{"id":17268,"date":"2024-03-19T22:31:34","date_gmt":"2024-03-19T14:31:34","guid":{"rendered":"https:\/\/firstmold.com\/?post_type=case-study&p=17268"},"modified":"2026-03-30T14:41:31","modified_gmt":"2026-03-30T06:41:31","slug":"custom-shim-manufacturing","status":"publish","type":"case-study","link":"https:\/\/firstmold.com\/es\/case-study\/custom-shim-manufacturing\/","title":{"rendered":"Fabricaci\u00f3n de calas a medida mediante fresado CNC"},"content":{"rendered":"
Una cu\u00f1a met\u00e1lica es una pieza fina y plana de metal que suele utilizarse para rellenar peque\u00f1os huecos entre objetos. Otros fines para los que resulta \u00fatil la fabricaci\u00f3n de cu\u00f1as a medida son proporcionar apoyo, garantizar la nivelaci\u00f3n de superficies o ajustar tolerancias en maquinaria.<\/p>\n\n\n\n
Las calas met\u00e1licas pueden fabricarse con titanio, acero inoxidable, aluminio, cobre o lat\u00f3n. Algunas de las razones por las que se utilizan cu\u00f1as met\u00e1licas en m\u00faltiples industrias son:<\/p>\n\n\n\n
\n
Gran resistencia y durabilidad:<\/em><\/strong> Son muy resistentes a las altas temperaturas y a las tensiones, en comparaci\u00f3n con el pl\u00e1stico, lo que los hace adecuados para aplicaciones pesadas.<\/li>\n\n\n\n
Ahorre costes a largo plazo:<\/em><\/strong> La cu\u00f1a met\u00e1lica absorbe las vibraciones y el desgaste, protegiendo as\u00ed la maquinaria compleja de posibles da\u00f1os. Esto reduce los costes de reparaci\u00f3n y el tiempo de inactividad.<\/li>\n\n\n\n
Extremadamente vers\u00e1til:<\/em><\/strong> Se utilizan habitualmente en la industria del autom\u00f3vil para espaciar los componentes del motor, alinear correctamente la maquinaria, en construcciones estructurales para nivelar vigas y en fijaciones industriales para montar maquinaria en superficies irregulares.<\/li>\n<\/ul>\n\n\n\n
Algunas de las consideraciones clave a la hora de emprender la fabricaci\u00f3n de cu\u00f1as met\u00e1licas son la selecci\u00f3n del material adecuado en funci\u00f3n de la aplicaci\u00f3n o las condiciones ambientales, las tolerancias de precisi\u00f3n para garantizar una alineaci\u00f3n correcta y los requisitos de carga. Otros factores que guiar\u00e1n la producci\u00f3n son el grosor, la forma y la planitud.<\/p>\n\n\n\n<\/figure>\n\n\n\n
Requisitos del cliente<\/h2>\n\n\n\n
Un cliente entr\u00f3 en las instalaciones de First Mold para solicitar el servicio de fresado CNC para la fabricaci\u00f3n de cu\u00f1as personalizadas de bajo volumen. El material preferido por el cliente para la creaci\u00f3n de este producto era el titanio. Se esperaba que la cu\u00f1a producida tuviera un aspecto brillante est\u00e1ndar con una tolerancia realmente ajustada de \u00b10,0254 mm. El cliente hizo hincapi\u00e9 en una estricta tolerancia de planitud y grosor.<\/p>\n\n\n\n
\u201cEsto puede considerarse un peque\u00f1o reto, especialmente por la ajustada tolerancia y la naturaleza del material\u201d, dijo el Director General de First Mold, James Li. \u201cPero nuestro enfoque como empresa siempre ha sido anteponer las necesidades del cliente\u201d.\u201d<\/p>\n\n\n\n
Retos y soluciones<\/h2>\n\n\n\n
Aunque se trataba de un producto de aspecto relativamente sencillo, el material elegido y la cu\u00f1a de titanio a medida -el fresado CNC de bajo volumen- planteaban retos \u00fanicos. El titanio es caro y desechar incluso una sola pieza conlleva grandes p\u00e9rdidas.<\/p>\n\n\n\n
Las piezas finas de aleaci\u00f3n de titanio son especialmente dif\u00edciles de procesar en el mecanizado CNC. La mayor\u00eda de nuestros colegas no suelen aceptar este tipo de pedidos, porque la aleaci\u00f3n de titanio es dif\u00edcil de cortar, y cuanto m\u00e1s fina es la pieza, m\u00e1s f\u00e1cilmente se deforma. La producci\u00f3n de bajo volumen tampoco es rentable.<\/p>\n\n\n\n
Fabricaci\u00f3n de calas a medida de bajo volumen<\/h3>\n\n\n\n
