What Is CNC Milling
CNC milling is a manufacturing process that uses a cutting tool mounted on a rotating spindle to selectively remove material from a block of raw substrate. The workpiece is rigidly mounted to a table, and this table moves or rotates on different planes so the tool can work at many angles. Sophisticated CNC milling machines can have 5 or more axes of independent motion to make more complex shapes or to avoid having to move the workpiece to a separate machine.
Advantages of CNC Milling
Precision
One of the biggest advantages of using CNC millings is that they can create parts exactly to specification. Because CNC mills rely on computer instructions to fabricate parts, they eliminate the possibility of human error common in manually operated machines. This means you can accurately create complex parts while achieving tolerances as tight as 0.004mm.
Fast and efficient
Conventional milling machines often require an operator to manually change cutting tools depending on the cutting operation to be performed. Not only is this time-consuming, but it is also inefficient as end results are based on the operator’ s judgment.
Wide range of material options
CNC mills boast compatibility with a wide range of materials, including plastics, metals, and composites. So long as you’ ve got blocks of the material, CNC mills will have no problem machining it.
Affordability
We can talk about precision, speed, and a ton of other advantages all day, but nothing beats affordability, especially for businesses looking to rely on third-party manufacturers. CNC milling is among the most affordable modern-day manufacturing processes.
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Why Choose Us
Advanced equipment
Shenzhen Tuohai has Mazak five axis, CNC machining center, CNC lathe, turning and milling compound, milling machine, Japan Okamoto grinding machine and other kinds of production equipment more than 30 sets, three dimensional, two dimensional, height meter, hardness meter, marble inspection platform and other kinds of quality inspection equipment more than 10 sets.
Our certificate
Has passed ISO9001 quality certification, SGS certification,Utility model patent certificate. The company has ISO9001:2015, high-tech enterprises, specialized new enterprises and other titles, and in 2023 through Ali SGS certification, won the Ali Jinpicheng enterprise.
Our service
Free drawing design, Engineer drawing analysis and free quotation consultation, recommend suitable materials and processes according to the requirements of customer, 7*24 hours on line service. The sales staff will maintain active contact and cooperation after signing the contract, follow up the production progress of the product and the delivery date of the processing completion in real time, etc. When receiving the customer's change request, they will respond to the change as soon as possible, in order to solve the customer's change. We can provide technical support and actively cooperate in the process of debugging and installation, quality problem, we can help repair or re-production.
Our product
We mainly engaged in a variety of precision machinery parts processing,CNC processing,CNC lathe processing, etc., the company set manufacturing, specialized, sales, after-sales service as one, processing precision parts are widely used in machinery manufacturing, oil mining, aviation military, precision instruments, medical, communication electronics, new energy, etc. Optics and other industries.
Types of CNC Milling
Vertical milling
Like the drill press mentioned earlier, vertical milling operations have the tooling rotation running vertically (in the direction of gravity). A simple vertical cnc milling machine will have three axes where the tooling moves vertically; the table moves from the front to the back of the machine, as well as from side to side. These machines are common in many machine shops because they are cost-effective, simple to program, but still offer diverse capabilities. This video shows a vertical machining center milling hardened tool steel.
Horizontal milling
Horizontal milling machines have the same primary function as vertical machines— removing material from a component; however, in a horizontal milling machine the tooling spins horizontally. The two different machines can use the same type of tooling as well. Horizontal milling machines are often more expensive but are better suited for production machining. A horizontal cnc milling machine will often have a fourth axis for rotation. In the previous video, you can see the table can rotate to allow the milling head to access other sides of the part. For production (producing many of the same parts) this machine also has a pallet changer. The machine has two working areas. One where the components are being machined and another where an operator can safely work on the next set of components. The advantage is the optimization of cutting time. Without the pallet changer, the machine sits idle while an operator is switching our components or changing machine setups. The video below shows the pallet changer in action.
