC machines have a fast production speed.
• Due to the fast production speed, manufacturers can remove bottlenecks from supply and fulfill large-scale manufacturing demands.
• The safety involved in the process is very high since human labor does not have to manually handle the product.
• Due to the precise movement of the cutting tool in as little increments as desired, there is very high precision in the process.
• Since there are no humans operating the cutting tool, there is no possibility of human error.
• The workforce, and thereby the labor costs, are significantly reduced. This manufacturing method only requires one CNC machinist which can oversee the entire CNC operation. In fact, a single CNC machinist can handle multiple CNC machines.
• Since there are no human errors and everything is monitored by automated systems, there are less chances of machine breakdowns leading to reduced maintenance costs.
• It is possible to create highly complex and intricate designs.
• CNC machines take consistency to the next level and all the parts look exactly the same. This is quite desirable in mass production.
• Due to the high precision, research and prototyping sector can visualize what the final product would exactly look like.
• Due to faster production, CNC machining can utilize energy in a better way.
• CNC machines are easier to upgrade, by simply upgrading the software of the machine.
• Since machines are controlled by the software, a single operator can operate multiple machines simultaneously.
• These machines are highly versatile and a single machine shop can work on a large number of materials.
• Due to the reduction of maintenance costs and operating costs, the production costs are decreased. This generates a bigger profit for the manufacturers.
• CNC machining is a reliable process. The machine monitors factors such as temperature and coolant control, so there are fewer breakdowns. In case of breakdowns, many machines can even self-diagnose the issue for faster resolution.
• Complex projects, such as those requiring a multi-axis milling machine, cannot be done properly with manual machines.

Disadvantages of CNC Machining

While CNC machining is the best option when it comes to manufacturing, there can be certain drawbacks to the process as well. These drawbacks are:

• CNC equipment requires high initial investment since the machines are costly. Installation costs are another major factor to consider.
• There is an added stage of computer programming which requires a skilled programmer to create the codes for the compoenents.
• The quality of machine operations are dependent on th operator skill. Therefore, a skilled machinist is required for good outcome.
• While breakdowns are fewer, in case a breakdown manufacturers need to call a highly skilled professional.
• Due to higher automation and a reduction in labor requirements, unemployment is increased.
• After parts are programmed, there is the need of debugging and error detection so that the CNC machines do not crash during operation. The debugging part requires added time and skills.

Advantages of Manual Machining

Manual machining processes have been ongoing since many centuries. They offer benefits such as:

• Manual machining has a low initial investment cost. Therefore, even small machine shops can purchase the equipment without second thoughts.
• There is no need for programming to machine the parts. The machinist can work on the part directly.
• For small projects or one-off orders, the turnaround time is reduced since the machinist does not have to go through programming phase.
• Manual machining can handle customization well since small changes in projects do not require starting from scratch.
• The machinist does not have to be skilled in operating computerized panels.
• In case of breakdowns, machines like manual milling are easy to fix and the cost of repairs is low.

Disadvantages of Manual Machining

Manual machining can have several drawbacks for manufacturers, such as:

• The manufacturing rate of this process is quite slow. What CNC machining can do in a few minutes can require hours of manual machining.
• It cannot handle the modern large scale production requirements and numbers.
• The precision of manual machining is quite precision and incorporates human errors.
• Due to a lack of precision and higher possibility of error, there are more rejections. This leads to higher waste and increased costs.

How to Choose Between CNC Machining vs Manual Machining?

While a CNC machine and a manual machine does the same thing, they are each suitable for different parts and production scales. Here are the applications for each technology:

Applications of CNC Machining

CNC machines are best suited for use cases like:

• A CNC machine is a must have for large scale production of parts. For instance, screw threads require a CNC lathe or CNC mills and using any other process such as manual lathe or manual mill will dramatically slower the production and wouldn’t be worth the cost of the project.
• In the case of prototyping, manufacturers want the prototype to resemble the final parts so they can study the characteristics and defects. For this purpose, CNC lathe, CNC mills, and other CNC equipment are preferred for prototyping tasks.
• For rapid tooling applications, CNC machining is preferred over manual lathes or manual milling machines. This is because rapid tooling works on very hard metals and alloys where manual tooling becomes hard to use due to poor machinability of materials.
• For highly complex parts, manual machines will not get the job done. Multi-axis CNC lathe and CNC milling machines are chosen for such projects. Examples include complex components in the military and aerospace industries.

Applications of Manual Machining

Manual machines can be the better solution for applications like:

• Smaller projects find better utilization of manual milling machine, manual lathe, and other manually operated equipment. This is because for smaller projects, the cost of the project is not big enough to cover the initial investment in a CNC machine.
• For less number of parts such as 1 to 10, manual machines are a better option since there is not enough margin to hire programming teams and create CAD and CAM models of the part.
• For short turnaround time of small manufacturing batches, manual machines are preferred since there is no time for extra steps such as programming.

What is the Cost Difference Between CNC Machining and Manual Machining?