La raz\u00f3n por la que la mayor\u00eda de los proveedores rechazan la fabricaci\u00f3n de calas de bajo volumen es que no es rentable. El fresado CNC de titanio para crear una cu\u00f1a personalizada tiene unos elevados costes fijos iniciales derivados de la configuraci\u00f3n de la m\u00e1quina, la programaci\u00f3n, la selecci\u00f3n de herramientas y la inspecci\u00f3n. Este coste fijo inicial debe amortizarse a lo largo de un n\u00famero reducido de piezas, lo que se traduce en un elevado coste por unidad. Otras razones por las que los proveedores rechazan la producci\u00f3n de calas a medida de bajo volumen son:<\/p>\n\n\n\n
\n
Falta de econom\u00edas de escala en la compra de material:<\/em><\/strong> Al fabricar calzos de bajo volumen, los fabricantes no pueden aprovechar los descuentos por material a granel, lo que se traduce en un mayor coste de la materia prima.<\/li>\n\n\n\n
Aumento de la mano de obra:<\/em><\/strong> Las producciones de bajo volumen suelen requerir un mayor n\u00famero de intervenciones manuales, ajustes personalizados y tiempo de operarios cualificados, lo que aumenta el coste global de producci\u00f3n.<\/li>\n\n\n\n
Alta exigencia de control de calidad:<\/em><\/strong> A diferencia de la producci\u00f3n a gran escala, que a menudo se beneficia de procesos automatizados, las producciones a peque\u00f1a escala necesitan inspecciones manuales rigurosas que requieren mucho tiempo.<\/li>\n<\/ul>\n\n\n\n
First Mold ha establecido s\u00f3lidas relaciones con los proveedores de materias primas, adem\u00e1s de contar con avanzadas capacidades de hardware y software para el fresado CNC. La combinaci\u00f3n de estos factores nos ayuda a producir calas de titanio de bajo volumen que otros proveedores no se atreven a aceptar.<\/p>\n\n\n\n
Deformaci\u00f3n de piezas finas de titanio<\/h3>\n\n\n\n
No todos los proveedores son expertos en la fabricaci\u00f3n de calas a medida con titanio. Esto se debe al bajo m\u00f3dulo el\u00e1stico o elasticidad del material (~110 GPa frente a ~200 GPa del acero). Adem\u00e1s, tiene una baja conductividad t\u00e9rmica (aproximadamente 1\/7 de la del acero) y una alta reactividad qu\u00edmica. Estas propiedades pueden provocar importantes desviaciones, desequilibrios de tensiones residuales o distorsiones inducidas por el calor durante el mecanizado.<\/p>\n\n\n\n
Por ejemplo, durante el mecanizado, el impacto del calor generado en el filo de corte no es arrastrado por las virutas, lo que da lugar a altas temperaturas concentradas que pueden superar los 1000\u00b0C. El calor localizado har\u00e1 que el titanio, delgado y d\u00e9bil, se expanda de forma desigual durante el corte. Cuando se enfr\u00eda, puede producirse un alabeo o una deformaci\u00f3n significativa. Otros factores que pueden provocar deformaciones al trabajar con titanio son:<\/p>\n\n\n\n
\n
Deformaci\u00f3n por apriete:<\/em><\/strong> Una sujeci\u00f3n desigual, radial o excesiva puede provocar una predeformaci\u00f3n de la cu\u00f1a. Una vez que se suelta despu\u00e9s del mecanizado, la cu\u00f1a se alabear\u00e1 o rebotar\u00e1.<\/li>\n\n\n\n
Deformaci\u00f3n por efecto \u201cspring back\u201d:<\/em><\/strong> Cada vez que la herramienta de mecanizado pasa durante la fabricaci\u00f3n de la cu\u00f1a met\u00e1lica, la fina cu\u00f1a se deforma y vuelve a su posici\u00f3n inicial. Esto puede provocar imprecisiones dimensionales.<\/li>\n\n\n\n
Endurecimiento del trabajo:<\/em><\/strong> Esto ocurre cuando la capa superficial se endurece por 30%. Cuando esto sucede, requerir\u00e1 una mayor fuerza de corte, lo que crea tensiones internas.<\/li>\n<\/ul>\n\n\n\n
First Mold cuenta con un equipo de ingenieros que llevan mucho tiempo trabajando con titanio. Juntos, crearon estrategias de mitigaci\u00f3n para superar algunos de los retos de la fabricaci\u00f3n de una cu\u00f1a personalizada mediante fresado CNC. Algunas de las estrategias de mitigaci\u00f3n utilizadas por First Mold para satisfacer los requisitos del cliente incluyen:<\/p>\n\n\n\n
