| 01 | Quantify Annual Volume | Prototype: 1–20 parts/year Low volume: 20–500 parts/year Medium volume: 500–10,000 parts/year High volume: more than 10,000 parts/year | Identify whether the workload is mainly one-off parts, repeat batches, or continuous production. | Define cycle-time targets, changeover frequency, and acceptable idle time before selecting machine capacity. | Choose flexible workholding and fast setup for prototypes; prioritize automation, chip removal, and high spindle utilization for repetitive production. | Request a cycle-time study based on the buyer’s actual part files, tooling plan, material, and inspection steps. |
| 02 | Match Materials to Machine Capability | Separate the workload by material family rather than using one average material for all calculations. | Aluminum alloys, low-carbon steel, stainless steel, tool steel, titanium alloys, engineering plastics, and graphite have different cutting loads and heat behavior. | Heat-sensitive or work-hardening materials may require tighter thermal control and stable cutting conditions. | Check spindle torque, spindle speed range, machine rigidity, coolant delivery, chip evacuation, and compatible toolholding. | Conduct a material-specific cutting trial using representative tooling, workholding, coolant, and cutting parameters. |
| 03 | Define Workpiece Size and Weight | Base the selection on the largest expected part, not only the average part. | Include raw-stock dimensions, castings, forgings, bar stock, fixtures, and possible distortion after roughing. | Allow sufficient clearance for tool access, probing, rotary axes, and inspection features. | Confirm travel on all linear axes, table dimensions, maximum table load, spindle-to-table distance, and door opening. | Compare the machine’s usable work envelope with a scaled drawing of the largest part and complete fixture package. |
| 04 | Separate Roughing from Finishing Needs | High material-removal work and precision finishing often require different operating priorities. | Heavy roughing of steel needs rigidity and torque; finishing aluminum or hardened steel may need higher speed and low vibration. | Typical general machining targets may range from approximately ±0.05 mm to ±0.01 mm, depending on process, material, geometry, and inspection method. | Evaluate structural stiffness, spindle power and torque curves, acceleration, thermal stability, and control features. | Run both a material-removal test and a finishing test using features that represent the actual production parts. |
| 05 | Classify Tolerances by Feature | List standard, close, and critical dimensions separately for every part family. | Consider hole size, bore geometry, flatness, perpendicularity, parallelism, profile, and position tolerance. | Standard features may use general drawing tolerances; critical bores, fits, and positional features may require approximately ±0.005–0.02 mm under controlled conditions. | Specify probing, tool measurement, thermal compensation, rigid workholding, and suitable finishing operations where required. | Request a sample inspection report showing dimensional results, measurement equipment, datum strategy, and environmental conditions. |
| 06 | Plan Surface-Finish Requirements | Identify whether surfaces are functional, cosmetic, sealing, sliding, or intended for later coating or assembly. | Material hardness, grain structure, tool geometry, coolant, and cutting parameters affect the final finish. | Common machined surface requirements may range from about Ra 3.2 µm for general machining to Ra 0.8 µm or lower for selected finishing operations. | Check spindle runout, machine vibration, toolholding accuracy, feed control, and the availability of finishing cycles. | Measure test surfaces with a calibrated surface-roughness instrument and record the cutoff, evaluation length, and measurement direction. |
| 07 | Select the Required Number of Axes | Use 3-axis machining for accessible prismatic parts; consider 4- or 5-axis machining when multiple setups or complex surfaces are common. | Complex castings, impellers, medical components, molds, and angled features may benefit from simultaneous or indexed multi-axis work. | Fewer setups can reduce datum-transfer errors and improve relative feature accuracy. | Evaluate rotary-axis accuracy, usable tilt range, collision clearance, post-processor compatibility, and machine-tool-center-point control. | Request rotary-axis calibration data and a sample multi-face or simultaneous 5-axis machining demonstration when applicable. |
| 08 | Match Spindle and Tooling to the Process | Base spindle selection on the balance between high-speed finishing and low-speed heavy cutting. | Aluminum commonly benefits from higher spindle speeds; steel, stainless steel, and titanium may require higher torque and controlled heat removal. | Tool deflection and spindle runout directly influence size, form, burr formation, and surface finish. | Review rated and peak power, torque curve, maximum speed, taper type, drawbar force, tool magazine capacity, and tool-change time. | Verify spindle runout, tool-change repeatability, vibration behavior, and cutting performance with the intended toolholder system. |
| 09 | Evaluate Thermal Stability | Thermal effects become more important during long cycles, high spindle speeds, high-volume production, and tight-tolerance work. | Materials with high heat generation or low thermal conductivity can increase temperature variation during machining. | Tight dimensional and positional tolerances require stable machine temperature, consistent warm-up, and controlled measurement conditions. | Check spindle warm-up routines, coolant-temperature management, enclosure design, environmental requirements, and thermal compensation functions. | Compare dimensional results at the beginning and end of a representative production cycle after a defined warm-up procedure. |
| 10 | Require ISO 230-2 Positioning Tests | Use acceptance testing before shipment, after installation, and periodically when accuracy is critical. | Test the axes used for the intended parts, including linear axes and rotary axes where relevant. | ISO 230-2 evaluates positioning accuracy and repeatability through repeated movements to programmed positions; it does not by itself guarantee finished-part accuracy. | Define test axis, travel range, target positions, measurement direction, environmental conditions, warm-up procedure, and acceptance limits in the purchase specification. | Request an ISO 230-2 test report with measurement equipment details, test temperature, uncertainty information, unidirectional and bidirectional results, and calculated positioning metrics. |