What is Custom CNC Milling?

Published by Worthy Hardware at April 11, 2022

Table of Content

■ Milling Process

■ Types of milling machines

■ 3-axis milling,4-axis milling, and 5-axis milling

■ Suitable Materials

■ Importance for Custom CNC milling

■ Conclusion

Milling Process

CNC machining is a subtractive manufacturing method like CNC turning to perform a machining task, and it uses machine tools and computerized controls to remove layers of solid block material. The CNC milling process is different from the CNC turning process.

CNC (computer numerical control) machining is a manufacturing process to produce CNC machined parts using a high-speed cutting tool. CAD model provides the part geometry so CNC mills can cut metal alloy of tight tolerances and high precision custom machined parts.

The milling process is considered best for the different features such as slotting, threading, etc. Various milling machining processes or operations are helpful in the production of these features. The followings are some commonly used milling processes.

Plain milling

Plain milling can term surface milling. In plain milling, commonly plain CNC mills are used. Its means that the rotational axis of the cutting tools remains parallel to the cutting surface. Various cutters can use in plain milling. These cutters can be narrow or wide, and the type of cutter used depends on the required outcome.

The material can be removed fast by using a wide cutter. But, it requires a fast feed rate, slow cutting speed, and coarse cutter teeth. The more delicate cutter teeth are used in the second step by changing the tools. Using the finer cutter teeth also needs slow feed rates and fast cutter speed. It results in the slower removal of material per uni time and an accurate final finish.

Face milling

Face milling is a commonly used CNC milling process. This CNC machining milling process can use cutting tools having the teeth on both sides and at the end. Most of the cutting is done by the teeth present on both sides. At the same time, the teeth on end give a better surface finish. In this process, the axis of the tools remains perpendicular to the parts that need to be machined. It can complete after the plain milling. The face milling process produces a better surface finish and better intricate contours.

Angular milling

The angular milling process helps create the features such as grooves, chamfers, and many other features. The features can make by using different ways. Various cutters are used to get the best results in the case of the regular 3 axis mill. These cutters are maybe the dovetail cutters for the production of the angled grooves. It can be a mill with a conical cutting head and used for chamfering. The cutter's axis may align with the surface in the angular milling process or be perpendicular to the surface.

Form milling

The form milling uses special tools to create the complex contours of the surfaces. In this process, commonly concave and convex cutters are used. A single cutting can create complex surface contours in the form of milling. The special tools can help make the features such as round edges, round recesses, and other features. The accurate parameters of the cutting tools are required to achieve the desired outcome. A sub-category of the form milling is gang milling. In gang milling, the different cutters can use at a time to create different patterns.

Types of milling machines

The followings are the primary milling machines.

Horizontal Milling

In the horizontal milling machines, the axis is present horizontally. In the case of end mills, the horizontal mills are considered best. It is straightforward to build a horizontal mill. The cutting tools are attached to the arbor to build a horizontal mill. The arbor brackets can be removed whenever a change of tooling is required. The spacers can also remove for tool replacement.

A vise is needed to fix the workpiece on the working table. The transverse can move the table on the X, Y, and Z-axis to remove the workpiece. Various spindles with different tools are available in the horizontal milling centers. These may be used for fast turnaround times. The tools and the tables can move in different directions, such as the rotational axis.

Advantages

The horizontal milling machines offer several advantages.
Complex parts can create by using horizontal milling machines.
It has a much longer tool life.
It aids in producing parts with fewer operations.
It is 4 times faster than compared to vertical milling.
It produces the best surface finish of parts.

Vertical milling

A vertical milling machine is considered best for end milling because of the vertical position of the tool axis. A verticle CNC mill has a variable speed spindle having a verticle axis orientation, and it starts by creating a digital part, then it converts into "G" code. The main components of both the vertical and horizontal axis are the same.

They only differ because of a few features. The machine head is present at the end of the ram while the spindle is attached to the head for the tool's cutting. The vertical mill can move in all three directions like the horizontal mill in CNC machining.

The similarity in the movement is due to the similar positions of the tables in horizontal and vertical mills. More access can obtain by rotating the parts through the modern 5-axis vertical mills. It may also help in attaining fast turnaround times. The automation of all the movements can get more accuracy. It may also result in a fast lead time for the CNC machining process.

Advantages

The vertical milling machines offer the following advantages.

Vertical milling machines are inexpensive, so they are easily available in workshops.
Less space requires because of the smaller size of the machines.
The visibility provided by the vertical mills is much better, so they are easy to use.
Vertical mills are 4-5 times cheaper than compared to horizontal mills.
It provides better results than horizontal milling machines.

Multi-axis milling

The tools can move in different directions in multi-axis milling, commonly over 4 directions. It helps manufacture the other parts by water jet cutting, milling away the extra material, and cutting through lasers. It has various axis, and these multiple axes can control by the levers that may locate on the cam plates. The cam plates control the tooling devices. The machine setup takes a lot of time due to the complexity and the large size of the machine. There are three main components found for multiaxis machines.

The CNC drive system needs to move the machine components such as ball screw, servo motors, and rapid traverse systems.
Physical capabilities of machines such as spindle speed, axis orientation, and torque.
The controller of the CNC machine transfers data within the machine.

3-axis milling,4-axis milling, and 5-axis milling

It is done by 3-axis mills in which the movement of the table is in two directions, i.e., X and Y directions. As a result, the workpiece is positioned relative to the cutting tool. But, it does not affect the distance, and it remains the same. Thus, a third axis called Z-axis is added by lowering the cutting tools. The movement of all three axes is controlled by the CNC controller, providing maximum flexibility.

