How do CNC Machining Milling vendors run the First Piece of Your Project?

Published by Worthy Hardware at June 27, 2022

Table of Content

■ Types for machines

■ Step1-Analyze the production process

■ Step2-Prepare the Programs

■ Step3-Input the Programs into the CNC System

■ Step4-Check out the First Piece to Test the Programs.

■ Step5-Cost Per Part in the CNC Milling Process

■ CNC Milling (Mill-Turn Machining Center) Essential Skills.

■ Conclusion

Types for machines

1.Horizontal milling machine

The horizontal milling machine (well famous) is a type of machine tool that uses disc cutters, cylindrical milling cutters, forming cutters, angle cutters, end mills, and other tools to process various planes, inclined planes, and grooves with a spindle parallel to the worktable.

The horizontal mill is the most excellent option for cutting one or more grooves in material, creating slots, working on numerous sides and planes, and finishing massive projects with weighty material. We will explain the distinction between horizontal and vertical machines.

Working Principle of Horizontal Milling Machine

Multiple cutters can install on a horizontal spindle across the table; when the horizontal arbor stretches the length of the bed, the rotating cutting tool press against the workpiece and removes extra materials to produce the necessary CNC milling parts. A built-in rotary table on some horizontal machines allows milling at various angles.

Advantages of Horizontal Milling Machines

For complex applications, a horizontal mill is preferable over vertical milling.

Cutting tools on horizontal milling machines are typically short and thick.
The spindle sleeve has a limit device and can be manually fed in tiny quantities. The milling head can rotate 45 degrees in either direction
The worktable can be fed vertically and horizontally by hand or automatically, and it can move vertically.
The main drive and feed both use a gear speed change system with an extensive speed range.
The spindle bearing is known as a tapered roller bearing with a high bearing capacity and low energy consumption, allowing for high braking torque, quick stops, and consistent braking.
The rectangular guide rail is relatively stable
Super audio frequency quenches the worktable and guide rail, increasing their robustness.

2.Vertical Milling Machines

The vertical milling machine played a significant part in our actual activity. It has a strict, consistent performance and is very efficient. The machine tool cutting efficiency is outstanding because the vertical milling machine bed is a whole. Users have complimented the vertical milling machine for usage in manufacturing processes.

The X5032-X5040 is our most commonly used vertical milling machine. Every milling machine has a disadvantage, such as the milling head part not being able to be extended very far. Designers typically use the length of the Y design in the design.

However, because some workpiece surfaces are more significant than the machine's Y-axis and the processing surface to be processed once done, the use of a vertical milling machine is limited at this moment. Because a portion of the bed is fixed, it cannot meet the processing requirements. The fatal flaw of vertical milling machines is this.

Advantages of Vertical Milling Machines

Several sectors use vertical milling machines for diverse applications. Vertical machines have various advantages since they are adaptable and precise.

Because, as we know, casings are smaller and there are fewer sophisticated interior elements, vertical mills and the projects they produce are frequently less expensive than horizontal mills.
Vertical mills are straightforward to operate and maintain because they don't require any additional fixtures. Less downtime implies a shorter learning curve.
Availability: Because vertical milling machines are more widespread, you'll have an easier time finding components or getting repair help in the future. This is very important if you need to find a milling machine fast and start using it, as milling machines are frequently the most readily available.
Vertical milling machines, as we know, take up less floor space than horizontal milling machines. This means that small shop owners will have extra space to work in or place additional machinery.
Vertical mills are an excellent alternative for someone new to milling or a firm that is just getting started. They are simple to use and do not require a significant initial investment as horizontal milling machines.

3.Multi-axis CNC Milling Machine

A multi-axis linkage machine tool is a CNC milling machine. Drilling, milling, boring, and reaming are all capabilities of the machine tool. And allowing it to not only do coordinate boring but also precisely and efficiently finish the automatic processing of various 3D complicated curved surfaces.

Such as templates, dies, arc grooves, and other parts. Machine tool body, column, spindle, feed mechanism, and other mechanical pieces are among its mechanical components.

Advantages of Multi-axis CNC Milling Machine

The ability to generate complex 3D things is one of the most well-known and significant advantages of multi-axis machines over 3-axis machines. Its other movements enable it to create a variety of arcs and angles. Previously, only clumsy setups and unique fixtures on the device allowed for these operations. This also makes prototyping and small-run product production considerably faster and less expensive, saving time.

