1. Usinage pré-CNC: Design and Preparation for TV Prototypes
Avant de commencer Usinage CNC for the TV prototype, a systematic design and preparation stage is essential to meet functional, de construction, and user experience needs. Cette étape suit une séquence linéaire, avec des détails clés organisés dans le tableau ci-dessous.
| Étape de conception | Exigences clés | Matériaux recommandés |
| Analyse de la demande de produits | Confirm core parameters: Screen ratio (Par exemple, 16:9), thin and light design (target thickness ≤15mm for the whole machine), heat dissipation hole layout (evenly distributed on the back), and button functions (pouvoir, volume, mode); Reserve space for internal components such as circuit boards and brackets, and design wall-mounted holes for installation needs. | – |
| Conception structurelle | Adopt a split structure: Screen frame + base (detachable or integrated) to facilitate transportation and assembly; Design internal support structures (Par exemple, stiffeners, s'enclenche) to ensure structural strength without affecting the appearance; Optimize the layout of heat dissipation holes to ensure smooth internal air circulation. | – |
| 3D Modélisation | Utiliser le logiciel CAO (Solide, et) to create 3D models with precise dimensions. Highlight critical features: Screen frame inner diameter (matches screen size with a 0.1mm gap), base mounting slots (positioning accuracy ±0.05mm), wall-mounted holes (diameter 6-8mm), et rainures pour boutons (depth 2-3mm); Add 3°-5° draft slopes for future mold compatibility. | – |
| Sélection des matériaux | Choose materials based on part function, machinabilité, et durabilité, while prioritizing compatibility with mass production processes. | Coquille (Screen Frame + Base): Alliage ABS/PC (léger, résistant à la chaleur, Facile à façonner); Pièces métalliques (Par exemple, Base Support): Alliage en aluminium 6061 (léger, facile à polir); Screen Simulation: Clear acrylic sheet or resin sheet (label “screen” position, no real display function). |
| Prétraitement des matériaux | Couper les matières premières en flans (leave 2-3mm machining allowance): For ABS/PC alloy sheets, Utiliser la coupe laser; For aluminum alloy blocks, use bandsaw cutting; Preheat ABS/PC alloy (60-80° C pour 1-2 heures) to prevent stress deformation during machining; Clean all blanks with alcohol to remove surface oil and dust. | – |
2. CNC Machining Preparation for TV Prototypes
Adequate preparation before formal machining is the key to ensuring the efficiency and quality of Usinage CNC for TV prototypes. This section mainly covers material and tool selection, as well as programming and fixture design.
2.1 Sélection des matériaux et des outils
The choice of materials and tools directly affects machining efficiency and prototype quality. Le tableau ci-dessous fournit des recommandations détaillées:
| Catégorie | Options spécifiques | Scénarios d'application |
| Matériaux de logement | ABS/PC plastic plate (épaisseur 3-5mm) | Suitable for processing screen frames and bases with complex surfaces, meeting the requirements of thin and light design. |
| Matériaux métalliques | Alliage en aluminium 6061 (thickness 5-8mm) | Used for base supports and other metal parts, featuring lightweight and easy polishing properties. |
| Outils d'usinage rugueux | Φ8-Φ10mm flat bottom knife or ox nose knife | Realize quick material removal, improving rough machining efficiency. |
| Outils de finition | Φ2-Φ4mm ball head knife | Used for machining arc surfaces (Par exemple, base edges) and chamfers, ensuring smooth surface finish. |
| Special Process Tools | Perceuses (diameter matching wall-mounted holes), frappeurs (for engraving buttons and logos) | Drill wall-mounted holes and engrave functional and decorative features on the shell surface. |
2.2 Programmation et conception de luminaires
Scientific programming and reasonable fixture design can effectively avoid machining errors and ensure machining accuracy.