The cost of CNC machining and manual machining services is a wide bracket, depending on a multitude of factors. If you are considering the cost of the machine alone, manual milling machines can start at around $, and CNC milling machines can start at around $.

Each of them can go up to hundreds of thousands of dollars, with CNC milling being a more expensive option by a major margin.

Similarly, a manual lathe can start at around $ while CNC lathes will cost upward of $.

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If comparing the hourly costs of each, manual machining services can cost around $40 per hour.

On the other hand, CNC machining services can cost somewhere around $80 per hour for a 3-axis machine, and rise up as the requirements become more complex.

While comparing the hourly costs, an important thing to remember is that the CNC machining will have an exponentially higher output than manual machining equipment.

How to Decide If CNC or Manual Machining is Better For Your Needs?

Deciding whether to use CNC machining vs manual machining mainly depends on your requirements and production goals.

If you only want to produce a one-off product for a custom project, manual machining can be a better option. However, for a proper production run or getting high precision parts, CNC machining is the way to go.

If the high initial cost of CNC machines dissuades you from using this technology, opting for 3ERP’s CNC machining can be a great solution. With 3ERP, you get to choose a wide array of options such as multi-axis CNC machines, 3-axis CNC machines, CNC milling machines, CNC lathes, and many other manufacturing options.

All these options come without the high cost of the equipment itself, which provides you with good quality and high precision components minus the added costs of the same.

Conclusion

CNC machines have overtaken most of the market of manual machine tools. Even so, machines like the manual milling machine are preferrable for some operators due to the lack of programming requirements and the ease of setup. However, when the requirement is of mass production, there is nothing better than CNC machining services.

Frequently Asked Questions

Here are the answers to some common questions regarding manual vs CNC machining:

1. Is CNC machining safer than manual machining?

Yes, CNC machining definitely provides a higher safety than manual machines. This is because most of the work in machines like the manual mill are done with human workforce. However, a CNC machine has automation of the cutter, keeping the operators at safe distance.

2. Is CNC machining suitable for a wide range of materials and applications?

Yes, CNC machines is one of the most versatile manufacturing process out there. CNC machining equipment, like the CNC mill, can work on every type of material be it metals, alloys, wood, plastics, ceramics, and even glass. This expands its applications more than other popular manufacturing technology like injection molding.

3. Is CNC more accurate than manual machining?

Yes, CNC machining has a very higher accuracy than manual machines. A CNC machine can provide an accuracy on a microscopic level, which is not possible through manual machines due to human limitations of the latter. This is why CNC machining equipment such as the CNC mill is used where tolerances need to be kept to a minimum.

Casting processing is a process in which molten metal liquid that meets the requirements is poured into a specific casting mold, and the desired shape, size, and performance are obtained after cooling and solidification. It is widely used in aerospace, automobile, machine tool manufacturing and other industries because of its excellent characteristics such as easy molding, low cost, and less time consumption.
Casting technology in our country is not a new technology, but a cultural heritage with a long history. However, the current traditional casting process has been unable to meet the modern needs for casting products in terms of design quality and design concepts. Therefore, how to create new casting process technology requires in-depth discussion and research. Compared with other processing and forming methods, the precision of the casting process is poor, and the structural properties are not as good as forging. Therefore, how to improve the accuracy of castings and optimize their structural properties is also worthy of attention and research.
The material for the mold can be sand, metal or even ceramic. Depending on the requirements, the methods used will vary. What are the characteristics of each casting process? What kind of products are suitable for it?
1. Sand casting
Casting material: various materials
Casting quality: tens of grams - tens of tons to hundreds of tons
Casting surface quality: poor
Casting structure: simple
Production cost: low
Scope of application: The most commonly used casting methods. Hand molding is suitable for single pieces, small batches and large castings with complex shapes that are difficult to use a molding machine. Machine modeling is suitable for medium and small castings produced in batches.

Process characteristics: Manual modeling: flexible and easy, but has low production efficiency, high labor intensity, and low dimensional accuracy and surface quality. Machine modeling: high dimensional accuracy and surface quality, but high investment.
Sand casting is the most commonly used casting process in the foundry industry today. It is suitable for various materials. Ferrous alloys and non-ferrous alloys can be cast with sand molds. It can produce castings ranging from tens of grams to tens of tons and larger. The disadvantage of sand casting is that it can only produce castings with relatively simple structures. The biggest advantage of sand casting is: low production cost. However, in terms of surface finish, casting metallography, and internal density, it is relatively low. In terms of modeling, it can be hand-shaped or machine-shaped. Hand molding is suitable for single pieces, small batches and large castings with complex shapes that are difficult to use a molding machine. Machine modeling can greatly improve surface accuracy and dimensional accuracy, but the investment is relatively large.
2. Investment casting
Casting material: cast steel and non-ferrous alloy
Casting quality: several grams---several kilograms
Casting surface quality: very good
Casting structure: any complexity
Production cost: In mass production, it is cheaper than completely machining production.
Scope of application: Various batches of small and complex precision castings of cast steel and high melting point alloys, especially suitable for casting artworks and precision mechanical parts.
Process characteristics: dimensional accuracy, smooth surface, but low production efficiency.
The investment casting process originated earlier. In my country, the investment casting process has been used in the production of jewelry for nobles during the Spring and Autumn Period. Investment castings are generally more complex and are not suitable for large castings. The process is complex and difficult to control, and the materials used and consumed are relatively expensive. Therefore, it is suitable for the production of small parts with complex shapes, high precision requirements, or difficult to perform other processing, such as turbine engine blades.