4-axis milling is done through 4-axis mills. It has all three axes, i.e., X, Y, and Z-axis. A 4th axis, termed as A-axis, is then added. Because of the addition of the 4th axis, the table can easily rotate around the 1st axis, i.e., the X-axis. It helps in the sizes of face milling without the workpiece's repositioning.

It is done through 5-axis mills. In 5-axis mills, a 5th axis called B-axis is added. It provides the rotational movement around Y-axis. 5-axis milling can produce complex parts as compared to other millings. There is no need for extra setup for 5-axis milling. It also aids in enhancing the tool life.

Suitable Materials

Several types of CNC machining materials can use for CNC milling, and it is one of the main advantages of the CNC machining process. These materials have specific features and characteristics such as have electrical conductivity, electrical insulation, and chemical resistance. Brass has low friction and excellent electrical conductivity. Epoxy grade industrial laminate for rocket cases and high-temperature applications.

Stainless steel offers many properties for industrial applications. Copper 101 can provide excellent electrical and thermal conductivity while used for wire connectors and bus bars. Plastics have their unique characteristic, such as PTFE is an excellent electrical insulator and surpasses many other plastics when comparing its chemical resistance and performance in the CNC machining process.

Some materials can enhance corrosion and wear resistance of other materials when they chemically react with other materials during the CNC machining procedure.

Worthy hardware uses various materials and offers CNC milling and CNC turning machining tasks. You can get customer support and material certifications with your request. At Worthy Hardware, many materials are available ‌suitable for CNC machining and custom milling.

We ensure flexible production and quality CNC machined parts and accept technical drawings for the production machining. Our CNC milling service and precision CNC machining services for production machining are exceptional in the industry.

Metals

Following metals are used for the manufacturing of CNC parts.

Brass with excellent electrical conductivity and low friction.
Tool steel for CNC machining
CNC machining brass alloys(copper 260 & copper 360)
CNC machining stainless steel alloys such as Stainless steel 303,Stainless steel 416,Stainless steel 420,Stainless steel 15-5,Stainless steel 440C
CNC machining Mild steel
CNC machining Aluminum
Titanium is a good insulator with low thermal expansion

Plastics

Following plastics are considered best for CNC milling and machined parts.

PEEK
PTFE
Polycarbonate
ABS
HDPE
POM
Nylon

Importance for Custom CNC milling

CNC machining has much importance, and it makes it possible to achieve tighter tolerances for stainless steel and custom CNC parts. CNC mill helps in the fast production of machined parts with high quality. CNC machining results in the production of more appliances. It produces high-precision parts at high rates. The parts made through custom CNC machining have great importance and can use in almost all fields.

Some main advantages of CNC machining advantages are as follows:

1: Availability of different CNC Machining Materials & Surface Finish

CNC machining is a fast process, and CNC machining surface options are unlimited such as metal materials and bulk plastic materials for the fabrication of plastic parts and metal blocks. The surface finish of CNC machining has visible tools marks, and you may need a secondary finish to sort out this problem. Surface finish has different prices and requirements. As for CNC milled surface finish, it will be the requirement of a minimum of 125 surface finish for CNC machining parts. Other types of surface treatments are available for the CNC machining production parts, such as:

Anodizing improves wear and corrosion resistance in the CNC machining process.
Electroless nickel plating for aluminum and stainless steel
Powder coating for stainless steel and aluminum for CNC machining.
Chromate conversion coating to improve corrosion resistance while performing CNC machining manufacturing.
Anodizing bead to enhance wear resistance and corrosion resistance.
Nickel plating and zinc plating are used in CNC machining for aluminum and stainless steel material.
As-milled surface finish, in this finish parts, remains left with visible tool marks.

2: Reduced Cost & Fast Production

CNC machining is a cost-effective method as the machinability and cost of the bulk material are significantly less. Using the CNC machining process, you can make desired cuts according to machinery and corresponding tools. It is a fast production machining system, and you can mill 80% of parts within minutes by using a computer numerical control system and special cutting tools. CNC machining is suitable for low volume and rapid prototyping production and low volume and bulk production fabrication. You can choose this manufacturing method to fulfill the specifications of your desired parts. Due to CNC machining and state-of-the-art machines, it is a fast method to produce parts in a short time.

3: Complex Parts Manufacturing

CNC milling and CNC machining make the possible intricate and complex shapes of CNC milled parts. You can get tight tolerances, irregular shapes, and highly complex parts. CNC milling is one of the best choices to produce production parts and rapid prototyping than other additive manufacturing methods. Intricate parts production is one of the significant advantages of CNC machining you can get at a cost-effective price.

Conclusion

Custom CNC Milling is a process that makes the use of computerized control and cutting tools for the production of custom-designed products or parts. Various CNC milling processes are used in CNC milling, including plain, face, angular, and form milling. These milling processes used different cutting tools or cutters to produce various parts features. The custom-designed complex parts are made using other milling machines.

You can get an instant quote for CNC machining and high precision milling parts by contacting us at Worthy Hardware, a place of excellence and a fully vetted CNC machines shop.

Worthy Hardware is a CNC manufacturing and sheet metal fabrication company,including CNC machining services,CNC milling services, CNC turning services, laser cutting services and stamping services.Call us +86-76989919645 or email us [email protected] for more discounts for your projects.