Stainless Steel CNC Milling Tips, Challenges & Tools

by | Mar 7, 2024 | CNC Steel Machining, CNC Turning and Milling

steel cnc machining

Mastering stainless steel CNC milling tips is essential for precision and efficiency. This guide explores key challenges and the best tools to use, ensuring optimal results in your projects.

Table of Contents:

  1. Understanding the Challenges
  2. Solutions to Overcome Challenges
  3. Essential Tools for Stainless Steel CNC Milling
  4. Practical Tips for Successful Stainless Steel CNC Milling
  5. Why Choose MDA’s CNC Milling Services

Understanding the Challenges

Alright, let’s get real about the challenges we face when we’re milling stainless steel.

Material Hardness and Toughness: Stainless steel, renowned for its durability, presents machining challenges due to its high hardness and toughness. Like cracking a tough nut, machining stainless steel needs specialized tools and techniques to handle its durability. Machining stainless steel requires precise cutting parameters, tool selection, and strategies to handle its toughness and achieve results.

Tool Wear and Breakage: The relentless nature of stainless steel machining places immense stress on cutting tools, resulting in accelerated wear and potential breakage. The abrasive stainless steel wears down tools quickly, requiring frequent inspection and maintenance to prevent machining disruptions.

Chip Evacuation Issues: During stainless steel milling operations, metal chips generated during the cutting process accumulate rapidly, posing challenges for efficient chip evacuation. The accumulation of chips can impede tool movement, compromise cutting efficiency, and adversely affect surface finish and dimensional accuracy. Effective chip evacuation strategies, including optimized toolpath design and implementation of appropriate coolant systems, are essential to mitigate these challenges and maintain machining efficiency.

Surface Finish and Dimensional Accuracy Concerns: Achieving a smooth surface finish and precise dimensional accuracy is paramount in stainless steel milling applications. However, the inherent hardness and toughness of stainless steel can complicate this endeavor, requiring meticulous attention to detail and precise control of machining parameters. Fine-tuning the milling process, selecting appropriate cutting tools, and implementing advanced machining techniques are critical to achieving the desired surface finish and dimensional accuracy while minimizing the risk of material distortion or surface imperfections. 

 

Solutions to Overcome Challenges

Let’s explore the solutions to tackle the challenges we face in stainless steel CNC milling:

Strategies to Address Material Hardness and Toughness

Dealing with the robust nature of stainless steel requires thoughtful strategies. This involves selecting cutting tools designed to withstand the challenges posed by stainless steel. Carbide end mills, for instance, are known for their resilience and durability in machining tough materials. Additionally, adjusting cutting speeds and feeds to match the hardness of the material and utilizing specialized tool coatings can enhance tool life and machining efficiency.

Techniques to Mitigate Tool Wear and Breakage

Stainless steel’s abrasive nature can cause tools to wear out quickly and break prematurely. To counter this, optimizing cutting parameters such as speed, feed rate, and depth of cut is crucial. Real-time monitoring of tool wear allows for timely replacements, preventing unexpected tool failures. Employing high-quality tool materials and coatings, such as titanium nitride or diamond-like carbon, can significantly improve tool durability and lifespan.

Improving Chip Evacuation for Enhanced Efficiency

Efficient chip evacuation is essential for maintaining machining efficiency, particularly in stainless steel milling. Optimizing toolpath designs to ensure proper chip flow and implementing effective coolant systems help prevent chip buildup and reduce machining interruptions. Adjusting cutting parameters, such as chip load and cutting depth, also facilitates smoother chip evacuation and improves overall milling performance.

Enhancing Surface Finish and Dimensional Accuracy

Achieving precise surface finish and dimensional accuracy is critical in stainless steel CNC milling. Fine-tuning machining parameters, including cutting speed, tool geometry, and tool path strategies, enables precise material removal and enhances surface quality. Post-processing methods such as polishing or deburring remove surface imperfections and ensure uniformity in the finished part. Advanced CNC programming, including high-speed machining and adaptive toolpaths, enhances precision and part quality through accurate tool movements.

