Things you should know about Custom CNC Milling

by admin | May 21, 2018 | CNC Machining, CNC Turning and Milling, Custom Machine Shop

CNC milling is one of the most popular CNC machining processes. Milling incorporates the technical aspects of both drilling and cutting processes; CNC milling uses a rotating cylindrical cutting tool just like in drilling. But, unlike the single axis motion of the latter, the cutter and workpiece in a milling machine can move along three, four and even five axes allowing it to produce shapes, holes and slots with tight tolerances. In addition, the workpiece is often moved across the milling tool in different directions, unlike the single axis motion of a drill.

However, multi-axis functionality isn’t the only unique thing about Custom CNC milling. In this article, we will be exploring some of the major/minor facets of the machining type including main components, CNC mill types, advantages with CNC milling and more.

CNC Milling Machine- Main Components

Let’s first familiarize ourselves with the critical components that comprise a CNC Milling machine.

1. Control panel: Control panel is the brain of a CNC milling machine. The machinist/controller feeds the G-code (required dimensions) using the keyboard which, in turn, instructs the axis motors to move the cutters and other components.

2. Table: The table is used to hold the workpiece stationary for the entirety of the milling process. The workpiece is fit to the metal/wooden/plastic table using T-slots and metal clamps.

3. Column: The columns run along the axis to give a backbone to the milling part.

4. Cutting tool: A cutting CNC machine tool is attached to the column. It moves across the axis to give the desired shape to the CNC machined parts.

5. Frame: As the name suggests, the frame gives sturdy support to the machine, providing them with maximum rigidity to withstand cutting forces. It is mainly built using cast iron.

6. Axes: The axes in a CNC milling machine allows cutting tool/workpiece to move around obtain the maximum possible precision.

7. Spindle: The spindle consists of a rotating assembly that holds the cutting tool and a motor that runs the entire workpiece.

8. Coolant supply tube: The coolant supply tubes are used to cool down the rapidly heating metal workpiece and to lubricate the cutting tool for smooth movement.

There are two types of CNC milling machines available with respect to its working- Vertical and Horizontal- with the major difference being in their spindle placement.

Vertical CNC Mills
Vertical CNC milling machines have a vertical spindle axis. In this machine type, the cutters are placed vertically in the spindle and are able to make drilling or plunge cuts. Popular examples of Vertical CNC mills include Bed mills and Turret mills.
Horizontal CNC Mills
In horizontal CNC milling machines, the cutters are placed horizontally on an arbor.

Here are a few features of a CNC Milling machine that makes it an ace in the CNC manufacturing industry.

1. Safety– Custom CNC Milling process is about 10x faster and safer than traditional milling machines’. With computer systems handling everything, there is minimal contact between the machines and the operators. The operator feeds in the codes and the machine is directed to produce custom machined parts with tight tolerances. The manual work is reduced by a multifold and the chances of human error is next to nothing.

2. Accuracy – CNC milling machines are notorious for producing guaranteed accuracy all thanks to its next-gen features and innovative working. Tight tolerances are no big deal with CNC milling machines.

3. Versatility – CNC milling machines are not limited to producing machined parts out of one material type. From metals to industrial plastics and alloys, almost every material type can be used with a CNC milling machine that too without compromising on the quality front.

4. Lower Overhead Costs – With a severely automated process in place with CNC milling machines, you save a huge chunk of machining and manufacturing costs which you can use in any other development facet.

Here at Machining Design Associated Ltd., we offer top of the line CNC milling services to businesses across all industry verticals. For more information, drop us an email at machiningdesign@mdaltd.ca or fill-up the form here.

