How to Accurately Estimate and Optimize CNC Machining Time?

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CNC machining time directly impacts production efficiency, cost control, and delivery schedules—making its accurate estimation and optimization critical for manufacturers. Whether you’re processing small precision parts or large structural components, understanding the factors that influence machining time and mastering practical calculation methods can significantly reduce waste. This article breaks down core influencing factors, step-by-step calculation logic, and actionable optimization strategies to help you manage CNC machining time effectively.

1. Core Factors That Influence CNC Machining Time

Machining time is not a fixed value—it depends on a combination of workpiece characteristics, material properties, process parameters, and equipment performance. Below is a detailed breakdown using a contrast and causal chain structure:

1.1 Workpiece Geometric Characteristics

The complexity and size of the workpiece directly determine tool path length and cutting difficulty, creating a clear causal relationship with machining time:

  • Complex features (curved surfaces, narrow grooves, deep cavities): Longer tool paths and lower feed speeds (to ensure accuracy) increase time by 30–60% compared to simple flat parts. For example, a deep cavity with a depth-to-diameter ratio >5:1 requires layered cutting, adding 2–3x more time than a shallow cavity.
  • Small features (0.5 mm wide ribs): Limited by machine acceleration, these take 1.5–2x longer to machine than large planes—even with the same material and parameters.
  • Thin-walled parts: Insufficient rigidity forces reduced cutting depth (to prevent vibration), increasing machining time by 30–50% (e.g., a 2 mm thick aluminum bracket takes 40 minutes vs. 25 minutes for a solid bracket).

1.2 Material Physical Properties

Different materials demand different cutting strategies, which directly affect speed and efficiency. The table below contrasts key material types and their time impacts:

Material TypeKey ChallengeRequired AdjustmentsTime Increase Ratio
High-hardness metals (HRC >45)Rapid tool wearLow spindle speed (1,000–2,000 RPM), small feed rate (0.03–0.05 mm/rev)× 2–3 times
Stainless steelPoor thermal conductivity (causes built-up edges)Frequent pauses for cleaning, low feed rate× 1.5–1.8 times
Soft metals (aluminum alloys)Sticky tools (causes surface defects)High speed (6,000–8,000 RPM) but careful tool selection× 0.6–0.8 times (faster than steel)
Titanium alloyExtremely low thermal conductivityUltra-low speed (500–1,000 RPM), small cutting depth× 2.5–3 times

1.3 Process Parameter Combination

Spindle speed (S), feed rate (F), and cutting depth (ap/ae) form an optimal ratio—any deviation increases time or reduces quality:

  • Spindle speed (S) & feed rate (F): Too high causes tool chipping (requiring rework, adding time); too low leads to inefficiency. For example, a steel part with S=3,000 RPM and F=0.1 mm/rev takes 30 minutes, but S=5,000 RPM (chipping) adds 20 minutes of rework, while S=1,000 RPM (too slow) takes 60 minutes.
  • Cutting depth (ap/ae): Roughing can use maximum machine limits (e.g., ap=5 mm for steel), but finishing needs ae=0.1–0.3 mm (to ensure surface finish)—finishing alone adds 10–15% of total time for precision parts.

1.4 Machine Tool & Auxiliary Operations

Old equipment and time-consuming auxiliary tasks often become bottlenecks:

  • Machine tool dynamic characteristics: Old machines have servo response lag—G00 rapid movement takes 20–30% longer than new 5-axis machines. Automatic tool changers (ATC) vary: a 40-tool magazine takes 15 seconds per change, adding 2.5 minutes for 10 tool changes in a multi-process part.
  • Auxiliary operations: Precision parts need online CMM inspections (30 minutes each), and heavy parts take 10–30 minutes to lift/position. Special fixtures with interference risks can take 1–2 hours of trial installation—exceeding actual cutting time.

2. Step-by-Step Logic to Calculate CNC Machining Time

Estimating machining time requires a structured approach: first calculate program execution time, then add non-cutting time, and finally reserve a safety margin.

2.1 Program Execution Time (Pure Cutting Time)

Use the core formula:

T = L / (F × η)

  • T: Program execution time (hours/minutes)
  • L: Effective cutting path length (mm)
  • F: Feed rate (mm/min)
  • η: Cutting efficiency coefficient (0.7–0.9, accounting for acceleration/deceleration, tool lifting, etc.)

Practical Example

Machining a Φ50 mm × 100 mm long axis outer circle with aluminum alloy:

  1. Layered cutting: ap=2 mm, so number of layers = 100 mm / 2 mm = 5 layers.
  2. Path length per layer: Perimeter of the circle = πD = 3.14 × 50 mm = 157 mm. Total L = 157 mm × 5 layers = 785 mm.
  3. Parameters: F=600 mm/min, η=0.8.
  4. Calculation: T = 785 mm / (600 mm/min × 0.8) ≈ 1.64 minutes (pure cutting time).

