Services.

 

Here are some of the services we provide. This page gives a brief description of some of the processes which are commonly used in the manufacture and finishing of parts.

Design Service.
 

Machine Shop Ireland can offer a design service which creates detailed technical drawings of your parts for manufacture. This service also allows advice on material selection, machining processes etc to be supplied. Working with you to allow your parts to be successfully made in the most cost effective manner at the required accuracy to ensure your project is successful. Sometimes small design changes have a huge affect on the machining process and so the cost of the part. We can work with you to identify these.

 

Drawings or sketches can be attached to your "Request for Quotation" for review. If you have hand sketches please scan them and attach them as pdf. 2d Cad formats such as dwg, dxf are catered for as well as 3d formats such as iges, step. 

 

Our team has years of experience in design and manufacture of custom components,

We have learned it the hard way so you don’t have to.

 

 

 

Cnc Milling.
 

Our team has years of experience in design and manufacture of custom components,

We have learned it the hard way so you don’t have to.

Cnc milling and turning are the most common methods of metal removal for the manufacture of machined parts. 

 

Cnc milling machines work by rotating a cutting tool in a spindle, this moves in a 3 dimensional tool path removing material from the part until the required shape is created.

Cnc milling is cost effective; it can produce most 2d and 3d shapes. It can hold tight tolerances and give good surface finish.

 

Tips for Cnc Milling.

Try to create holes, pockets, features on one side of the part. This will reduce set ups.

Avoid long thin sections as it makes the part hard to hold.

Avoid internal sharp corners, allow radius of 10% of wall height.

Avoid large quantities of metal removal; it might be more cost effective to split the design into two parts.

 

Click Here for more information on Milling.
 
Cnc Turning.
 

Cnc Turning work by clamping the work piece in a chuck and rotating it, while the cutting tool moves in a 2 dimensional tool path to create the desired shape.

Cnc Turning is a cost effective way of producing parts that are symmetrical around an axis, i.e. shafts, threads, tapers, internal tapers etc.

 

Tips for cnc turning.

Avoid long thin shafts if possible.

Avoid large quantities of metal removal; it might be more cost effective to split the design into two parts.

 

Click Here for more information on Turning.
 
Wire EDM.
 

A Wire EDM can produce parts to high dimensional accuracy. It used an electrified wire which sparks against the grounded work piece and erodes it. It can be used for almost any 2d parts. It can also generate almost sharp internal corners. 

Wire edm can cut hardened material.

Although wire edm has advantages, it can be expensive to utilise.

 

Tips for EDM.

Reduce cut surface.

Reduce number of holes / cut-outs.

Wire Edm will cut hardened materials just as easily as soft,

 

Click Here for more information on EDM.

 

Grinding.

 

Surface grinding is used to create a flat surface on the face of a work piece. The work piece is usually fixed to a table and moved in the X-Y direction under the grinding wheel. This produces a precision flat surface on the top face of the work piece. 

 

Tips for surface Grinding.

Reduce tolerances on ground part.

Reduce area that requires grinding.

Ensure the highest point is the surface which requires grinding.

A lot of surface grinders utilise a magnetic table to hold parts while grinding. This only works on magnetic material. (Non magnetic material can be ground in a vice)

 

Click Here for more information on Grinding.

 

Heat Treatment.
 

Heat treatment involves heating and cooling a material to alter is physical properties. Hardening is carried out to increase the strength and hardness of a material to increase its resistance to wear. In order to Harden material it must contain sufficient carbon content.

Usual materials for hardening are:

Tool Steels A2, D2

Stainless Steel   420, 440

 

Once material is hardened it can become brittle. To resolve this Tempering can used to reduce hardness slightly but also increase toughness (less brittle).

 

Tips for Heat Treatment.

Select the correct material.

Grinding after heat treatment can achieve very tight tolerances.

It is hard to machine hard materials; Grinding and EDM can be used.

 

 

Click Here for more information on Heat Treatment.

 

Anodising.

 

Anodising is usually used on Aluminium Parts. It creates an oxide layer which protects the parts from further oxidisation. The anodised layer can be created in a number of colours to suit the aesthetic needs of the part. The anodised layer will increase the thickness of the part slightly, which will only cause problems if trying to achieve tight tolerances, It can also cause problems in small tapped holes. These can be protected by plugging for anodising or retapping after anodising to recreate the threads.

Hard anodising can be utilised to create a hard ware resistant surface. This is usually grey in colour and is thicker than standard anodising. 

 

Tips for Anodising:

Surface defects will not be covered by anodising,

Anodising will increase part thickness, reduce hole internal diameter.

Anodising different grades of Aluminium can create different shades of colour.

 

 

 

Click Here for more information on Anodising

 

Powder Coating.
 

Powder coating is applied as a charged dust which sticks to an oppositely charged part. The dusted part is then placed in an over to heat the coating which forms a skin over the part.

Powder coating can be supplied in a large range of colours. It provides a robust and wear resistant finish.

Click Here for more information on Powder Coating.
Waterjet cutting
 

Water jet cutting is a fast and efficient way of cutting out 2d parts. It uses high pressure water to cut through the metal. Water jet creates a small kerf as it cuts through the metal. This is due to the fanning effect of the water flow as it passes through the material. Tolerances are not as accurate as other methods (milling), but is more cost effective. Water jet is better for Aluminium as it gives a better edge finish than laser cutting in softer materials. 

Click Here for more information on Waterjet Cutting.
 
Laser Cutting.
 

Laser cutting is a fast and efficient way of cutting out 2d parts. It is similar to waterjet, but uses a laser to cut the metal instead of a water jet. Lasers are commonly used for thinner materials such as stainless steel. It can produce a good surface finish but does have some kerf, which is more noticeable when cutting thicker materials. 

 

Metal folding and welding

 

Sheet metal can be folded to produce a variety of shapes. This is done on a break press which presses the metal to create a fold on selected lines to bend the metal as required. Once the folding is complete the work piece can be welded. This could be done to make the work piece more rigid, add extra pieces to create an assembly, or to seal the edges to create a tank.

Sheet metal can prove to be a cost effective alternative to machining for some applications.