5 Best Benefits of using 5-axis CNC Machining

by admin | Mar 6, 2018 | 5-Axis CNC Machining, CNC Machining

The Machining world is growing at an unbelievable pace. Handheld machines have advanced to highly sophisticated computerized machines (CNC) and use CNC machining to produce machined parts. Similarly, basic 2,3-axis CNC machining have now led on to a more improved, more like 5-axis CNC machining. While expensive, 3+2 axis and 5-axis machining processes are now a staple in almost every CNC machine shop. It’s imperative that both large-scale and small and medium manufacturing units are utilizing the one and many benefits of this machine type – who is going to pass the opportunity to get better productivity, higher accuracy at much lower costs (leaving the initial set-up cost, of course). In this article, we will cover benefits of 5 axis CNC machining.

But, there is more to 5-axis CNC machines than just that. Ready to find more?

1. Heightened Accuracy, Efficiency & Cost Effectiveness: Sophisticated Machines

First on our list is, obviously, the points we mentioned before. There is a reason why machinists are fond of this machine type, even with complex processes and all. 5-axis machining is the more efficient, accurate, and improved of all its counterparts, here’s everything you need to know about 5 axis cnc machining. Owing to less fixturing at multiple operations, using it directly translates to better work-piece quality and durability. This means good parts, less wastage, lower tooling costs, and shorter working duration.

2. Complicated Shapes, Angles Made Possible

With its ability to reach even the most complicated of angles, five-axis machines serve as a savior to all those looking for more complex 4D and 5D parts. Something we would never be able to achieve with your regular 2 axis, 3 axis machines. That too in a single setup, all thanks to its structure which makes it possible to reach out to both sides at one-sitting. All these things translate to better productivity and improved work-piece quality.

3. You Can Make Use of Shorter Cutting Tools

Shorter cutting tools are a mess to handle, especially with your general CNC machines. Thankfully, we are fully able to utilize the power of better tooling angles, better cutting speed, and precision parts with these tools as they can be fit well to a 5-axis machine. Here, you can have the head oriented towards the job and the cutter towards the surface. As the machine holds the tool well, the load on the cutter is reduced, resulting in decreased unfortunate breakages and vibrations.

4. Improved Drilling Process

5-axis machining is an absolute blessing for the drilling process, drilling of holes. This is due to its ability to reach smaller and more complex angles (see point no. 2), giving a much cleaner finish. On the contrary, with 3 axis machines, you have to set up separate sitting for every angle. Which, of course, is both time-taking and cost engaging?

5. They are Compatible with CAD/CAM

This compatibility brings better execution to the planned designs. You are now able to achieve even the most complex of structures, quite easily. Plus, this mix has engaged a lot of job opportunities in the sector. All sounds good here.

In a nutshell, 5-axis CNC machining is an amazing process to work with. Do you want to experience the sophisticated products resulting from it? Drop us a request and we’ll get you the machined parts fabricated exactly to your needs.

CNC Machining Tips: Why should you go for Flat Bottom Tools?

by admin | Feb 5, 2018 | CNC Machine Tools, CNC Machining, CNC Machining Guides

Proper tooling is the most important part of every machining process. We need to have specific functioning milling tools if we want to develop milling parts. Same goes for all other operations. Think of it as cooking; one cannot choose potatoes as the main ingredient when making an apple pie. Yep, this analogy is not far from reality.

So we have different tools for different operations in a CNC machining shop. We might reuse some particularly reusable tools, replace the old types with advanced ones, but that’s about it. True, we focus on quality and durability, something that’ll extend its working capability (and less wear and tear). But, did you ever give a thought to tool shape?

If you didn’t, we’ll tell you why you should pay attention to your tool shapes. Let’s get to the BOTTOM of the CNC machine tools world!

Benefits of Flat Bottom Tools:

At Machining Design, we work with a plethora of tools but flat bottom tools have definitely won our hearts (and infrastructure) over. Here’s a list of reasons why we would suggest it to you as well:

1. Lower Machining Costs

As CNC’rs, we’re all aware that machining is not cheap. Add in tool maintenance and replacement costs, and it’s going to cost us more than ever. While we cannot cut on labor and operational costs, we can definitely save some using the flat bottom tools.

Now, how do they make that possible?