\n
Utilizando abrazaderas de mordaza blanda:<\/em><\/strong> Esto ayuda a distribuir uniformemente la presi\u00f3n para evitar una concentraci\u00f3n excesiva de la misma.<\/li>\n\n\n\n
Integraci\u00f3n del refrigerante de alta presi\u00f3n:<\/em><\/strong> Esto ayuda a gestionar el calor alrededor de la superficie de corte, as\u00ed como a facilitar la eliminaci\u00f3n de virutas.<\/li>\n\n\n\n
Utilizando una herramienta de corte afilada:<\/em><\/strong> Cuanto m\u00e1s afilada sea la herramienta de corte, menor ser\u00e1 la fuerza de corte. As\u00ed se reduce la generaci\u00f3n de calor y la presi\u00f3n sobre la cu\u00f1a.<\/li>\n\n\n\n
Alivio del estr\u00e9s:<\/em><\/strong> El equipo recoci\u00f3 la cu\u00f1a para liberar tensiones internas antes del acabado. Esta medida garantiz\u00f3 una estricta tolerancia de planitud y grosor.<\/li>\n<\/ul>\n\n\n\n
Soluciones personalizadas y entrega r\u00e1pida de prototipos<\/h3>\n\n\n\n
Mientras que la mayor\u00eda de los proveedores en China se negar\u00e1 calza de titanio personalizado - bajo volumen de fresado CNC, First Mold es capaz de entrega r\u00e1pida para proyectos de bajo volumen debido a nuestra avanzada tecnolog\u00eda y las asociaciones que hemos construido a lo largo de los a\u00f1os.<\/p>\n\n\n\n
Por ejemplo, en este proyecto, el fabricante quer\u00eda entregar los prototipos en menos de cuatro semanas. La b\u00fasqueda de titanio para el proyecto habr\u00eda consumido la mayor parte del tiempo disponible. El inventario de First Mold, y el de nuestros socios, incluye distintas materias primas. La disponibilidad de materia prima permiti\u00f3 al equipo acelerar la fabricaci\u00f3n de prototipos de calzos personalizados.<\/p>\n\n\n\n
El tiempo que se ahorra en buscar material se invierte en perfeccionar el dise\u00f1o CAD del prototipo. First Mold tambi\u00e9n utiliz\u00f3 la avanzada m\u00e1quina CNC de 5 ejes para reducir el tiempo de preparaci\u00f3n en hasta 40%, as\u00ed como para aumentar la precisi\u00f3n. El prototipo se someti\u00f3 a pruebas de precisi\u00f3n dimensional, planitud y grosor con m\u00e1quinas de medici\u00f3n de coordenadas (MMC) para garantizar que cumpl\u00eda las especificaciones del plano del cliente.<\/p>\n\n\n\n
Fabricaci\u00f3n de cu\u00f1as met\u00e1licas para industrias de gama alta<\/h3>\n\n\n\n
El cliente era un fabricante de gama alta. El reto de fabricar cu\u00f1as a medida para sectores de gama alta como el aeroespacial, el m\u00e9dico, el deportivo y la maquinaria de precisi\u00f3n es que requieren una atenci\u00f3n extrema a la integridad de los materiales, la precisi\u00f3n y la t\u00e9cnica de fabricaci\u00f3n para eliminar defectos.<\/p>\n\n\n\n
Por ejemplo, deben eliminarse las rebabas de los bordes porque pueden provocar desalineaciones o crear zonas de alta fricci\u00f3n. Algunas de las consideraciones cr\u00edticas para la fabricaci\u00f3n de cu\u00f1as personalizadas de alta gama son:<\/p>\n\n\n\n
\n
Grosor uniforme:<\/em><\/strong> La cu\u00f1a debe cumplir unas tolerancias de grosor extremadamente estrictas para evitar un fallo desastroso de la m\u00e1quina. El grosor debe ser constante en toda la superficie para evitar concentraciones de tensi\u00f3n o cargas desiguales.<\/li>\n\n\n\n
Acabado superficial:<\/em><\/strong> La superficie debe tener un acabado liso para minimizar el desgaste y la fricci\u00f3n. Dado que el proyecto implicaba una fabricaci\u00f3n de bajo volumen, First Mold consigui\u00f3 el nivel deseado de suavidad y planitud de la superficie mediante la t\u00e9cnica de lapeado.<\/li>\n<\/ul>\n\n\n\n
