CNC milling is reliable and can make many products, from smartphones to jets that fly faster than sound. It's a great way to quickly make plastic and metal prototypes and volume manufacturing metals and plastic. Let's take a closer look at some great things about CNC milling and how it can be used.
CNC milling is a form of manufacturing that uses a cutting tool on a spinning spindle to remove a piece from a block of raw material in a specific way. The workpiece is fixed to a table, and this table can move or rotate in different planes so that the tool can be used from many different angles. Modern CNC milling machines can have five or more axes that can move independently. This lets them make more complicated shapes or keep the workpiece from having to be moved to a different machine.
Depending on the type and level of sophistication of the CNC milling machine, the cutting tool will rotate and move differently. The process can be used with various materials, including aluminum, plastic, wood, and glass. CNC milled parts have a high tolerance because milling machines can get a tolerance of +/- 0.001 in. to +/- 0.005 in. (some machines can get a tolerance of +/- 0.0005 in.).
Aside from CNC turning and drilling, CNC milling is the most important part of CNC machining. However, it works uniquely compared to others. It uses a computer-controlled rotating cylindrical cutting tool that moves along multiple axes and removes pieces from a workpiece.
● Step 1: Prepare a 2D or 3D CAD Model
The CNC milling process can be divided into three main steps, and they are:
Use CAD/CAM software like SolidWorks or Autodesk Inventor to make a 2D or 3D drawing of the machinable finished product. How you get a CAD file ready for CNC machining depends on the software you are using. On the one hand, some software can make 3D CAD files from 2D images. On the other hand, you can trace a 2D image to turn it into a 3D file with some software.
The operator is also given a technical drawing that tells them things like:
● Construction lines
● Indication of threads
● Critical features/dimensions of a part
● Tolerances
● Finishing preferences
● Tolerances
● Step 2:Export Your Design in a Format that a CNC Machine Can read
The CNC milling machine will only be able to read the model you make if it is in a file format that it can understand. So, you need to use the CAD/CAM software to export your CAD model into file formats that CNC can read. STEP and STL are two examples of such formats.
If the software can't convert the design to that format, you can use online services like Convert.emachineshop.com. and Cadexchanger. When the file is converted, it will tell the machine how to move rotationally and linearly, how to cut, and the speed of the machine and the workpiece.
● Step 3: Set Up and Operate a CNC Mill
The operator will attach the cutting tools to the spindle and put the workpiece on the table. Then, they will set up the machine to start the milling program and start milling.
There are different ways to set up and use CNC milling's different operations. Here are some of the common forms of operation:
Form milling is the best way to make a part with an irregular shape. The shape can be straight or straight with curves. The edges can be either concave or convex, and they are made with teeth that go in the opposite direction. So, if you want to make a product with a concave edge, you should use a form milling cutter with a convex edge.
In face milling, the rotating axis of the cutting tool (a face milling cutter) is parallel to the surface of the workpiece. The face milling cutter is unique because it has cutter inserts that can be switched out. It cuts through things with its many cutting teeth. As a result, face-milled parts have better surface finishing. Also, the process is easy to control, making it easy to get the surface you want.
Plain milling is an operation that uses a column and knee to mill flat, horizontal surfaces. The tool for cutting is in line with the workpiece. So, cutting goes from one end of the piece of work to the other. The table can be fed in a longitudinal, cross, or vertical direction.
Angular milling involves milling flat surfaces using a cutting tool at an angle. The only difference from plain milling is how the machine is set up. Angled milling cutters come in two types: single-angle and double-angle.
The single-angle cutters have teeth on the angled side of the cutter and large flat sides. They can be used to cut at angles of 450 or 600. The double angular milling cutters are better for flat surfaces at 45°, 60°, and 90°.
Choosing suitable materials can be challenging because there are so many. Here are some of the things to consider and the most common materials you can use for CNC milling:
Cost is the most important thing to consider when making a choice. But make sure you choose the best material you can afford with the best mechanical properties.
Milling is more accurate when there is a dimension tolerance. So it is easy to put these parts together. You can read the article or contact us at Ares Prototyping if you need to learn about CNC machining dimensional tolerance.
The temperature at which the material melts must be below the temperature at which the CNC milling machine works. This will help keep the milling from getting messed up.
CNC milling can be used on a wide range of materials. Some common ones are:
● Plastics: ABS, Polycarbonate, and Nylon
● Metals: Aluminum, stainless steel, tool steel. Mild steel, Brass, Copper
● Others, like Ceramics, composites, and phenolics
Because of its benefits, the process is an essential part of many industrial production steps because of its numerous benefits. However, it also has some disadvantages. Here are some good and bad things about the process.
● Accuracy and Accuracy
The accuracy and precision of CNC milling machines are better. So they can make parts that meet their technical requirements. So, they can mill parts with as little as 0.0004 mm of error. Also, because the process is automated, mistakes made by people are less likely to happen.
● Quick and effective
CNC millers are faster and more efficient than traditional millers. This is because, depending on the ATC, they can carry many cutting tools, making it easier to change tools and speed up the process.
● Wide Range of Materials
The process works with many materials, such as metals, plastics, and composites. If you have a block of material, CNC milling is the best way to work with it.
● High Level of Maintenance
CNC millers need a lot of care and maintenance to keep working well. The machine costs a lot. Therefore maintenance is important.
● Waste of Material
The process is subtractive, which means that the material is taken away to make the part. So, there is a lot of material waste compared to other manufacturing processes, like 3D printing services.
Milling is very precise and has a high tolerance for error. So, it can be used for a lot of different things. These are some of the ways it is used in industry.
Using materials like titanium and aluminum, computer numerical control milling can be used to make a lot of aeronautic parts. These materials are strong and don't weigh much. Because accuracy and precision are so important, CNC milling is the best option.
The automotive industry uses milling machining because it needs to be fast and accurate simultaneously. Interior panels, cylinder heads, drive axles, suspension parts, exhaust parts, and gearboxes are good examples of things that can be made using this process.
Medical parts such as prostheses require precise and unique designs. So, CNC milling is the best way to make these parts. The design stays the same, and it works well and is productive.
We offer professional CNC milling services that focus on making precise metal and plastic parts with tight tolerances at a reasonable price. Our factories have high-tech CNC milling machines with multiple axes to help you quickly make high-quality parts.
After you upload your CAD file and choose your material and quantity, you can use our online quotation platform to get instant quotes with a DFM report. You can also manage your order and keep track of the milling process until it is delivered.