For one, they eliminate the extra run-time by fitting exactly where they are required. Due to their shape, they are often sturdier when compared to traditional machining tools. Carbide fit flat bottom tools beat every other tool in terms of durability. Imagine the amount of money you’ll save!

2. They are more functional

There is a list of drilling operations where these flat bottom tools play the role of a hero. Take thin plate drilling for example. When performing this operation, regular tools often face irregularities due to pushing materials through the exit hole. This derails us from achieving the desired perfection in the drilled holes. Flat bottom drills are extremely beneficial here as due to their general geometry they even downward forces. Hence, more clean surfaces.

3. They don’t create burrs

Unlike traditional tools, using flat bottom drilling tools helps us avoid unexpected (and undesired) burrs on the other side of the material. Make way for straighter and regular holes.

4. Is fit even for angular functions

Flat bottom drills are perfect for irregular surfaces due to their geometry, especially if it’s required to perform angular or tilted operations.

5. It’s stable

When countering with a half hole drilling, flat bottom drilling is proven to extremely beneficial. This is because due to the lack of material on both sides of the drill, any other machining tool may walk to the side of the material, creating an extremely undesirable situation. A flat bottom drill works closely on the entire cutting geometry, making it perfect for drilling half holes even on the edge of the material.

Working with flat bottom CNC tools definitely, make our lives (and machining process) easier. It’s easy to keep, light on pockets and DURABLE. Now, ain’t this what all of us need in our CNC machine shop?

Got questions? Want to go deep into the wonderful world of machining? Just drop us a line, and one of us will get back to you soon!

CNC Machines – The Face of Modern Manufacturing

by admin | Jan 12, 2018 | CNC Machine Shop, CNC Machining

Over the past few decades, the world has witnessed a major shift in the high-tech field. From being just a ‘wanted aspect’, it has slowly become a necessity in our everyday lives. New-age technology has made everything more convenient and efficient, regardless of the industry involved.

The computer-aided revolution has made a large impact on the manufacturing world as well. Automated equipment has given us the ability to produce a more precise part in a much shorter time. While CNC machines date back to the late 1950s, they continue to evolve and enhancements are made on a continuous basis. Modern CNC lathes give the operator the ability to produce a part with milled and cross-drilled surfaces. Something that was unavailable just a short time ago.

How has this impacted us:

1. Reduced Human Efforts
CNC Machines have allowed us a more hands-off approach. Parts can be completed on one machine in one set-up with very little human intervention. Machines can now run lights out; 24 hours a day seven days a week. The equipment can be fed by robotic arms or magazines that hold multiple lengths of raw material. Human error has greatly decreased with the use of this high-tech equipment.

2. Increased Accuracy in Mass-Production
With these machines being handled by computer controls the chances of non-conforming parts being produced has been greatly reduced. If the machines are programmed correctly from the start and tool wear is monitored, the repeatability of conforming CNC machined parts should be over 99%. Gone are the days when each part was physically manipulated in a turret lathe or manual mill in hopes of achieving repeatability.

3. Complex Product Development
Multi-axis machines have allowed us to machine parts to greater tolerances and with more complex features. This is something that was very difficult to achieve just a short time ago.

4. Reliability
The equipment is ready to work every day with just the push of a few buttons. It rarely gets sick and only requires some maintenance and the occasional repair part. The machines are ready to work 24 hours a day. Machines today require much less human interaction and are able to produce parts faster and with more accuracy.

5. Highly Adaptable
CNC machines are amazingly accommodating. The machines will constantly evolve and new innovations will continue to be introduced. Today we can work with all types of metals and plastics in an efficient and accurate manner.

Types of CNC machines

Generally, there are six types of CNC machines, all used for different purposes and materials:

Milling Machines: Widely popular. In fact, they might even be the most popular type of CNC machine used today. Milling machines utilize rotary cutters to shape workpieces to perfection. They can be programmed to provide the required depth, angle and cutting direction.