 

Essential Tools for Stainless Steel CNC Milling

Let’s delve into the essential tools needed for successful stainless steel CNC milling:

Carbide End Mills: 

stainless steel cnc milling

These tools stand out in stainless steel milling due to their exceptional hardness and wear resistance. Carbide end mills are crafted from a combination of carbide and cobalt, rendering them capable of enduring the rigors of stainless steel machining. With their robust composition, carbide end mills maintain sharp cutting edges over extended periods, facilitating efficient and precise milling operations. Their resilience against the abrasive nature of stainless steel contributes to reduced tool wear and enhanced machining productivity.

 

High-Speed Steel (HSS) Cutters: 

stainless steel cnc milling cutters

While not as hard as carbide, HSS cutters remain a popular choice for stainless steel milling applications. Offering a balance of toughness and affordability, HSS cutters are adept at handling moderate cutting speeds and less demanding milling tasks. Their toughness makes them ideal for cost-effective stainless steel machining, overcoming challenges and ensuring durability in demanding applications.

 

Coated Tools for Wear Resistance: 

Coated Tools for Wear Resistance

stainless steel cnc milling for wear resistance

Coated tools play a pivotal role in enhancing wear resistance and extending tool life during stainless steel milling operations. Coatings such as titanium nitride (TiN) or titanium carbonitride (TiCN) are applied to cutting tools to reduce friction and heat buildup during cutting, thereby minimizing tool wear and enhancing durability. The slick surface provided by these coatings promotes smoother cutting action and facilitates chip evacuation, resulting in improved machining efficiency and surface finish. Utilizing coated tools is a proactive measure to mitigate tool wear and optimize performance in stainless steel milling processes.

Practical Stainless Steel CNC Milling Tips

Operator Training and Skill Development: Operator training programs should cover a wide range of topics, including machine operation, tool selection, programming, and safety protocols. Ongoing skill development ensures operators stay abreast of new technologies and best practices, enabling them to adapt to changing production demands and optimize milling processes effectively.

Regular Maintenance of CNC Machines and Cutting Tools: Regular maintenance routines should encompass various aspects of CNC machines and cutting tools. This includes inspecting machine components for signs of wear, ensuring proper alignment and calibration, and replacing worn-out or damaged cutting tools promptly. Preventive maintenance helps prevent unexpected breakdowns, prolongs equipment lifespan, and ensures consistent machining accuracy and quality.

Monitoring and Analyzing Machining Data for Process Optimization: Machining data provides valuable insights into the performance of milling processes. By monitoring key metrics such as tool wear, cutting forces, and surface roughness, machinists can identify areas for improvement and fine-tune machining parameters accordingly. Advanced data analysis techniques, such as statistical process control (SPC) and predictive analytics, enable proactive problem-solving and continuous process optimization, leading to enhanced productivity and cost savings.

Collaboration between Machinists, Engineers, and Material Specialists: Effective collaboration between different stakeholders is essential for optimizing milling operations. Machinists provide valuable insights into practical challenges and opportunities for improvement on the shop floor, while engineers offer technical expertise and support in designing efficient machining strategies. Material specialists play a role in selecting the most appropriate materials for specific applications and optimizing material usage to minimize waste and costs. By fostering a collaborative environment, organizations can leverage collective expertise to overcome obstacles, drive innovation, and achieve excellence in milling operations.

Why Choose MDA’s CNC Milling Services 

CNC milling project

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MDA offers specialized custom CNC milling services tailored to stainless steel fabrication needs. MDA’s expertise lies in its ability to navigate and overcome the unique challenges of stainless steel milling. MDA distinguishes itself by its utilization of cutting-edge tools, state-of-the-art techniques, and customized solutions tailored to each client’s specific requirements. We offer: 

  • Faster delivery 
  • Custom finishes
  • High dimensional tolerances

Optimize your manufacturing with MDA’s affordable Stainless Steel CNC milling Tips. Get precision components on time—transform your project seamlessly! Contact Us Now!

Milling Processes in CNC Machine Shops

by | Aug 8, 2023 | CNC Machine Shop, CNC Turning and Milling

cnc milling

In the realm of modern manufacturing, CNC machine shops stand as the vanguard of precision and innovation. Central to their prowess is the art of milling – a process that shapes raw materials into intricate and accurate components. From aerospace engineering to medical advancements, the applications of milling are as diverse as the industries they serve. 

This article focuses on a journey to unravel the array of milling processes offered by CNC machine shops, delving into the nuanced techniques that underpin the creation of custom components. 