Multi-axis cnc milling machines
Each additional axis represents an additional type of movement. Going beyond three-axis machines greatly expands the capability of a cnc milling machine. Below is a quick reference to the various types of CNC turnings along with some advantages and disadvantages of each. Generally speaking, matching the complexity of the part to the complexity of the machine is a best practice. It doesn’ t make sense to produce a low tolerance / simple part in a 5 axis milling machine. That is, unless the increased efficiency of having more axes yields a cost savings advantage.
How Do CNC Milling Work
Create a CAD model
Machinists use a design program such as Autodesk Fusion 360 to create a CAD model of a specific component.
01
Convert CAD model for CNC machine
Next, import the CAD model into the CAM computer-aided manufacturing system. Done right, you’ ll end up with a series of digital instructions that tell the CNC machine what to do—otherwise known as G-code. G-code commands let machines identify where to move and how fast to do it to make a specific component.
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Set-up up the CNC milling machine
Attach the workpiece or block of material on the machine bed—and make sure it's properly aligned through metrology tools or touch probes. Install the machine spindle and do all steps required for setting up the milling machine.
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Begin the milling process
Load the program to start the CNC milling process. The specialized cutting tools rotate at high speed or a fixed revolution per minute to subtract material from the workpiece—until it accurately replicates the desired component.
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CNC Milling Process
Some milling machines will be more appropriate than others, depending on various factors. The complexity of the CNC milling operations will be dependent on the design of the final part. The more structurally important and high-end the part or product is, the more complex the design may need to be. For example, a more complex machine may need to be used for intricate designs requiring high precision, such as medical or aerospace components. This is to achieve the final design, finish, and aesthetic. Basic parts that are machined for more general use may not require such high precision or high-quality finish. Complex and intricate designs will typically require additional milling. Often milling machines utilise either 3, 4 or 5 axes.
For simpler parts, fewer axes are needed to achieve the final design. Simple geometries can generally utilise a 3-axis milling machine. They are easy to program and operate, achieving excellent accuracy at a low cost. The cutting tools are attached to a spindle that works on three linear axes. They can spin at thousands of RPM, meaning even the sturdiest of materials can be cut through with ease and accuracy. 3-axis machines are the most common variety of a CNC mill and can cut vertically (Z-axis) and in an X and Y direction. However, it’s usually not possible to machine undercuts with 3-axis CNC mills. These are features that cannot be accessed with a standard end mill. This means that more complex designs may require a more complex milling machine.
The 4-axis milling machine is more sophisticated, with the additional ability to rotate on the X-axis (similar to a lathe). 5-axis milling machines include rotation in both the X and Y-axis. They are the most complete milling machines available and are implemented for highly complex designs such as medical devices and implants for the medical industry, impellers and aerospace structures.
Parts of a CNC Milling
CNC controller
The CNC controller serves as the brain of the machine. It is responsible for controlling the movements and functions of the CNC milling machine. CNC controllers eliminate the need for manual machining. They read the CNC program or G-code supplied by the input device, and convert these codes into the respective machine movements. The CNC controller then executes the commands by sending the proper signals to the stepper and servo motors. This facilitates efficient and precise machining processes.
Column and base
The column and base are designed to support all other components in a CNC machine. They also provide rigidity and resist vibrations generated during the machining process. These components are often made of cast iron. The column and base are also typically filled with epoxy granite which improves their ability to resist vibrations during machining operations. This leads to higher quality machined parts.
Knee
A knee is a cast iron component that is fixed to the column through a dovetail. It can be moved up and down by a vertical positioning screw. This allows for vertical adjustment of the work table. The knee also provides extra support to the saddle and milling table. CNC mills are equipped with an automated system that adjusts the position of the knee based on the G-code supplied to the CNC controller. You can also move the knee manually through a hand crank.
Saddle
The saddle is positioned between the knee and the work table. It is typically made of cast iron and serves to support the work table. The saddle allows for the vertical and horizontal adjustment of the workpiece.
Feed mechanism
The feed mechanism of a CNC machine is housed in the knee. This electromechanical system controls the vertical (up and down), longitudinal (left and right), and transverse (in and out) feeds. The feed mechanism comprises electrical motors that receive signals from the controller and create the desired movement in the workpiece to facilitate the cutting operation.