3. Lost foam casting
Casting material: various materials
Casting mass: several grams to several tons
Casting surface quality: good
Casting structure: more complex
Production cost: lower
Scope of application: more complex and various alloy castings in different batches.
Process characteristics: The dimensional accuracy of the castings is high, the casting design freedom is large, and the process is simple, but the pattern combustion has certain environmental impact.
Lost foam casting is to bond and combine paraffin or foam models similar in size and shape to the castings into model clusters. After brushing with refractory paint and drying, they are buried in dry quartz sand and vibrated to shape, and poured under negative pressure to vaporize the model. , a new casting method in which liquid metal occupies the position of the model and solidifies and cools to form a casting. Lost foam casting is a new process with almost no margin and accurate molding. This process does not require mold taking, no parting surface, and no sand core. Therefore, the casting has no flash, burrs and draft slope, and reduces the cost of mold cores. Dimensional errors caused by combination.
The above eleven casting methods have different process characteristics. In casting production, corresponding casting methods should be selected for different castings. In fact, it is difficult to say that the difficult-to-grow casting process has absolute advantages. In production, everyone also chooses the applicable process and the process method with lower cost performance.
4. Centrifugal casting
Casting material: gray cast iron, ductile iron
Casting quality: tens of kilograms to several tons
Casting surface quality: good
Casting structure: generally cylindrical castings
Production cost: lower
Scope of application: small to large batches of rotating body castings and pipe fittings of various diameters.
Process features: Castings have high dimensional accuracy, smooth surface, dense structure, and high production efficiency.
Centrifugal casting refers to a casting method in which liquid metal is poured into a rotating mold, filled and solidified into a casting under the action of centrifugal force. The machine used for centrifugal casting is called centrifugal casting machine.
The first patent for centrifugal casting was proposed by the British Erchardt in . It was not until the early twentieth century that this method was gradually adopted in production. In the s, our country also began to use centrifugal tubes and cylinder castings such as iron pipes, copper sleeves, cylinder liners, bimetallic steel-backed copper sleeves, etc. Centrifugal casting is almost a major method; in addition, in heat-resistant steel rollers , some special steel seamless tube blanks, paper machine drying drums and other production areas, the centrifugal casting method is also used very effectively. At present, a highly mechanized and automated centrifugal casting machine has been produced, and a mass-produced mechanized centrifugal pipe casting workshop has been built.
5. Low pressure casting
Casting material: non-ferrous alloy
Casting quality: tens of grams to tens of kilograms
Casting surface quality: good
Casting structure: complex (sand core available)
Production cost: The production cost of metal type is high
Scope of application: small batches, preferably large batches of large and medium-sized non-ferrous alloy castings, and can produce thin-walled castings.
Process characteristics: The casting structure is dense, the process yield is high, the equipment is relatively simple, and various casting molds can be used, but the productivity is relatively low.
Low-pressure casting is a casting method in which liquid metal fills the mold and solidifies into a casting under the action of low-pressure gas. Low-pressure casting was initially mainly used for the production of aluminum alloy castings, and later its use was further expanded to produce copper castings, iron castings and steel castings with high melting points.
6. Pressure casting
Casting material: aluminum alloy, magnesium alloy
Casting quality: several grams to tens of kilograms
Casting surface quality: good
Casting structure: complex (sand core available)
Production costs: Die-casting machines and molds are expensive to make
Scope of application: Mass production of various small and medium-sized non-ferrous alloy castings, thin-walled castings, and pressure-resistant castings.
Process characteristics: Castings have high dimensional accuracy, smooth surface, dense structure, high production efficiency, and low cost, but the cost of die-casting machines and molds is high.
Pressure casting has two major characteristics: high-pressure and high-speed filling of die-casting molds. Its commonly used injection specific pressure is from several thousand to tens of thousands of kPa, or even as high as 2×105kPa. The filling speed is about 10-50m/s, and sometimes it can even reach more than 100m/s. The filling time is very short, generally in the range of 0.01-0.2s. Compared with other casting methods, die casting has the following three advantages: good product quality, high dimensional accuracy of castings, generally equivalent to grade 6 to 7, or even up to grade 4; good surface finish, generally equivalent to grade 5 to 8; strength It has higher hardness, and its strength is generally 25~30% higher than that of sand casting, but its elongation is reduced by about 70%; it has stable dimensions and good interchangeability; it can die-cast thin-walled and complex castings. For example, the current minimum wall thickness of zinc alloy die-casting parts can reach 0.3mm; the minimum wall thickness of aluminum alloy castings can reach 0.5mm; the minimum casting hole diameter is 0.7mm; and the minimum thread pitch is 0.75mm.

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