CNC Lathes: A lathe is utilized to develop highly precise conical and spherical shaped parts. This particular machine uses turning centers wherein the cutting tool shaves off the excess material while the material is rotating on a spindle.

Drilling machines: CNC drills are highly advanced drilling machines where the speed of the drill and the depth to be drilled is handled by highly sophisticated computer programs.

Screw Machines: Screw machines are the advanced version of automated lathes. They are used to produce smaller yet complex machined parts for automotive, aerospace, medical and electrical hardware industries.

CNC Grinders: This type of machine utilizes a rotary wheel that abrades the material into the desired shape by repeatedly grinding it.

CNC Plasma Cutters: Plasma cutters uses plasma beam to cut the materials into 2D shapes.

Materials used by CNC machines

A CNC machine is highly versatile, utilizing almost every type of materials to produce some quality machined parts. From common materials like aluminum, copper to exotic alloys and wood, a CNC machine can handle them all. Here’s a list of the in-demand materials that MDA Ltd. Uses:

Material Type	Properties
Brass	Highly durable and corrosion resistant
Aluminum	Lightweight, malleable, inexpensive
Steel	Economical, high strength, versatile
Industrial plastics	Versatile, lightweight
Phenolics	Heat resistant and durable
Copper	Corrosion resistant, versatile, conductor of heat
Stainless steel	Corrosion resistant
Alloy steel	Tensile, wear resistant
Plywood	Wear & tear resistant, dimensionally stable

CNC machining has revolutionized the whole Manufacturing industry and it is still improving. It will be quite interesting to see where it can take us in the years to come!!!

Tool Wear During CNC Machining: Types and How to Avoid Them

by admin | Aug 8, 2017 | CNC Machine Tools, CNC Machining

The introduction of CNC machining has revolutionized the way our industry processes goods.

The dependency on human labor has been reduced to half, with computers taking their place. As a result, we are able to witness an increased efficiency, improved product quality and the ability to produce almost everything with exact precision- 3D, 4D or 5D.

But then again, it’s a computer system directing actual ‘CNC machines’ to perform a task. Tool wear is as common as it gets. It may experience a breakdown or failure after working for an extended period of time. In fact, every cutting tool will experience wear at some point in its production life.

While it might be common, excessive wearing is not good for our product or machine. The inconsistencies caused by such wears and tears may have unwanted effects on your workpiece and may do damages to the primary piece of equipment. Its failure might even lead to irreplaceable damages such as rework, a collection of scrapped parts, or a total breakdown which might cost us more than the product itself.

Thus, it’s pretty important to find out such abnormalities and correct them in real-time so we get optimal end mill performance. Here’s our take on the various types of tool wear, and how to identify and mitigate them, complied with our experience. Hope they will help you manage tool wear better!

Abrasive Wear

Mechanical stress is one of the major causes of tool wear with thermal taking a close second place.
Abrasion, especially the wear land abrasion, is pretty common amongst cutting tools. It is caused by the uniform abrasion on the cutting edge of the tool, dulling the edge as a result. If severe like added thermal stress at higher speeds, it can even alter the dimensions of the tool edge. This is why a tool coating is of utmost importance for tool longevity.

How to Avoid

If you start witnessing a certain abrasion pattern on your tool’s edges, it’s time for you to reduce the cutting speed and optimize coolant usage, especially when working with this particular tool. Even High-Efficiency Milling (HEM) tool paths can be used to reduce wear by distributing the work done across the entire length of the cut. This helps focused abrasion while contributing to the longevity of the tool life.

Thermal Cracking

Thermal cracks are caused by temperature fluctuations during a milling process. They are identified as a series of cracks on the tool’s surface perpendicular to the cutting edge. Such cracks form over a long period of time and are often the most difficult to deal with once present.

How to Avoid

One of the best ways to divert thermal cracking is to add a proper heat-resistant coating to the end mill. Similar to abrasion wear, HEM tool paths can also be utilized for an even distribution of the head across the tool, thus reducing the heat on a certain area.

