Photo Story: Current Trends in Machining

Machining puts the finishing touches on a casting – smoothing out rough edges to improve the surface area, removing excess material to meet tight tolerances, and adding shine. In recent years, advancements in Computer Numerical Control (CNC) technology, 5-axis machining and automated processes have been major drivers in foundry machining. Foundries like Stainless Foundry & Engineering (SF&E) offer castings produced using state-of-the-art CNC machining centers and cutting-edge equipment to meet the high spec demands of industries including aerospace, military & defense, power generation, petrochemicals, pulp & paper, and oil & gas.

Emphasis on Precision and Efficiency

One of the main trends in machining today is the focus on precision. SF&E leverages high-precision CNC machines that can handle X-axis travel of up to 200 inches and workpieces weighing thousands of pounds, which ensures accurate manufacturing of large and complex parts. These machines allow for tight tolerances, which are essential when dealing with post-casting machining to meet final specifications. Modern machining technologies reduce the need for extensive manual intervention, improving performance, productivity, and safety.

Machined parts for the aerospace industry (left). Machined ball valve housing and closed impeller used in the oil and gas industry (right).

Automation

SF&E utilizes automated processes like CNC Swiss machining, where high precision is needed for small, intricate parts, often down to diameters as small as 0.045 inches. This not only speeds up production but also ensures high repeatability, making it suitable for industries requiring mass production. Parts can be produced in high volume for cost efficiency and peace of mind, then stored at SF&E as part of an inventory stocking program.

Machined impeller for the food and beverage industry (left). Machined gearbox used for the defense industry (right).

Customization and Adaptability

There is also a growing demand for custom machined parts. SF&E offers customization in machining operations, allowing for quick adjustments in tolerances and dimensions based on specific client needs. This flexibility is crucial in industries like nuclear energy and petrochemicals, where components often need to be tailored to meet unique environmental and operational conditions.

We leverage the expertise of preferred partners including Strohwig Industries, which serves as an extension of our in-house team. When SF&E poured the largest nuclear impeller in its history, we needed a precision machining partner to finish the 6,700 pounds pour weight of CA6NM martensitic stainless steel. Without Strohwig’s capabilities, this part would have been delivered to the customer with rough machining they would need to finish themselves. Just another example of the value-added, customer-first approach at SF&E!

Nuclear impeller in the process of being machined.

Dimensional Tolerances and Finishing

The importance of machining allowances and dimensional tolerances cannot be overstated. Depending on the size, shape, and hardness of the material, varying machining allowances are needed to account for warping and other casting imperfections. SF&E employs advanced techniques in both rough and finish machining to ensure that the final products meet precise specifications without compromising structural integrity. This trend towards more controlled and precise machining ensures that foundries can produce parts that are both high in quality and durability.

Machined valve body used in the defense industry (left). Machined and painted parts used in the pulp and paper industry (right).

Non-destructive Testing

Many SF&E customers looking for casting and machining services also require non-destructive testing (NDT) validation to ensure the working surface of the machined parts are clear of defects. SF&E offers liquid penetrant inspection (PT) and magnetic particle inspection (MT) for all finished machined castings to ensure a sound and compliant casting. Once the final NDT passes, SF&E also provides dimensional inspection, including calipers, height gauges, Farro Arm, and CMM. This is a critical step for machined components so customers can receive and implement the component in their pump or valve.

The future of machining in foundry operations is leaning heavily on automation, precision, and efficiency. With the continuous development of advanced CNC technology, NDT, and a focus on customization and quality, foundries like SF&E are well-equipped to meet the growing demands of modern industries.

If you are looking for a turn-key foundry partner that can serve your needs for casting, machining, and testing high quality parts, contact us today.

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