| Lien | Opérations clés | But & Effet |
| Programmation de came | – Usinage sous-zone: First process the shell main body, then separately machine the base and brackets to avoid mutual interference.- Set layered cutting: Roughing layer thickness 1mm, finishing layer thickness 0.2mm, ensuring machining accuracy while reducing tool wear. | Improve machining efficiency, ensure the precision of each part, and extend tool service life. |
| Conception de luminaire | – For plastic plates (Alliage ABS/PC): Use a vacuum adsorption platform for fixation to avoid deformation caused by uneven clamping force.- Pour les pièces métalliques (alliage en aluminium): Clamp with a precision vise, and use a level to calibrate to ensure flatness (erreur ≤0,02 mm). | Prevent part displacement during machining, ensure the flatness and dimensional accuracy of the prototype. |
3. Core CNC Machining Process for TV Prototypes
Le formel Processus d'usinage CNC is the core link in transforming design models into physical TV prototype parts. It needs to be carried out in strict accordance with the process steps to ensure the precision and functionality of the prototype.
3.1 Housing Machining (Screen Frame + Base)
Housing machining is divided into roughing and finishing, and different parameters are set according to different materials:
| Étape d'usinage | Matériel | Paramètres clés | Effets de traitement |
| Brouillage | ABS/PC Alloy | Faible vitesse (6,000RPM), vitesse d'avance élevée (800mm / min), cutting depth 1mm | Quickly remove excess material, forming the basic shape of the shell. |
| Alliage en aluminium | Grande vitesse (12,000RPM), cutting depth 0.5mm, retain 0.3mm margin | Avoid material hardening caused by excessive cutting temperature, ensuring subsequent finishing quality. | |
| Finition | ABS/PC Alloy | Use Φ2-Φ4mm ball head knife to machine curved surfaces, surface finish Ra3.2 | Make the shell surface smooth, without obvious machining marks. |
| Alliage en aluminium | Polish to achieve surface finish Ra0.8-Ra1.6, and perform edge chamfer (C1mm) | Enhance the texture of metal parts, prevent sharp edges from scratching users. |
3.2 Detail Machining
Detail machining is crucial to realizing the functional and decorative effects of the TV prototype, including button and interface machining, logo engraving, and heat dissipation hole machining:
- Button and Interface Machining: Use milling cutters to machine power button grooves (size matching button diameter, depth 2-3mm), volume key grooves, and drill holes for interfaces such as USB and HDMI (diameter matching interface size, positioning accuracy ±0.1mm). Ensure that buttons can be smoothly installed and interfaces are aligned with the shell.
- Logo Engraving: Use small-diameter milling cutters (Φ1-2mm) to engrave the “TV” logo or decorative lines on the screen frame or base surface. The engraving depth is 0.5-1mm, ensuring clear patterns and good visual effects.
- Heat Dissipation Hole Machining: Process array small holes (diameter Φ1-2mm) on the back of the shell, or use hollow geometric patterns (Par exemple, circulaire, carré) to improve heat dissipation efficiency. The hole spacing is 5-8mm, ensuring that the structural strength of the shell is not affected while achieving heat dissipation.
3.3 Base and Bracket Machining
The base and bracket are important components to support the TV prototype, and their machining accuracy directly affects the stability of the prototype:
- Base Machining: Machine mounting slots on the base (matching the screen frame’s snap structure, gap ≤0.1mm) to ensure a tight fit between the base and the screen frame. For aluminum alloy bases, anodize them (noir ou argent) after machining to enhance texture and corrosion resistance.
- Bracket Machining: Machine the bracket interface (matching the internal structure of the shell, positioning accuracy ±0.05mm) to ensure that the bracket can stably support internal components such as the circuit board. For brackets with wall-mounted functions, machine wall-mounted holes (positioning accuracy ±0.05mm) to avoid installation deviation.
4. Post-Processing and Assembly of TV Prototypes
Après Usinage CNC, post-processing and assembly are required to make the prototype have a better appearance and complete functionality.