As we explore these diverse methodologies, we uncover the remarkable impact they have on shaping the intricate designs that define our technological landscape.

Let’s begin. 

 

Traditional Milling Processes

In the realm of machining, traditional milling processes hold a significant place, each characterized by its unique approach and advantages. This section focuses on two fundamental processes: up-cut milling and down-cut milling.

#1. Up-cut Milling

Up-cut milling involves the removal of material by the cutter rotating in the opposite direction of the workpiece’s motion. This technique offers distinct advantages, including efficient chip evacuation, reduced heat buildup, and extended tool life. The upward movement of the cutter aids in preventing workpiece surface damage and enhances the overall surface finish.

Applications of up-cut milling are widespread, finding prominence in various industries. Woodworking, for instance, relies on up-cut milling to create smooth edges and accurate profiles in lumber and composite materials. 

In metalworking, this technique is favoured for its ability to prevent work-hardening, making it suitable for softer metals like aluminum and brass. Additionally, up-cut milling is often chosen for plastics and composite materials due to its effectiveness in preventing delamination and chipping.

 

#2. Down-cut Milling

In contrast, down-cut milling involves a cutter rotation following the workpiece’s motion, leading to benefits like reduced tear-out and improved surface quality. The downward cutter motion minimizes splintering and ensures clean edges, particularly vital for materials prone to chipping.

Down-cut milling is applied when achieving a polished top surface is crucial. Woodworkers choose it for furniture components, delivering clean edges. In laminate machining, it prevents fraying and chip-out, ensuring precise edges.

Understanding up-cut and down-cut milling distinctions optimizes machining for material properties, finish, and product intricacies. These traditional techniques enhance precision and efficiency in CNC manufacturing.

 

#3. High-Speed Machining

High-speed machining (HSM) is a revolutionary approach to material removal that has transformed modern manufacturing. This section explores HSM, its principles, advantages, and impact on industries.

HSM employs advanced tools and techniques to achieve significantly higher cutting speeds and feed rates than traditional methods. The focus is on optimizing tool dynamics, reducing vibration, and maximizing material removal while maintaining precision.

Advantages of HSM include improved efficiency, reduced machining times, and enhanced productivity. Rapid chip evacuation and continuous tool engagement dissipate heat, minimizing distortion. HSM often results in finer surface finishes, reducing secondary operations.

Industries like aerospace, automotive, and medical benefit from HSM’s precision and speed. It creates intricate aircraft components, complex engine parts, and precise medical implants.

 

#4. Multi-Axis Milling

The world of precision machining has been revolutionized by multi-axis milling. Also known as 5-axis or 6-axis machining, it introduces rotational axes beyond the traditional X, Y, and Z. This flexibility enables intricate geometries previously unattainable.

Multi-axis milling’s versatility is evident in aerospace, where it precisely shapes airfoil designs for optimal aerodynamics. Medical implants are crafted with precision, while mould-making produces intricate cavities. Automotive, electronics, and defense also benefit from its precision and efficiency.

This advanced technique empowers CNC machine shops to tackle complex projects with accuracy and ingenuity, transforming modern manufacturing.

 

#5. End-Milling 

End milling is a crucial machining process that removes material using a rotating cutting tool called an end mill. The tool’s edges perform various cutting actions, gradually shaping the workpiece.

Variations of end milling include:

  • Ball Nose End Mill: Shapes contoured surfaces and complex forms.
  • Square End Mill: Creates flat-bottomed grooves, pockets, and surfaces.
  • Corner Radius End Mill: Adds rounded corners to components.
  • Roughing End Mill: Rapidly removes material in the initial stages.
  • Finishing End Mill: Achieves fine finishes and precise dimensions.

End milling finds applications in industries like automotive, aerospace, electronics, and manufacturing of molds and dies. It’s vital for crafting furniture, medical equipment, and renewable energy components, contributing to modern product development.

 

#6. Face Milling

Face milling is a machining technique that removes material from a workpiece’s flat surface using a face mill cutting tool. Unlike end milling, which targets edges, face milling covers a larger area with a broad cutting action. The face mill has multiple cutting edges, enabling efficient material removal.