2.2 Non-Cutting Time Accumulation

Add fixed and variable overheads that are often overlooked:

Overhead TypeExamplesTypical Time
Fixed OverheadStart-up warm-up, program call, first-piece trial cut10 + 5 + 20 = 35 minutes (average)
Variable OverheadTool changes (15 sec/change), CMM inspections (30 min/inspection), coolant connection10 tool changes = 2.5 min; 2 inspections = 60 min → Total 62.5 min

For the long axis example: Total non-cutting time = 35 + 62.5 = 97.5 minutes.

2.3 Safety Margin Setting

Reserve 15–30% of total time for unexpected issues (tool wear, power outages, process changes):

  • Total time before margin = 1.64 (cutting) + 97.5 (non-cutting) = 99.14 minutes.
  • Safety margin (20%) = 99.14 × 0.2 ≈ 19.83 minutes.
  • Final estimated time: 99.14 + 19.83 ≈ 119 minutes (≈2 hours).

3. Practical Strategies to Optimize CNC Machining Time

Reducing machining time doesn’t mean sacrificing quality—focus on smart process, tool, and equipment adjustments:

3.1 CAM Programming Optimization

Use these techniques to minimize empty strokes and redundant moves:

  • Spiral down cutting: Replace vertical piercing (which risks tool breakage and slow speed) with spiral paths—reduces empty stroke time by 20–30%.
  • Mixed ring + row cutting: For island structures (e.g., a part with multiple raised features), this avoids frequent tool lifting—saving 15–25% of path time.
  • Residual blank function: Let subsequent processes cut directly into remaining material (instead of re-machining the entire area)—shortens path length by 10–15%.

3.2 Tool Selection Principles

Choosing the right tool boosts speed and reduces wear:

  • Roughing: Use large chip groove dense-tooth milling cutters (e.g., 4–6 teeth) to increase material removal rate by 30–40%.
  • Finishing: Opt for fine-tooth plated tools (e.g., TiAlN coating) to maintain high feed rates without surface defects.
  • Deep cavities: Select long neck shrinking rod tools with high-pressure internal cooling—improves chip removal efficiency, cutting time by 25–35%.
  • Material match: Carbide tools last 10x longer than high-speed steel (HSS)—even with higher upfront cost, they reduce tool change time by 50%.

3.3 Machine Tool & Workflow Adaptation

Match equipment to part requirements to avoid bottlenecks:

  • Large workpieces: Use gantry machines (better load-bearing and travel range) instead of vertical centers—reduces re-clamping time by 40–50%.
  • Precision parts: Choose vertical machining centers with good thermal stability (paired with a constant temperature workshop) to avoid rework from thermal drift—saving 1–2 hours per batch.
  • Batch production: Invest in special combination machines with parallel stations—e.g., a 2-station machine can cut cycle time by 50% (one station machines while the other loads/unloads).

4. Correction Coefficients for Typical Working Conditions

Adjust estimated time based on common challenging scenarios using the table below (multiply base time by the coefficient):

Working ConditionTime Correction CoefficientReasoning
Thin-walled parts (thickness <3 mm)1.3–1.5Reduced cutting depth and added supports slow progress
Deep & narrow grooves (width <2 mm, depth >10 mm)1.4–1.6Tool stiffness issues cause chatter, requiring slower speeds
Graphite electrode machining1.8–2.2Dust protection and special coated tools reduce efficiency
Microporous processing (hole diameter <1 mm)3–5Micro-drills break easily, requiring high-frequency reversal for chip evacuation

Yigu Technology’s Perspective

At Yigu Technology, we believe CNC machining time management is about balancing accuracy and efficiency. For clients across automotive and aerospace, we start with a data-driven approach: our historical database of 5,000+ parts lets us apply precise correction coefficients (e.g., ×2.8 for titanium alloy right-angle parts) to avoid overestimating time. We also optimize toolpaths with UG/NX’s residual blank function, cutting empty strokes by 25%, and use carbide tools with high-pressure cooling to boost feed rates by 30% for aluminum parts. For batch production, we’ve deployed 2-station combination machines that cut cycle time by 45% without compromising precision. Ultimately, the goal isn’t just faster machining—it’s predictable, cost-effective timeframes that keep projects on track.

FAQ

  1. How do I adjust machining time estimates for a new material I’ve never used before?

Start with a “three-point estimation method”: calculate optimistic (best-case, e.g., high speed with no issues), normal (average parameters), and pessimistic (slow speed with rework) times. Use the formula: (Optimistic + 4×Normal + Pessimistic)/6. For example, if titanium alloy parts have optimistic=60 min, normal=90 min, pessimistic=120 min, the estimate is (60 + 360 + 120)/6 = 90 min.

  1. Can CAM software alone accurately estimate CNC machining time?

CAM software (e.g., Mastercam, UG/NX) calculates program execution time well but often misses non-cutting time (tool changes, inspections) and safety margins. Add 30–40% to CAM’s initial estimate to account for these—this aligns with real-world results for 80% of parts.

  1. How much time can I save by upgrading from a 3-axis to a 5-axis CNC machine for complex parts?

For parts requiring multiple setups (e.g., a 5-sided housing), 5-axis machines eliminate re-clamping—saving 40–60% of non-cutting time. For deep cavities or curved surfaces, 5-axis dynamic cutting also reduces tool path length by 20–30%, cutting total time by 30–50% compared to 3-axis machines.

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