4.1 Traitement de surface
Different materials require targeted surface treatment to improve the appearance and performance of the prototype:
| Matériel | Méthode de traitement de surface | But & Effet |
| ABS/PC Alloy Shell | Sprayed matte paint (simulated TV texture), partial highlight treatment (Par exemple, screen frame edges) | Enhance the texture of the shell, make it consistent with the appearance of formal TV products, and avoid reflection affecting the viewing experience. |
| Laser engraving translucent buttons (Par exemple, red LED indicator effect) | Realize the decorative and functional indication effect of buttons, improving the user experience. | |
| Pièces en alliage d'aluminium | Anodisation (noir/argent) ou sablage | Anodization enhances corrosion resistance and texture; sandblasting achieves anti-slip and anti-fingerprint effects. |
| Acrylic Sheet (Screen Simulation) | Polissage (surface finish Ra0.8) | Improve transparency, make the “screen” position more realistic, and avoid scratches affecting the appearance. |
4.2 Assembly and Test
Scientific assembly and strict testing ensure that the TV prototype meets design requirements and can be used normally in subsequent scenarios.
4.2.1 Processus d'assemblage
Follow this step-by-step sequence to avoid assembly errors:
- Vérification avant assemblage: Inspect the size and surface quality of all machined parts (Par exemple, coquille, base, support) to ensure no dimensional deviations (tolérance ± 0,1 mm) et défauts de surface (no scratches >0.5mm).
- Component Installation:
- Fix the screen simulation acrylic sheet on the screen frame (use double-sided tape with strong adhesion, ensuring no offset).
- Assemble the screen frame and base: For detachable structures, install the snap or screw (M3-M4) to ensure a tight fit (no looseness); for integrated structures, weld or bond them firmly.
- Install internal brackets: Fix the bracket on the shell using screws, ensuring the bracket is level (tilt ≤0.05mm) to stably support subsequent internal components.
- Final Assembly Check: Après l'assemblage, shake the prototype gently (tilt 10°) to check for loose parts; use a level to calibrate the base to ensure the prototype is placed stably (no tilting).
4.2.2 Test Procedures
Conduct comprehensive tests to verify the performance and reliability of the prototype:
- Structural Stability Test: Test the load-bearing capacity of the wall-mounted holes (hang a 5kg weight for 24 heures, check for no deformation or damage to the holes); test the stability of the base (place the prototype on a 30° inclined plane, check for no sliding).
- Heat Dissipation Test: Simulate the heat generation of internal components (use a heating plate with 50W power), test the heat dissipation efficiency of the prototype under air-cooled or natural cooling conditions (measure the surface temperature of the shell after 1 heure, requiring ≤40°C).
- Button Performance Test: Test the feel of the buttons (pressing pressure 2-3N, stroke 1-2mm, requiring consistent stroke and no stuck phenomenon); press each button 1000 fois, check for no damage to the button grooves.
- Appearance Inspection: Check the color consistency of the prototype (ΔE ≤1.5), the clarity of logos and patterns (pas de bavure), and the smoothness of edges (pas de bavures).
5. Application Scenarios of CNC Machining TV Prototypes
CNC machined TV prototypes have a wide range of application scenarios, providing strong support for product development and market promotion:
| Scénario d'application | Specific Uses | Advantage of CNC Machining |
| Product Design Verification | Verify the feasibility of appearance design (Par exemple, ultra-thin bezels, curved screens) and structural design (Par exemple, detachable base); Optimize human-computer interaction (Par exemple, disposition des boutons, interface position) based on the prototype. | CNC machining has high precision, which can accurately restore design details, helping designers find and solve design problems in a timely manner. |
| Marketing and Exhibition Display | Use the prototype for product exhibitions, customer presentations, and market research to collect user feedback on appearance and structure; Display the product’s design concept and functional characteristics in advance to enhance market expectations. | The prototype has a good appearance and structural stability, which can intuitively show the product’s advantages and attract user attention. |
| Personnalisation en petits lots | For high-end customization needs (Par exemple, corporate gifts, concept machines), directly use CNC machining to produce a small number of finished products (≤100 units) to meet personalized needs. | CNC machining is flexible, suitable for small-batch production, and can quickly respond to customization requirements without opening molds, Réduction des coûts. |
| Education and R&D | As an industrial design case, it is used for teaching mechanical structures, material applications, and surface treatment processes; Provide experimental samples for R&D institutions to study TV structural optimization and heat dissipation technology. | The prototype has complete structural and functional characteristics, which can help students and researchers understand the production process of TV products intuitively. |
6. Key Precautions for CNC Machining TV Prototypes
To ensure the quality and efficiency of CNC machining TV prototypes, the following key precautions must be observed:
- Contrôle de précision: Strictly control the tolerance of the shell (± 0,1 mm) to ensure a perfect fit between the screen frame and the acrylic sheet; the positioning accuracy of the wall-mounted holes must be controlled at ±0.05mm to avoid installation deviation. Pendant l'usinage, Utilisez une machine à mesurer de coordonnées (Cmm) to inspect key dimensions every 2 hours to ensure machining accuracy.
