Engineer’s Insight: How We Improved CNC Tolerances in One Year
In the competitive field of high-tech manufacturing, staying ahead means continuously refining processes and investing in the most advanced technology. Ductile CNC micromachining has improved the machining of technical ceramics and glass by achieving better surface finishes, higher dimensional accuracy, and reducing sub-surface damage. While traditional grinding and polishing remains essential for specific applications, CNC ductile milling expands our capabilities, allowing for even higher precision and efficiency.
LouwersHanique has been at the forefront of these advancements, integrating the Kern machine into production for over a year. This investment has strengthened our position as a leader in the field, giving us the ability to manufacture technical ceramic and glass components at an unprecedented micron-level precision. To evaluate the impact, we spoke with our Senior Production Engineer who has been leading this initiative.An Interview with LouwersHanique’s Senior Production Engineer: Evaluating the CNC ductile machining Performance
An Interview with LouwersHanique’s Senior Production Engineer: Evaluating the CNC ductile machining Performance
Q: How has the CNC dutile machining elevated LouwersHanique precision in technical glass and ceramic manufacturing?
"The biggest improvement we've seen is in flatness and surface roughness. While we already achieved tight tolerances, the CNC ductile machining allows us to go even further. For example, we can now reach 1.5 microns in SiSiC for a 75 mm component and 2 microns in Zerodur for a 100x100 mm sophisticated mechatronics part. This puts us at the cutting edge of precision manufacturing."
Q: Can you elaborate on the improvements in surface roughness?
"Absolutely. Previously, side polishing allowed us to reach a roughness (Ra) of 0.4 micrometres. Now, we can reach an Ra of 0.15 micrometres. This advancement is crucial for industries requiring high-performance surfaces, such as semiconductor and aerospace applications."
Q: What materials have we worked with so far?
"We have successfully worked with SiSiC (Silicon-Infiltrated Silicon Carbide) and Zerodur, both key materials in high-precision industries. However, this machine is capable of processing any hard, brittle material as Sapphire and Aluminum Nitride, further expanding our range of possibilities.
Q: What are the biggest advantages of using the CNC ductile machining compared to other methods?
"It complements our existing processes by enabling the production of smaller and more intricate features with higher accuracy. Our other grinding techniques remain valuable for many applications, but CNC ductile milling and jig grinding will meet the highest industry demands. Additionally, by performing multiple operations in one machine, we reduce handling, minimizing the potential for human error and breakage, enhancing both efficiency and consistency."
Q: Can you give examples of the products we've manufactured with this technology?
"We've successfully produced mirror blocks and mechatronic components, both of which require extreme precision. Ductile CNC machining allows us to meet these stringent demands while ensuring repeatability."
Why LouwersHanique Stands Out: Advantages of Ductile CNC Micromachining
- Unmatched Precision and Surface Quality: Ductile CNC micromachining minimizes sub-surface defects, preserving material integrity and strength (Yan et al., 2012). Our enhanced capabilities allow us to achieve industry-leading flatness and roughness standards.
- Optimized Surface Finish: The ability to reach polished-like surfaces directly from the machining process improves functional performance and eliminates unnecessary secondary steps.
- Reduced Contamination: Lower contamination levels enhance cleanability, a critical factor for semiconductor, aerospace, and medical applications.
- Superior Dimensional Accuracy: Precise control over cutting parameters ensures exceptional profile accuracy and dimensional stability.
- Minimized Chipping and Defects: Ductile machining prevents chipping-related issues, ensuring high-quality, reliable components.
Conclusion
With the integration of the CNC ductile machining technology,, LouwersHanique continues to set new benchmarks in high-precision manufacturing. This technology, combined with our extensive expertise in technical glass and ceramics, allows us to deliver components that exceed industry standards. With our other machining capabilities and combined technologies we can push the boundaries of precision and efficiency even further.
Our commitment to continuous improvement ensures that we remain at the forefront of the semiconductor, aerospace, and high-tech industries, providing cutting-edge solutions for the most demanding applications.