Fracture

Fracture, as the name suggests, refers to the sudden breakage of a tool during a machine operation. It, of course, results in improper speeds and feeds, and incorrect coating, thus spoiling the product or part in hand altogether.
Such fracture cases aren’t restricted to abrasion or wear only. A loose handle, inconsistent workpiece, incompetent materials, or other tool holder issues can cause them too.

How to Avoid

You may go ahead and adjust the speed, feed and depth of the cut to keep the tool fracture at bay. Checking the machine set up of appropriate rigidity and optimizing coolant usage can also help reduce fracturing.

Chipping

Chipping is caused by a number of different reasons such as excessive shock-loading during operation, thermal cracking or abrasion. It can be seen as a series of chips or flaked bits on the cutting tool. This type of wear often leads to a poor surface finish and may even cause a severe tool failure if not corrected in time.

How to Avoid

There are several steps to check whether your cutting tool is experiencing chipping or not. First, you need to ensure your CNC milling machine is free of vibration or chatter. Then adjust your speeds and feeds accordingly, increase the speed and reduce the feed rate.

Importance of Planning & Strategy Before Starting Your CNC Machining Project

by admin | Feb 1, 2017 | CNC Machine Shop, CNC Machining, Machine Shop

CNC (Computer Numerical Control) machining is a game-changer in manufacturing, enabling the creation of precise, complex parts for industries like aerospace, automotive, and medical devices. However, the key to a successful CNC machining project goes beyond having advanced equipment and skilled operators—it starts with meticulous planning and strategy.

Think of embarking on a road trip without a map. While you might eventually reach your destination, you’d face unnecessary detours, wasted time, and frustration. Similarly, diving into a CNC machining project without proper planning can lead to costly errors, delays, and subpar results. Proper planning is your roadmap, guiding every step from understanding project requirements to material selection, part design, and quality management.

In this blog, we’ll explore why thorough planning and strategic thinking are essential for the success of your CNC machining projects. From defining objectives to managing risks, we’ll show how to ensure your journey from concept to finished product is smooth and efficient. Let’s lay the groundwork for success by highlighting the importance of planning and strategy in CNC machining.

#1 Understanding the Project Requirements

Understanding project requirements is crucial for the success of a CNC machining project. This involves clearly defining the project scope and setting measurable, achievable goals. A well-defined scope prevents scope creep and ensures all stakeholders are aligned on deliverables, resources, and timelines.

For example, a precise scope might state, “Produce 500 aluminum brackets with a tolerance of ±0.01 mm, using 6061 aluminum alloy, by July 31, 2024, adhering to ISO 9001 standards,” whereas a vague scope like “Make some aluminum parts quickly” can lead to confusion.

Setting SMART goals—Specific, Measurable, Achievable, Relevant, and Time-bound—is also essential. Goals should align with client or business needs, such as reducing production time or improving quality. For instance, aiming to “increase machining accuracy by 10% within six months by implementing new calibration techniques” is a clear and actionable objective. By defining the scope and setting aligned, measurable goals, you create a solid foundation for your project’s success.

#2 Material Selection

Material selection is crucial in CNC machining projects as it impacts the quality, cost, and feasibility of the final product. Common materials include metals (aluminum, steel, brass), plastics (ABS, polycarbonate, nylon), and composites (carbon fiber-reinforced polymers). Each material’s properties, such as hardness, tensile strength, and machinability, must be evaluated to ensure suitability for the project’s requirements.

Additionally, the cost and availability of materials play a significant role. Choosing cost-effective, readily available materials helps maintain the project budget and timeline. The right material choice ensures efficient machining, minimizes tool wear, and avoids delays, ultimately contributing to the project’s success.

#3 Designing for CNC Machining

Effective design is crucial for successful CNC machining projects, influencing efficiency, quality, and cost. Creating detailed CAD models using tools like AutoCAD, SolidWorks, and Fusion 360 is essential, as these models provide precise specifications that guide the machining process, reducing errors and rework.