Work table
As the name implies, most machining operations are conducted on the work table. The table is a flat platform used to hold the workpiece during machining. It is mounted on top of the saddle. In most CNC machines, the worktable is made of cast iron and is equipped with T-slots. These T-slots allow for the workpiece to be secured onto the table through different fastening devices such as clamps or vices.
Ram
The ram is an adjustable, arm-shaped component that is specific to a vertical milling machine. It’s positioned on top of the column and it serves to hold the milling head.
Overhanging arm
Just as the ram is specific to vertical milling machines, the overhanging arm is a feature of horizontal milling machines. This cast iron beam is mounted on top of the column and it holds the milling head which supports the milling tool assembly.
Arbor support
The arbor support is a cast iron part that is specific to a horizontal milling machine. It is linked to the spindle via bearings and is responsible for supporting the cutting tool. The arbor support also plays an important role in dampening vibrations generated during machining activities.
Spindle
A spindle is one of the key components of a CNC system. It consists of a taper that holds the milling tool. The spindle is linked to the main motor of the CNC machine. The CNC controller reads and translates the G-code, rotating the spindle at the specified speed. Spindle rotation is very important as it drives the cutting tool. This component also houses the milling chuck.
How to Maintain and Extend the Lifespan of Your CNC Milling
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Regular cleaning and lubrication
To maintain the lifespan of your CNC milling, regular cleaning and lubrication are essential. Remove chips, debris, and coolant from the machine regularly. Use brushes, air compressors, or vacuums to clean the spindle, tool holders, way covers, and other components. Apply appropriate lubricants to the machine’ s moving parts as specified by the manufacturer. This includes the spindle, ball screws, linear guides, and tool changers. Regular lubrication minimizes friction, reduces wear and tear, and ensures smooth operation.
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Implement a preventive maintenance program
A well-designed preventive maintenance program can significantly extend the lifespan of your CNC milling. Develop a schedule for routine maintenance tasks, including inspections, lubrication, and part replacements. Adhere to this schedule to prevent unexpected breakdowns and costly repairs. Regularly check electrical connections, cables, and wiring for signs of wear or damage. Replace any faulty components promptly to avoid potential malfunctions. Inspect the coolant system for proper fluid levels and cleanliness. Replace coolant filters regularly and clean or replace coolant tanks to prevent clogging and maintain effective cooling.
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Train operators and maintain proper tooling
To ensure the longevity of your CNC milling, proper training for machine operators and maintenance of tooling are crucial. Train your operators to use the machine correctly, including understanding the programming language, tool selection, and proper loading and unloading procedures. This helps prevent operator errors that can lead to machine damage. Regularly inspect and measure the condition of cutting tools. Replace worn or damaged tools promptly to prevent poor-quality cuts, excessive strain on the machine, and potential tool breakage.
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Monitor machine performance and address issues promptly
Monitoring the performance of your CNC milling allows you to identify potential problems early and take corrective action. Monitor spindle performance: Keep an eye on the spindle’ s temperature, vibration, and noise levels. Unusual readings may indicate issues with bearings or other internal components that require attention. Periodically check the machine’ s accuracy by running calibration tests and verifying the alignment of the machine’ s axes. Adjustments can be made as necessary to maintain precision.
Our factory
Shenzhen Tuohai Automation Equipment Co., Ltd. was founded in 2014, mainly engaged in a variety of precision machinery parts processing,CNC processing,CNC lathe processing, etc., the company set manufacturing, specialized, sales, after-sales service as one, processing precision parts are widely used in machinery manufacturing, oil mining, aviation military, precision instruments, medical, communication electronics, new energy, etc. Optics and other industries.Shenzhen Tuohai has Mazak five axis, CNC machining center, CNC lathe, turning and milling compound, milling machine, Japan Okamoto grinding machine and other kinds of production equipment more than 30 sets, three dimensional, two dimensional, height meter, hardness meter, marble inspection platform and other kinds of quality.
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