Quick Change Compared to its predecessors, CNC machining requires substantially less setup. Multi-axis machining can mill almost every visible surface, with the exception of the clamping or bottom areas. This characteristic means that it can be used without using multiple specific fixtures or additional setups. This can sometimes decrease the number of configurations required to just one.

Multi-Axis machining has better relational precision since it requires fewer setups. You increase your chances of experiencing imprecision every time you move apart for re-fixturing or a setup change. If you shift one section of the machine, the precise alignment will be lost. Relational correctness will be significantly improved by having fewer setups and using the same "home" or "zero" location.

Multi-axis machining can actually extend the life of a tool. It improves due to the instrument or table being titled regularly. This ensures that the best cutting position is maintained.

A shorter cutting tool can be used on a multi-axis machine. As a result, there are fewer vibrations at very high speeds. As a result, improved surface finishes. Using the machine's fourth and fifth axes, you may accomplish this. The part can then be oriented and brought much closer to the cutting tool. The closer the position is to the cutting tool, the shorter it can be, which minimizes vibrations greatly. If you already have outstanding surface finishes on the part, you can save a lot of time hand-finishing it.

The Multi-Axis machine's 3+2 axis machining is another significant benefit. Some items can only be machined using the 5-axis movement, while others are better machined using the 3+2 axis movement when creating several products. The fourth and fifth axes are employed in 3+2 axis machining to locate either the cutting tool or the workpiece in a fixed position, depending on the machine used. This implies you won't have to move all five axes at the same time.

Step 1-Analyze the production process

The milling process uses a revolving tool that comes into contact with the workpiece to chop off chips. The desired shape is achieved through continual cutting.

milling techniques
Milling ascent
The thickness of the cutting chip rises. This can also bring about an increase in blood pressure.
temperatures conducive to job hardening
More rubbing and friction occur at the start of a cut, causing tool wear and limiting its lifespan.
Chips may fall back into the cutting path as the teeth move them upward, lowering the finish quality.
The workpiece must be clamped and fixed more tightly to avoid displacement produced by the large upwards forces.

How You Should Choose Milling Machine & How its Components Work

A milling machine, as we know a machine that uses a revolving cutter to remove metals from a workpiece. Feeding the workpiece against a spinning milling cutter is used to machine flat, rough, and uneven surfaces.

A 2D or 3D CAD part design is used to start the CNC milling process. The finished design is finally then exported to a CNC-compatible file format and turned into a CNC machine program by CAM software, which directs the machine's operations and tooling movements over the workpiece.

When the CNC milling process is started, the machine starts spinning the cutting tool at speeds of thousands of RPM. As the tool cuts into the workpiece, depending on the type of milling machine used and the milling application's needs, the machine will do one of the following activities to generate the necessary cuts on the workpiece:

Slowly feed the workpiece into the revolving tool that is stationary.
It Moves the tool in a very proper way around the whole workpiece that isn't moving.
Both the tool and the workpiece should be moved in relation to each other.

Unlike manual milling, CNC milling feeds mobile workpieces with the cutting tool's rotation rather than against it. Climb milling processes follow this convention, whereas traditional milling techniques go against it.

The column and base of a milling machine give support for the other components. The spindle is then lubricated by an oil reservoir and pumped into the column. The base always supports the column and includes a coolant reservoir and pump for machining operations.

Types of CNC Milling Machines

There are many different forms of CNC milling and a variety of milling machines with other qualities and functions. The following are some examples of milling machines:

Ram-type:

This machine has a spindle attached to a movable arm on the column that allows the machine tool to move on the XY axes. Ram-type horizontal milling machines are standard.

Knee-type:

machines will adjust the worktable vertically rather than the spindle. The knee will drop and raise the worktable along the column to reach the machine tool. A knee-type machine is frequently used for plain milling.

Planner-type:

The worktable is fixed along the YZ axes in this milling machine, while the spindles can move along the XYZ axes. They can also support up to four machine tools at once.

Bed-type:

The workpiece is fixed underneath the cutting tool in these milling machines. It's possible that the machine tool can move along the XYZ axes.

