Understanding CNC Milling: A Comprehensive Guide
If we look into a few metal parts, we can realize how important CNC milling is in manufacturing. Let’s consider the engine block. We can find that it is a vital component in every automotive vehicle. Similarly, flanges are one of the most crucial components in pipe connections for fluids or gases. metal electronic parts, auto parts, mechanical parts, UAV parts, and many more are noteworthy in this case.
Therefore, CNC milling serves a vital role in manufacturing a wide range of machining parts and components. Keeping this importance in mind, we are going to talk about it in this article today. By reading it, our readers can make an informed decision while choosing the right CNC-milled products for your project.
What Are CNC Milling Parts?
In general, the parts made from CNC milling operations are called CNC milling parts or CNC milled parts. The components mentioned in the introductions are some typical names from different industries. So, we can realize that CNC milling parts are prevalent in diverse industries.
The structure of a milling machine includes horizontal or vertical moving drills that make holes, plain surfaces, or edges on metals. Well, note that turning machines and milling machines are two distinct technologies. In a turning machine, the object to be turned rotates at a certain speed. Conversely, in milling machines, the object to be cut remains stationary, and the drill bits rotate at certain speeds. However, adding the CNC or Computer Numerical Control technology into the milling operation makes CNC milling machines.
How Does CNC Milling Parts Are Made?
The manufacturing process of CNC milling parts has six fundamental steps. Starting from designing to final milling, all these steps are very important for precise & efficient production.
Step 1 Design & Simulation
You can make your design using various CAD software. AutoCAD is one of the most recommended & widely used software. Well, simulation allows you to identify potential issues in your design. Therefore, it actually helps you to correct those issues before moving to the next stage.
Step 2 CNC Coding(CAM Process)
Once your design is ready, you need a sequence of codes for manufacturing. In this case, CAM software is an excellent tool. What it does here is convert the sequence of codes into machine movements.
It actually interprets your commands into machine language. You know, the accurate code always ensures the precise machining process. Ultimately, you can achieve the tightest tolerance from the CNC milled parts.
Step 3 Materials Selection
In CNC milling, selecting the material is an important step. It actually tells you what type of tools you need for milling. For example, SS316, a relatively hard metal, needs high-quality & robust tools.
aluminum is a relatively soft metal compared to SS316 or SS304, but aluminum and stainless steel also are ideal materials.
Step 4 Tool Selection
An extensive range of tools are used in CNC milling operations. But in different production processes, different tools are used. It actually depends on your design & type of materials to be used. To solve this, you can consider a few factors. These are materials, geometry, and size. To enhance the overall quality of the milled part, selecting the optimal tool ensures efficient material removal.
Step 5 Machine Calibration & Setup
Before proceeding to the final step, you must check the machine setup & calibration. This step is actually necessary for accurate machining. However, configure the machine’s parameters & verify tool alignments as per the requirements.
Step 6 Final Milling
You can begin the final milling operation once you finish all five steps above. All you need to do is wait for the machine to finish its job. The machine will automatically follow the codes you have inserted. Consequently, it will precisely remove the material as mentioned in the instructions. During the production process, continuous monitoring & quality checks ensure that your product meets the specified design requirement.
CNC Milling Operations: 3 Axis | 4 Axis | 5 Axis
CNC milling can be of various types. In most cases, horizontal and vertical milling are popular. However, compared to different axes of rotations, there are typically three types. Each type offers unique advantages and precise solutions.
3 Axis CNC Milling
3-axis CNC milling is the most popular and widely used method in metal part manufacturing. It is actually the simplest type of milling. In this method, the cutting tool moves along these perpendicular axes (X, Y, and Z). It means that the cutting can only move vertically, horizontally, and in & out of the workpiece.
Compared to 4-axis & 5-axis CNC milling, this method is typically suitable for manufacturing simple & less intricate parts. We often see this method in industries where the components require straightforward machining without intricate detailing. For example, the parts with narrow cavities which are not too deep. Although, you can still make the deeper parts using 3-axis CNC milling.
