CNC Milling Services
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CNC Milling Parts
China CNC Milling Services
The CNC Milling process works by the machine reading coded instructions and then putting them into operation. It all starts with developing a 3D CAD file representing the final part. Once completed, the design is converted into a machine-readable format. CAM (Computer-Aided Manufacturing) software then exports this to a CNC machine program, usually in G-code format, which acts as the instructions, directing every move that the machine makes. This replicates the CAD design in the chosen material with high accuracy and efficiency.
Using subtractive machining technology, CNC Milling can produce high and low volumes of highly complex and intricate parts. Material is removed from a blank workpiece, and the milling machine uses a rotating cylindrical tool called a milling cutter. Depending on the milling machine being used, the machine can cut in different angles and move along different axes.
The final part will have first been designed via CAD, or Computer-Aided Design, before being inputted into the milling machine for final production.
Types of CNC Milling
With vertical milling, a 3-axis milling table is the work surface, which sits below the arm, to which a spindle is attached.
The spindle can be stationary if a vertical turret mill is used. In this case, the table moved along both X and Y axes. Meanwhile, the table only moves along the X-axis if a bed vertical mill is used. The spindle travels along the length of the arm in the Y-Axis direction.
With horizontal milling, the spindle operates horizontally instead of vertically, and all other components are similar to vertical milling. Generally speaking, horizontal mills are best suited to heavier projects or longer projects. They are also suited to parts that require a large amount of material to be removed as the swarf falls away from the part and cutter.
The cutting tool’s axis of rotation is perpendicular to the surface of the workpiece.
It employs face milling cutters, with teeth both on the periphery and the tool face, the latter of which is used for finishing applications. Face milling is also used to create flat surfaces and control a finished piece. Face milling can produce higher quality finishes than other milling processes and is compatible with vertical and horizontal milling machines.
The cutting tool’s axis of rotation is parallel to the surface of the workpiece. Plain milling cutters have teeth on the periphery that perform the cutting operation. Both narrow and wide cutters are used. This allows for deeper cuts and for larger surface areas to be worked on. A course and fine-toothed cutter are both used. Slow cutting speeds and fast feed rates are used for the course cutter and vice versa for the fine-toothed cutter. This enables a more detailed final part.
This is a milling operation where the cutting tools’ axis of rotation is at an angle relative to the surface of the workpiece. Therefore, single angled milling cutters can produce more angular features, such as grooves, serrations, or chamfers.
Form milling is best used for milling operations where more irregular surfaces are involved. Contours, outlines, edges, or parts with curved, flat surfaces. It employed milling cutters or fly cutters specialised for particular applications – for example, concave cutters or corner rounding cutters. Hemispherical or semi-circular designs or other similarly intricate designs with complex parts would benefit from the form milling technique.
Benefits of CNC Milling process
- High quality and precision is guaranteed The very nature of CNC Machining as a process leaves very little room for error and high levels of accuracy and precision. This is because it operates from a computer led program, inputting 3D designs that have been developed via CAD (Computer-Aided Design). All operations are launched via a machine interface.The machine executes these instructions without the need for manual input. These automated processes allow for ultimate precision to ensure even the most finite and complex geometry can be technically managed.
- CNC Milling allows for high production output The level at which CNC Machines operate means they are capable of high levels of production due to the automated processes involved. CNC Milling is a trusted and popular option if a part needs to be produced in high volume, with every part meeting the same level of consistency in terms of quality and finish. It is particularly easy to program and operate a 3-axis machine, achieving high accuracy at a low cost.
CNC Milling Manufacturing FAQs
CNC Milling is an abbreviation for computer numerical control milling, which is a technology that controls milling machines through computer programs for automated processing. It uses a rotating tool to cut the surface of the workpiece to produce the desired shape and size.
CNC Milling can provide the advantages of high precision, high efficiency, good repeatability, stable machining accuracy, large production batches, and flexible processing technology. In addition, product development and improvement can be accelerated by using CAD/CAM software for programming and simulation.
CNC Milling is suitable for machining a wide variety of materials including metal, plastic, wood and more. It is widely used in aerospace, automobile, medical equipment, electronics, communication and other industries.
CNC Milling requires two main pieces of equipment, a milling machine and a computer control system. In addition, auxiliary equipment such as milling cutters, fixtures, tools and coolants are required.
Tool selection needs to consider factors such as material, shape, size and cutting performance. Usually choose materials with high hardness and good wear resistance, such as cemented carbide and ceramics. The tool shape and size need to be selected according to the shape and size of the workpiece to ensure a good cutting effect. The cutting performance of the tool also needs to be selected according to the characteristics of the workpiece material to obtain the best processing effect.
The extension of tool life needs to consider factors such as the material, shape, size and cutting conditions of the tool. Tool life can be extended by using high-quality tool materials and tools with high machining accuracy. In addition, choosing the appropriate cutting parameters, such as cutting speed, feed rate and depth of cut, etc., can also prolong tool life.
CNC Milling machining accuracy is affected by factors such as tools, fixtures, workpiece materials, cutting parameters, and machine rigidity. In the actual processing process, it is necessary to select appropriate tools, fixtures and processing parameters according to the shape, material, size and processing requirements of different workpieces to ensure that the processing accuracy meets the requirements.