Step2 -Prepare the Programs

CNC programming is a mysterious and challenging task. You'll never have to write CNC programming by hand again. Make parts faster the first time by generating G-code with Worthy Hardware så. Let's take a look at what goes into a milling machine. New milling centers have the ability to conduct a wide range of operations, but they are also more complex. To glance at an overview of the given machine components, we'll stick to the more standard benches.

Step3- Input the Programs into the CNC System

How can CNC Machining be programmed? CNC programming entails the programmer (or CNC machine operator) compiling a set of instructions that may be executed on the CNC machine tool to fulfill the specified processing tasks in accordance with the part drawings and process documents. CNC machine tool programming encompasses the complete process, from part drawing and process requirements analysis to program inspection.

Manufacturers use CNC programming worldwide to operate a machine's tools and make items. A set of instructions that informs a CNC machine where – and how – to move is at the heart of this automated manufacturing process. G-Code is the name for these instructions.

G-code has been generated via CAM, or computer-aided manufacturing, since computers became smaller, cheaper to operate, and more widely available. Your 3D CAD model, tool options, and other data are all inputs into a CAM application. It then optimizes the tool paths and generates G-code to instruct the CNC machine.

G-code programs can be written by hand (I created a brief one in grad school!) Unless you're a perfectionist masochist, you generally don't want to do it for sophisticated machining procedures needing tens of thousands of lines of code.

Step4- Check out the First Piece to Test the Programs.

Always start with the program above the segment. 0% quickly, even if you think everything is fine because perfection is nearly difficult to achieve. To mimic your tool path, use the graphics. To allow for some part dimension flexibility, change the diameter offset on your milling tools.

This is especially critical if you're working on a complicated part or only have a limited amount of stock to work with. Don't stress about doing it quickly the first time. After you've got the dimensions down, experiment with increasing feed rates and fine-tuning your starts, stops, and step-over distances. PLEASE TAKE YOUR TIME.

Step5- Cost Per Part in the CNC Milling Process

Many factors determine CNC milling costs. CNC milling costs are determined mainly by the time it takes to machine each item. The necessity to remove significant amounts of material or hard materials may result in more extended milling periods.

Depending on the part design, some sections may require more difficult tools or cutting. Material and part complexity are also factors that influence CNC milling costs. You can request a CNC Milling quote from the Worthy Hardware team by clicking here or learning more about our CNC Machining services.

CNC Milling (Mill-Turn Machining Center) Essential Skills.

The CTX TC, NT, and NTX series turn-mill machines represent the pinnacle of universal turning centers. These turning machines can perform up to 6-side turning and 5-axis CNC milling in a single setup.

A part that requires multiple processes can be machined in one configuration, mainly if a sub-spindle permits the item to be passed from one spindle to another while being machined, effectively machining two sections simultaneously.

Faster part production, higher precision (no re-chucking), and shorter setup periods are all possible when these procedures are combined in one complete cycle. Absolute's CNC mill/turn centers provide those benefits at a low cost.

Other elements that contribute to the uniqueness of these versatile, high-performance machine tools include dynamic linear drives, robust B-axis, and rapid revolvers as tool carriers or a swivel-mounted counter spindle (NTX).

Conclusion

A variety of firms sell most CNC milling machines and machining centers. Worthy Hardware, Asia's leading machine tool manufacturer, offers a wide range of CNC milling machines, CNC milling equipment, and 5-axis machining centers in various sizes and configurations to match your needs.

Make your product a reality while exceeding customer expectations. We use CNC milling, turning, and other manufacturing methods to turn your plans into well-made items.

Our service for your interest is second to none, whether you need a custom prototype or low-volume production for 1000+ copies. We get the work done right the first time, thanks to a strong focus on quality control. We'll go above and above to assist you in realizing your product concepts! You can look through our product list or request a consultation by filling out the contact form.

Choose Worthy Hardware and get service updates every time there are some made. Services updates are critical as you will be able to find something new every time, they bring up recent service updates. Also, you will get fast delivery at your doorstep.

We deliver machined aluminum parts and manufacturing metals used in CNC milling for aircraft and medical industries. The range of the types of machined aluminum parts is varying and vast.

Using CNC machine, the material and aluminum parts range from aircraft and medical to workshop and food industry.

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.