Tras el fresado CNC para aplicaciones de alta gama, First Mold limpia y embala la cu\u00f1a para evitar la contaminaci\u00f3n. El motivo es que, en las industrias aeroespacial y m\u00e9dica, las part\u00edculas diminutas pueden provocar fallos.<\/p>\n\n\n\n
Qu\u00e9 gan\u00f3 el cliente con la soluci\u00f3n de First Mold<\/h2>\n\n\n\n
El cliente no pod\u00eda ocultar su entusiasmo cuando recibi\u00f3 los prototipos de calzos personalizados antes de lo previsto. Tras la inspecci\u00f3n, confirmaron que la tolerancia dimensional, la planitud, el grosor y el acabado superficial eran exactos seg\u00fan lo indicado en el plano.<\/p>\n\n\n\n
\u201cEstamos realmente agradecidos a First Mold por aceptar encargarse de este proyecto de fabricaci\u00f3n de calzos de bajo volumen\u201d, dijo el cliente. \u201cDe hecho, fueron los primeros de alrededor de una docena de proveedores con los que contactamos que aceptaron encargarse de este proyecto. Fue un gran alivio\u201d.\u201d<\/p>\n\n\n\n
First Mold no se limit\u00f3 a enviar unos cuantos prototipos al cliente. Entregamos el n\u00famero exacto de calas personalizadas que se necesitaban. Gracias a una tecnolog\u00eda avanzada y a un equipo de ingenieros especializados en el trabajo con titanio, este proyecto se complet\u00f3 dentro del presupuesto del cliente.<\/p>\n\n\n\n
PREGUNTAS FRECUENTES<\/h2>\n\n\n\n
\u00bfPor qu\u00e9 es dif\u00edcil fabricar calas a medida con titanio?<\/strong>
Las propiedades deseables del titanio, como su alta resistencia, resistencia al calor y bajo peso, hacen que su mecanizado sea un reto, sobre todo cuando se crean piezas finas, delicadas y de alta precisi\u00f3n. Por ejemplo, la baja conductividad t\u00e9rmica del material hace que el calor generado durante el corte se concentre en la interfaz entre la herramienta y la pieza. Esto puede da\u00f1ar la herramienta o aumentar la tensi\u00f3n del material.<\/p> <\/div>
\u00bfQu\u00e9 causa la deformaci\u00f3n de las piezas finas de titanio?<\/strong>
La liberaci\u00f3n de tensiones residuales, la fuerza de sujeci\u00f3n, la tensi\u00f3n t\u00e9rmica por concentraci\u00f3n de calor y las vibraciones durante el corte son algunos de los factores que pueden provocar deformaciones al mecanizar calas de titanio. \u00a0<\/p> <\/div> <\/div>","protected":false},"excerpt":{"rendered":"
Este estudio muestra un caso de las capacidades de la f\u00e1brica de mecanizado CNC para producir calzos de pi\u00f1\u00f3n con servicio de fresado CNC de precisi\u00f3n.<\/p>","protected":false},"author":2,"featured_media":17271,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"_acf_changed":false,"inline_featured_image":false,"footnotes":""},"case-study-category":[80],"case-study-tag":[78],"class_list":["post-17268","case-study","type-case-study","status-publish","has-post-thumbnail","hentry","case-study-category-cnc-machining-cases","case-study-tag-tools-and-equipment"],"acf":{"photo_gallery":{"case_study_gallery":[[{"id":17271,"title":"CNC machined Pinion Shims","caption":"CNC machined Pinion 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Custom Metal Shim Manufacturing Via CNC Milling<\/title>\n<meta name=\"description\" content=\"This study shows a case of the CNC machining factory's capabilities to produce pinion shims with precision CNC milling service.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/firstmold.com\/es\/case-study\/custom-shim-manufacturing\/\" \/>\n<meta property=\"og:locale\" content=\"es_ES\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Custom Shim Manufacturing Via CNC Milling\" \/>\n<meta property=\"og:description\" content=\"This study shows a case of the CNC machining factory's capabilities to produce pinion shims with precision CNC milling service.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/firstmold.com\/es\/case-study\/custom-shim-manufacturing\/\" \/>\n<meta property=\"og:site_name\" content=\"First Mold\" \/>\n<meta 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