CNC milling is one of the most common processes when looking to produce complex parts. Why complex? Whenever other fabrication methods like laser or plasma cutting can get the same results, it is cheaper to go with them. But these two do not provide anything similar to the capabilities of CNC milling.
So, we are going to take a deep dive into milling, looking at the various aspects of the process itself as well as the machinery. This will help you understand if you require CNC milling services to produce your parts or is there a more cost-effective alternative Available.
What is CNC Milling?
We are going to look at the process, machinery, etc. in later paragraphs. But let's first make clear what CNC milling means and bring clarity to some of the more confusing points about the term itself.
First, people often ask for CNC machining when looking for milling. Machining entails both milling and turning but these two have distinct differences. Machining refers to a mechanical cutting technology that uses physical contact to remove material, using a wide range of tools.
Secondly, all CNC machining uses CNC machines but not all CNC machines are for machining. Computer numerical control is what lies behind these three letters. Any machine using CNC utilises computerised systems for automating the cutting process.
Therefore, CNC machines also include laser cutters, plasma cutters, press brakes, etc.
So CNC machining is a mix of these two terms, bringing us the answer to the question posed in the heading. CNC milling is a substractive fabrication method that uses computer numerical controls systems for automating the process.
Milling Process
We could limit ourselves to describing the fabrication process only but giving an overview of the complete flow gives a more wholesome picture.
The milling process includes:
Designing the parts in CAD
Translating the CAD files into code for machining
Setting up the machinery
Producing the parts
Designing the CAD files & translation into code
The first step is creating the virtual representation of the final product in CAD software.
There are many powerful CAD-CAM programs that let the user create the necessary Gcode for machining.
The code is available for checking and amending, if necessary, to suit the machine's capabilities. Also, manufacturing engineers can simulate the whole cuttinq process using this kind of software.
This allows checking for mistakes in the design to avoid creating models that are not possible to produce.
G code can also be written manually, as was done in the past. This, however, prolongs the whole process considerably. Therefore, we would suggest making full use of the possibilities modern engineering software offers.
Setting up the machine
Although CNC machines do the cutting work automatically, many other aspects of the process need a machine operator's hand. For example, fixing the workpiece to the worktable as well as attaching the milling tools to the spindle of the machine.
Manual milling depends heavily on the operators while newer models have more advanced automation systems. Modern milling centres may also have live tooling possibilities. This means they can change the tools on the go during the manufacturing process. So there are fewer stops but someone still has to set them up beforehand.
After the initial setup is done, the operator checks the machine program one last time before giving the machinery a green light to start.
Post time: Jun-03-2019