Advantages of face milling include achieving flat, smooth, and accurate surfaces. It’s time-efficient, covering more area in a single pass. This technique finds use in diverse industries:

  • Automotive: Machining engine blocks, cylinder heads, and transmission housings.
  • Industrial Machinery: Creating components like baseplates and mounting brackets.
  • Aerospace: Manufacturing aircraft structural parts, wing panels, and fuselage sections.
  • Construction: Crafting architectural elements such as facade panels and structural beams.
  • Consumer Electronics: Making laptop casings, smartphone bodies, and tablet frames.

Illustrative examples include precision machining for shipbuilding and creating molds for plastic injection molding. Face milling ensures structural integrity, even surfaces, and dimensional accuracy.

CNC machine shops rely on face milling for exceptional surface quality and precision, making it indispensable for industries seeking accurate and visually pleasing components.

 

Read More: Why CNC Milling Is Ideal For Manufacturing Machined Parts?

MDA’s Milling Mastery: Crafting Precision Components

Machining Design Associated Ltd., an ISO: 9001:2015 certified firm, is fully committed to crafting CNC machined and custom metal parts of exceptional quality, tailored to precise customer requirements. Our unwavering dedication to ongoing enhancement drives us to adhere solely to optimal methodologies, guaranteeing that our customers’ projects are executed with utmost efficiency, precision, and affordability.

 

Ready to Elevate Your Manufacturing? Contact us for Custom Milling Requirements

 

 Contact Us

 

We commit to utilizing a wide range of milling techniques in their precision manufacturing processes. Rather than relying on a single approach, MDA embraces various methods and strategies for milling, adapting their techniques to suit different materials, designs, and project requirements. By doing so, MDA showcases their versatility and expertise in employing diverse milling approaches to achieve the desired outcomes for each unique project. This adherence to diverse milling techniques underscores MDA’s dedication to providing comprehensive and tailored solutions to their clients’ machining needs.

CNC Milling vs CNC Turning – Which is the Best Option?

by | Sep 14, 2022 | CNC Turning and Milling

CNC Milling vs CNC Turning

Many industries rely on CNC machining to produce parts and prototypes. There are various types of CNC machining, and this article will concentrate on CNC turning and milling. These are the subtractive processes included in CNC machining.

These two processes may appear familiar to some machinists, but they are not. Customers are frequently perplexed about which method to use for their machining requirements. We hope that after reading this, you will determine which process is best for your manufacturing needs.

What do you mean by CNC milling?

CNC milling is a machining process used by owners to produce machined parts. They become accustomed to creating one-of-a-kind functional prototypes. CNC mills rotate the cutting tool using computer instructions. When the spinning tool comes into contact with the workpiece, the material gets removed in a controlled manner.

With the help of the vice, the workpiece remains stationary. To create cutting angles, multi-axis CNC mills rotate the workpiece. It allows machinists to easily create complex machined parts without the need to regenerate the workpiece. CNC milling gets preferred by machinists due to its shorter lead times.

 

CNC Milling comes with the following perks……..

Capability to Produce

CNC milling’s production capabilities are best suited for batch processes. In layman’s terms, CNC milling is a business that produces small batches of parts in a single run. A CNC milling machine’s additional production capabilities include a variety of operations such as

  • Thermal
  • Mechanical
  • Chemical
  • Electrical

Cutting Tools

Milling does not always require the use of explicit tooling. You can use a completely different set of milling cutting tools for each operation. This not only improves mills over lathes but also makes them more efficient in their work.

Furthermore, while a mill can produce complex-shaped tools, it is limited by lathes, which are commonly used in turning operations.

CNC milling gets used to make the following machined parts:

  • CNC milling gets used for engine blocks and other pieces of equipment.
  • CNC mills aid in producing surgical instruments, implants, and other medical devices.
  • Straight and spiral gears for mechanical devices get made using CNC milling.

 

Here are some more things about CNC milling you should know. 

 

What is CNC turning?

CNC turning is excellent for producing conical, rounded, and cylindrical parts. Aside from CNC milling, it is one of the most popular CNC machining services. Lathes are machines that perform the CNC turning process.

A CNC turning machine, similar to a CNC lathe machine, can rotate the part using a stationary cutting tool. The cutting operation enables machinists to create designs that would not be possible with a traditional cutting tool. CNC turning assists in threading, tooling, and other processes by removing material in the same shape.