Cutting failure refers to the phenomenon that the cutting tool breaks, wears or overheats during the processing, which affects the processing quality and efficiency. To avoid cutting failure, the following measures need to be taken: select appropriate tool material and tool shape; control cutting parameters, such as cutting speed, feed rate and depth of cut, etc.; strengthen cooling and lubrication of tools to reduce wear and heat accumulation; replace damaged parts in time Tools and adjustment fixtures, etc.
The program design process includes the following steps: determine the shape and size of the workpiece; select the appropriate tool and cutting parameters; plan the cutting path; write the CNC program; perform simulation and debugging; upload the program to the milling machine and process it. In the process of program design, it is necessary to pay attention to the accuracy and stability of the program to avoid program errors and operational errors.
Operation and maintenance precautions include the following aspects: proficient in the operation methods and precautions of milling machines; pay attention to safety to avoid accidents; regularly inspect and maintain equipment such as milling machines and tools to ensure the normal operation of equipment; clean up milling waste and chips in time, Keep the working environment clean and tidy; record processing data and fault information in time to provide a basis for follow-up work.
Common question in CNC Milling Production
CNC Milling processing is widely used in various fields of manufacturing industry, including aerospace, automobile, electronics, communication, medical equipment, mold and so on. In these fields, CNC Milling processing can realize high-precision, high-efficiency and high-stability processing to meet the requirements of different workpieces. For example, the aerospace field needs to process complex parts of high-strength and high-temperature-resistant materials; the automotive field needs to process auto parts with complex shapes; the electronics and communication fields need to process high-precision electronic components, etc.
To ensure the machining accuracy of CNC Milling, we need to start from the following aspects: select the appropriate tools, fixtures and processing parameters; reasonably arrange the processing sequence and path planning; perform pre-processing inspection and calibration; timely replace damaged tools and adjust fixtures, etc.; Cooling and lubrication of cutting tools to reduce wear and heat accumulation; use high-precision control systems and measuring instruments. At the same time, strengthen the skill training and quality awareness of employees to ensure the operation standard and stable quality.
Compared with traditional milling machines, CNC Milling has the following advantages: First, it has high processing precision, which can realize high-precision, high-efficiency and high-stability processing; second, it has strong adaptability, and can process workpieces of various complex shapes and materials; It is high production efficiency, which can realize automation and continuous production, improve production efficiency and reduce costs; fourth, it is easy to operate, and can be processed by writing programs to reduce the possibility of manual operation and human error; fifth, it has high reliability, through monitoring and The feedback mechanism can detect and eliminate faults in time to ensure production stability and quality.
Selecting an appropriate tool requires consideration of the following factors: workpiece material and shape; cutting conditions, such as cutting speed, feed rate, and depth of cut; tool material and shape; processing quality requirements; and economy. When selecting a tool, it is necessary to select the appropriate tool material and shape according to the characteristics of the workpiece and the processing requirements to ensure the processing quality and efficiency.
To ensure the surface quality of the workpiece, we need to start from the following aspects: select the appropriate tool and cutting parameters; control the machining accuracy and stability; strengthen the cooling and lubrication of the tool to reduce heat accumulation and wear; control the vibration and resonance during the process ; Select the appropriate tool path and tool compensation; timely replace damaged tools and adjust fixtures, etc. At the same time, it is necessary to adopt different processing methods and technological processes according to the characteristics and processing requirements of the workpiece to achieve different surface quality requirements.
To prevent workpiece deformation, we need to start from the following aspects: choose the appropriate workpiece material and processing method; control cutting conditions and depth of cut; use appropriate fixtures and processing sequences; perform appropriate cutting allowance and relaxation; control tool cooling and lubrication to reduce heat accumulation and wear; strengthen workpiece inspection and calibration before machining. At the same time, it is necessary to strengthen the skills training and quality awareness of employees to ensure standard operation and stable quality.
Tool maintenance and replacement is an important link to ensure the quality and efficiency of CNC Milling. The maintenance of the tool includes regular cleaning, oiling and checking the wear degree of the tool, as well as grinding and calibrating the edge of the tool. The replacement of the tool needs to select the appropriate tool shape and material according to different workpiece materials and shapes, and select the appropriate cutting parameters according to the processing requirements and cutting conditions. When changing tools, tool compensation and tool calibration are required to ensure machining accuracy and stability. At the same time, it is necessary to reasonably arrange the service life and replacement cycle of the tool to prolong the service life of the tool and reduce production costs.
Processing quality inspection is an important means to ensure the processing quality of CNC Milling. Processing quality inspection can be done in many ways, such as visual inspection, three-coordinate measurement, surface roughness inspection, hardness measurement, material composition analysis, etc. In the processing quality inspection, it is necessary to select the appropriate detection method and equipment according to the characteristics of the workpiece and the processing requirements, formulate the detection standards and methods, and record and analyze the detection data. At the same time, it is necessary to strengthen the quality awareness and skill training of employees to ensure standard operation and stable quality.
Ensuring machining safety is an important task in CNC Milling. Processing safety needs to start from the following aspects: establish a sound safety management system and rules and regulations; strengthen employees’ safety awareness and skill training; strictly implement operating procedures and safe operation procedures; keep equipment and facilities in good condition and maintenance; Equipment failure and potential safety hazards; take effective safety protection measures, such as protective covers, safety switches, emergency shutdown devices, etc.; conduct regular safety inspections and assessments to ensure a safe environment in the processing site. At the same time, it is necessary to strengthen safety awareness and safety culture construction to create a good safety atmosphere.