Adhering to Design for Manufacturability (DFM) principles further enhances efficiency by simplifying geometries, minimizing machining operations, and selecting easily machinable features. These design choices directly impact machining time, quality, and cost, with simplified designs reducing time and tool wear, and precise tolerances ensuring high-quality results without excessive rework.

#4 Tooling and Equipment Selection

Choosing the right tools and equipment is crucial for CNC machining projects to ensure efficiency and quality. When selecting CNC machines, factors such as capabilities (like cutting and milling), size compatibility with workpieces, and precision in achieving required tolerances must be considered. Common types include milling machines for shaping materials and turning machines for rotational operations.

Equally important is selecting the correct cutting tools, which significantly impact material removal rates, surface finishes, and dimensional accuracy. Proper tool materials, geometry, and maintenance are key to optimizing performance and extending tool life. Regular maintenance routines, including cleaning, sharpening, and timely replacement of worn tools, are essential for minimizing downtime and maintaining consistent machining quality throughout the project.

#5 Developing a Process Plan

Developing a thorough process plan is crucial for CNC machining projects to ensure efficiency and precision throughout the manufacturing process. Detailed planning clarifies the sequence of operations, tool requirements, and quality checks from initial setup to final finishing. Key steps include material preparation, CAD modeling, toolpath generation, and setup involving fixture design and tool selection.

Machining progresses through roughing, semi-finishing, and finishing stages to achieve precise dimensions and surface quality. Concurrently, establishing efficient workflows minimizes downtime and optimizes production flow, supported by realistic project schedules that account for complexities, resource availability, and deadlines. By adhering to a structured process plan and coordinated workflows, CNC machining projects can effectively meet quality standards and delivery timelines.

#6 Quality Control and Assurance

Quality control is pivotal in CNC machining to maintain precision and adhere to standards throughout production. Implementing rigorous quality control measures ensures that parts meet specifications and customer requirements, minimizing deviations and enhancing reliability. Techniques such as CNC machines and tool calibration uphold precision, while advanced metrology tools like coordinate measuring machines (CMMs) verify dimensional accuracy and surface finish.

Inspection involves dimensional checks against CAD specifications and assessments of surface texture for smoothness and functionality. Regular testing throughout production detects deviations early, facilitating adjustments to maintain consistency and high-quality standards. This comprehensive approach to quality control and assurance ensures that CNC machining projects deliver precise components that meet exacting specifications and customer satisfaction.

#7 Team Coordination and Communication

Effective team coordination and communication are essential for the success of CNC machining projects. Clear role assignment ensures accountability and efficiency by defining each team member’s responsibilities clearly, thereby minimizing overlaps and maximizing collaboration. Leadership roles, such as project managers or lead machinists, play a crucial role in coordinating tasks and resolving issues promptly to keep the project on track.

Tools like ERP systems and cloud-based collaboration platforms facilitate real-time communication and information sharing, centralizing project data and schedules for streamlined workflow. Regular team meetings with structured agendas ensure alignment on project progress, challenges, and adjustments, promoting agility and responsiveness to project needs. This systematic approach to team coordination and communication enhances productivity, minimizes errors, and contributes to the successful delivery of CNC machining projects.

Conclusion

In conclusion, careful planning and strategic preparation are fundamental to the success of any CNC machining project. By defining clear project scopes, setting achievable goals, and selecting suitable materials and equipment, teams can streamline operations and minimize costly delays. Detailed CAD modeling and design for manufacturability principles ensure efficient production processes and superior product quality.

Moreover, rigorous quality control measures and effective team coordination through clear role assignments and robust communication channels are pivotal in maintaining precision and meeting project timelines. Embracing these practices not only enhances project outcomes but also fosters a collaborative environment where innovation and efficiency thrive, ultimately leading to the delivery of exceptional results that meet or exceed client expectations.

Things you should know about Custom CNC Milling