 

Here are some benefits that make CNC turning a better option

Production Rates

CNC turning is faster for Boring, Drilling, and Shaping jobs. This allows the industrialist to meet deadlines while also increasing production capacity on the fly. On the other hand, complex designs struggle and take much longer to complete.

Accuracy

CNC Turning is more precise and can finish operations with pinpoint accuracy. As a result, it is trusted with many critical parts with round surfaces, including rollers, bullets, gears, and drilling bits.

Adaptability

CNC turning is highly adaptable and can be linked with CNC milling to meet industrial needs. It can also make parts for other machines, such as bolts and nuts, torques, and turbines. However, for this interconnection to be beneficial, backward compatibility and asymmetrical designs are required.

Examples of machined parts with CNC turning

  • CNC turning gets used for rounded connective devices that are ball joints.
  • CNC turning is also ideal for round turbine blades that are a fit for the energy industry.
  • CNC turning can manufacture cylindrical and hollow parts. Therefore, it is easier to produce nozzles with CNC turning.

 

Difference between CNC milling vs CNC turning

There are visible differences between CNC milling and turning processes in the operational features and use of parts with complexities. Given below, I have explained the differences:

Function: In the milling process, the material gets removed when the tool rotates around the workpiece. In CNC turning, the tool works on the rotating workpiece.

Parts Manufactured: With the help of CNC milling, machine shop owners manufacture geometrically complex parts. CNC turning fabricates conical and cylindrical parts like ball bearings and tubes.

Cutting Process: The tool disengages from the workpiece in CNC milling. In CNC turning, the tool is in continuous contact with the tool piece.

The tool features: CNC mills use multi-point cutting tools such as end mills, and reamers. The tool has more than two cutting edges that engage with the workpiece for the fabrication. CNC turning processes use single-point cutting tools such as fly cutters to remove the material. In CNC turning, only one point of the tool will come in contact with the workpiece.

 

| Also Read: How Has CNC Turning and Milling Machining Changed The Manufacturing Industry?

 

So, CNC Milling vs CNC Turning which would be the right one for you?

It will be easier to decide now that you know what each of these processes can and cannot do.

However, keep in mind that CNC Milling is generally considered the most recommended method for producing parts with complex shapes, while CNC Turning is equally good for simpler, round shapes. Nonetheless, you can use these two processes sequentially because there may be situations where both operation processes are required.

If you’re still unsure and don’t have a clear idea, hire professional machining services and let them make the decision for you.

Why work with Machine Design Associated?

Whether you need CNC turning, milling, or any other precision engineering service, you need a reliable supplier. The components you require must be of the highest quality and built to last.

We will never sacrifice quality and have stringent control practices to ensure that everything we produce meets even the stringent standards and specifications. This constant pursuit of quality has resulted in accreditations in recognition of our efforts.

We also guarantee a quick quote and can accommodate orders of all shapes and sizes – whatever you need, we can make it.

 

Need Experienced Company Providing CNC Milling & Turning Services?

 

 Contact Us

 

 

Why CNC Milling Is Ideal For Manufacturing Machined Parts?

by | May 5, 2022 | CNC Machined Parts, CNC Machining, CNC Turning and Milling

CNC Milling Is Ideal For Manufacturing Machined Parts

CNC milling is one of the popular machining processes present in the market. It is suitable for most industries as it is apt for machining various materials such as metal, plastic, wood and glass. By leveraging CNC milling, the industry owners can create CNC parts and products. 

If you are interested in incorporating CNC milling in your machining process, this article is suitable for you, explaining why CNC milling is the right choice for CNC parts. 

What is CNC Milling? 

CNC milling is the machining process that utilizes computerized controls to manage the movement and operation of multi-point rotary cutting tools. The tool rotates and moves across the surface of the workpiece. They slowly remove any excess material to get the desired shape and size. 

The process is classified into four stages: 

  • CAD model design: In this process, engineers create a 2D or 3D design of the desired part.
  • CAD model conversion to a CNC program: The design gets exported into a compatible file format and machine instructions using CAM software. 
  • CNC milling machine setup: The machine operator prepares the machine and the workpiece.
  • Milling operation execution: The machine operator initiates the machining program.

