Introduction(steel vs titanium strength Bishop)

  • Time:
  • Click:9
  • source:DAHLER CNC Machining
CNC (Computer Numerical Control) machines are automated milling machines that are programmed to accurately machine parts and components. CNC machines are used across many industries like aerospace, automotive, medical, and more for their precision, speed, consistency, and efficiency. When considering adding CNC capabilities, one of the biggest factors is determining the costs associated with purchasing and operating CNC machines. In this article, we’ll break down the key cost factors to consider when evaluating CNC machines.
Machine Purchase Costs
The upfront purchase price of a CNC machine represents a significant part of the overall investment. Costs vary widely based on the size, capabilities, and features of the machine. Key factors that influence cost include:
- Machine Size - The overall footprint and work envelope determine how large of parts the CNC can machine. Larger machines cost more.
- Number of Axes - More axes (3-axis, 5-axis, etc.) equates to more complexity and capabilities. 5-axis machines are more expensive than 3-axis.
- Precision/Accuracy - More precise machines with tighter tolerances cost more.
- Power and Speed - Faster/more powerful spindles and axis motors equate to higher costs.
- Material Capabilities - Machines optimized for harder materials like titanium or steel cost more than aluminum-cutting machines.
- Brand Name - Well-known CNC brands like Haas and Okuma carry a price premium over lesser-known brands.
- Automation Features - Automated part loading/unloading, tool changers, probes, etc. add cost.
On the low end, hobbyist and benchtop CNC mills start around $2,000. On the high end, large 5-axis CNC machining centers with automation can surpass $500,000. The average cost of a new mid-size 3-axis vertical machining center is $75,000 to $150,000.
Operational Costs
In addition to the base machine price, there are ongoing costs related to operation and maintenance that must be factored in:
- Tooling and Fixtures - End mills, drills, vises, tool holders, and custom fixtures are required to hold and machine parts. This can range from $2,000 to tens of thousands for a fully tooled machine.
- Accessories - Additional workholding, coolant systems, probes, etc. add cost. Expect to spend 10-20% of machine cost on accessories.
- Software - CAM software for programming and simulation costs $5,000-$15,000. Some machines come with software included.
- Materials and Consumables - The metals and consumable tooling/supplies used in day-to-day production must be accounted for.
- Maintenance - Regular maintenance and repairs will be required, at about 5-10% of machine cost annually.
- Training - Proper training on programming, setup, and operation is crucial, at a cost of $2,000+/person.
- Facilities - CNCs require cabinetry, power, compressed air, coolant systems, and climate control.
Evaluating the Total Cost
As you evaluate CNC machines for purchase, focus first on machines that meet your requirements for part size, accuracy, materials, and capabilities. Then compare total costs between machines by calculating:
- Purchase price
- Estimated tooling/accessories
- Software
- Facilities upgrades needed
- 3-5 years operating costs for maintenance, materials, labor
The machine with the lowest total cost over this period is likely the best value. Buying lower-priced machines often results in hidden costs and headaches from lack of capabilities, poor accuracy, or low reliability. Like most major manufacturing investments, buying quality upfront pays off in the long run.
Strategies to Reduce CNC Costs
Here are several tips to get the most value from your CNC purchase:
- Consider used/refurbished machines to save on purchase price
- Start with a smaller 3-axis machine then add capabilities as needed
- Choose a flexible, modular machine that allows added accessories later
- Use a machine shop when starting out rather than purchasing
- Join a shared machine shop membership to access CNCs at lower cost
- Leverage tooling suppliers that allow flexible rentals or leasing
- Choose inexpensive CAM software to start and upgrade later
- Focus on operator training and efficiency to maximize machining time
- Keep machines well maintained and optimize production schedules
- Consider creative financing options like leasing to preserve capital
Conclusion
While CNC machines require significant upfront investment, the long-term benefits of automation, precision, speed, and consistency outweigh the costs for most manufacturing shops. Carefully evaluating purchase and operating costs and looking for ways to maximize value enables manufacturers to add CNC capabilities with the greatest return. With some planning and strategic decision making, the high productivity and versatility of CNC machining can be achieved at very reasonable total costs. CNC Milling CNC Machining