- Material Property Adaptation: During the machining of ABS/PC alloy, preheat the material to prevent stress deformation; Après l'usinage, cool the material to room temperature before subsequent processing. When machining aluminum alloy, control the cutting temperature (use cutting fluid to cool) to avoid material hardening or deformation caused by excessive temperature.
- Optimisation des coûts: CNC machining is suitable for small-batch production (≤100 units); pour la production de masse (>1000 units), it is recommended to switch to injection molding + stamping process to reduce production costs. During the design stage, simplify complex surfaces (Par exemple, replace irregular curved surfaces with regular ones) to reduce tool wear and machining time, thereby lowering machining costs.
- Safety Operation: Pendant l'usinage, operators must wear safety glasses and gloves to avoid injury caused by flying chips; use fume extractors when spraying paint or anodizing to avoid inhaling toxic gases and protect the environment and operator health.
Point de vue de la technologie Yigu
À la technologie Yigu, nous croyons CNC machining is the core guarantee for creating high-quality TV prototypes. It can accurately restore the design details of TV products, whether it is the precision of ultra-thin bezels or the positioning accuracy of wall-mounted holes, and can meet the strict requirements of prototype production. When producing TV prototypes, we focus on two core points: one is material-function matching, selecting ABS/PC alloy for the shell to balance lightweight and heat resistance, and aluminum alloy for metal parts to ensure structural stability; the other is process optimization, through reasonable programming and fixture design, improving machining efficiency while ensuring accuracy. By integrating strict quality control in each link from design to post-processing, we help customers shorten the prototype development cycle by 20-30% and provide reliable support for product market verification. À l'avenir, we will further apply intelligent technologies such as AI-driven machining parameter optimization to CNC machining, continuously improving the precision and efficiency of TV prototype production.
FAQ
- What materials are most suitable for CNC machined TV prototype shells, et pourquoi?
The most suitable material for TV prototype shells is ABS/PC alloy. Because it has the advantages of lightweight (meeting the thin and light design requirements of TV), résistance à la chaleur (adapting to the heat dissipation needs of internal components), and easy shaping (suitable for processing complex surfaces such as screen frames), and its machinability is good, which can ensure the smooth progress of CNC machining and the high precision of the prototype.
- Can CNC machined TV prototypes be directly used for mass production?
Non. CNC machined TV prototypes are mainly used for design verification, market display, and small-batch customization. Pour la production de masse (>1000 unités), it is recommended to switch to injection molding + procédure d'estampage. Because CNC machining has high single-piece costs and low production efficiency, while injection molding can realize large-scale production at a lower cost and higher efficiency, which is more in line with the needs of mass production.
- How long does it take to produce a CNC machined TV prototype from design to assembly and testing?
The production cycle depends on the complexity of the prototype. For a simple TV prototype (with a regular screen frame and base, no complex curved surfaces), it takes about 7-10 jours, y compris 2-3 days for design and 3D modeling, 2-3 days for CNC machining, 1-2 jours pour le post-traitement, et 1 day for assembly and testing. For a complex prototype (with ultra-thin bezels, curved screens, and multiple metal parts), the cycle may be extended to 12-15 days due to more intricate machining and testing processes.