4 Axis CNC Milling
This type of milling method typically has an additional axis for cutting tools. It is often called the A-axis. This additional axis typically allows the cutting tool to provide enhanced flexibility in machining. It means that you can make more intricate shapes than 3-axis CNC milling. The X, Y, Z, and A axes normally come in vertical machining type. Note that, in this type of machining process, the spindle rotates about the Z axis.
This added flexibility finds applications in making more complex geometries. You know, Industries such as automotive and medical require cutting components from different angles. Thus, 4-axis CNC milling is prevalent in these sectors.
5 Axis CNC Milling
5-axis CNC milling comes with an additional axis along with four axes from the previous type. Therefore, other than the X, Y, and Z axes, we have two more axes, denoted as the A and B axes. Therefore, in this CNC milling method, the cutting tool can technically move in five different axes. Therefore, you can create components with even more complexity and intricate patterns.
This milling method finds extensive applications in making medical parts & equipment, auto parts, electronic parts, and many more.
Advantages Of CNC Technology In Milling Operations
1. CNC milling technology boasts the production process. The traditional milling technique is slow and brings down productivity. Combining automation technology, you can use up to 30 different tools on a rotating carousel.
2. CNC milling technology is highly precise and accurate. Since it’s an automated production method, there is no use for manual labor. As a result, you can ensure your product tolerance is up to 0.01mm.
3. CNC milling machines come with the latest features every year. It means that you can get upgraded technology with enhanced productivity.
4. CNC milling machines are safe since human labor is not used.
5. This milling technique is widely versatile for a wide range of materials. You can work with almost all types of metals, wood, plastics, or ceramics. Noteworthy metals are stainless steel (SS304, SS316), Carbon steel, aluminum, brass, and more.
What Are The Applications Of CNC Milling Parts?
The ability to make precise components at high production speed makes CNC milling technology prevalent in many applications.
In the auto industry, CNC milling methods are used to manufacture various engine parts, turbine blades, and structural components. In medical industries, orthopedic implants, surgical instruments, dental prosthetics, and medical kits are noteworthy.
The electronics industry heavily depends on CNC milling for manufacturing precision electronic device parts. Popular products are metal terminal connectors, aluminum electronic enclosures, and more. On the other hand, in the agriculture industry, CNC milling machines are used to manufacture various tractor parts and irrigation parts.
Some Returning Questions
What Materials Can Be Milled?
Answer: CNC milling is a widely used machining method. You can typically work with almost all types of materials. Metals are commonly used in CNC milling operations. Some popular metals are stainless steel (SS304, SS316), CS, MS, aluminum, and brass. Choose the right milling cutter for the type of metal to be milled.
What Is The Difference Between Machined And Milled?
Answer: CNC milled parts can be regarded as CNC-machined parts. CNC machining may involve turning, milling, drilling, threading, or stamping.
What Is The Difference Between Milling & Turning CNC?
Answer: What sets them apart from each other is their axis of rotation. In the CNC milling method, the cutting tool rotates at a certain speed. On the other hand, in the CNC turning method, the workpiece rotates at a certain speed. CNC turning is suitable for cylindrical parts. Conversely, CNC milling is ideal for creating holes, plains, or edges.
Experts Advice
Choosing the right tools & materials is the ultimate goal for successfully manufacturing various metal parts. So, when selecting the suitable materials, consider their properties.
This is very important for quality outcomes. You can go through their mechanical, thermal, and chemical characteristics. You must be aware that these factors typically ensure the optimal performance in the milling process.
Concerning choosing the right machined parts for a specific application, there are some factors that you must evaluate.
First, understand the unique requirements of your applications. In this case, check load-bearing capacities, environmental conditions, and functional specifications.
Second, equally evaluate the cost-effectiveness & production efficiency.
Third, always ensure the quality & cost, optimizing production processes to achieve high-quality final machined parts.
For more information, feel free to contact us. We have a team of experts who are always waiting for your queries.