It can accommodate a variety of materials that include metals, ceramics and engineered materials. It makes it easier for the manufacturers to choose the material that suits their requirements. This material flexibility is beneficial for several industries. Some of them are: 

  • Aerospace
  • Automotive 
  • Commercial 
  • Electronics
  • Medical 
  • Telecommunications
  • Transportation 

 

How do CNC Milling Machines Work? 

A CNC places the tool under the guidance of a computerized operating system. Successful milling is the combination of the three elements: 

  • A cutter with many teeth and ideal sharpness for a material.
  • Spinning a tool at a high enough speed to process the material correctly. 
  • An appropriate feed rate for advancing the chosen material via the process. 

CNC allows extremely close control of these elements. The process takes directions in customized codes such as NC code and G-code from the project’s CAM or CAD designs. The code gets translated into the machine’s controls that run along the two axes, and the tool spindle runs in the depth. Here are some things these machines can do: 

Flat surfaces: These machines can precisely cut and level away material areas from one material to the other, ensuring tight closures. 

Drilled holes: Threads get carved through to make bolts or screws fit, and it bores similarly for every material.

Bored holes: It follows a programmed size. So, each assembly of parts becomes precise and permits tight sealing. 

 

Why Use A CNC Milling Machine For CNC Parts?

It allows the production of precise parts, which provides businesses with a competitive edge over their competitors, which are complex in design, have structural benefits and more. Let’s look at the reasons to use CNC milling for CNC parts: 

  • It improves profitability

Every industry aims to keep making a profit, achievable with high-quality products. It allows the manufacturing owners to set it up with the annual calibration to keep working for a long time. As long as the machine is in proper condition, it’ll produce quality products. 

  •  It is a reliable and trusted

CNC milling machines are valuable for producing various parts in multiple industries such as aeronautics, electronics, automotive and transportation. When using high-performing equipment, these industries see you as a like-minded business person who can deliver the results. Thus, you get more customers and contracts. 

  • Undeniable accuracy

These machines are superior to conventional manual machines created with advanced technology. The machines are equipped with software to keep the processes consistent and follow data. The CNC milling machines are your best bet when you want your parts with the exact measurements and material at incredible speeds. 

  • Efficient like no other 

All CNC milling machines require regular care and calibration by a certified technician. However, milling machines withstand the pressure of continuous operation. The machines are programmed to replicate the same design repeatedly at the same interval so that you can expect a smooth production flow. 

 

Why Choose MDA? 

To produce precision machined parts, you require professional CNC milling services. You should know certain things about custom CNC milling before starting your project. It’s tough to find professional milling services, but your search for a one-stop shop for your machining needs ends here. We at MDA are one of the leading players in CNC parts. The CNC programmers working at MDA have years of experience and hands-on experience with the technology to offer quality milling services. 

We also take care of the post-production process. If your CNC machining parts need special finishes, MDA can send you finished CNC machined parts. The company can machine parts with any specific angle and complexity no matter what industry.

Essential CNC Milling Tools Guide To Achieve Precise CNC Machined Parts

by | Sep 20, 2021 | CNC Machined Parts, CNC Turning and Milling

CNC Milling Tools

Since the days of the industrial revolution, there has been an increase in the mass production of equipment. Mass production means producing the same part thousands of times. Slowly, this process got done with the help of CNC milling machines. Now, for the CNC milling process, you require apt CNC milling tools. Having the right tools can make a difference during the milling process. 

This guide is here to help you choose the right CNC milling tool, types of milling tools, and how to select milling tools. 

 

What is CNC Milling?

CNC milling is a machining process. The whole process is based on using computerized controls. It involves the rotation of multi-point tools that eliminate unwanted materials from the workpiece. It leads to custom-designed products. The CNC milling process helps to machine various materials like glass, wood, metals, and plastics. It does so by drilling and turning to get the desired shape. The cutting tools’ edges make plenty of quick cuts helping to sculpt the raw material surface that gets removed as the process goes on. 

 

Types of CNC Milling Tools

Different types of CNC milling tools allow getting the perfect customization of the final products. All these tools get used to cut the material into various shapes and sizes. Your final design will determine the tool you use for the machining process. It depends on the professionals to select the tools to balance the speed with the desired finish. Here are some tools available for CNC milling: 

#1. Chamfer Mills

It is the most common tool used in the CNC machining industry. During the creation of a part, machining operations can leave a sharp edge on the workpiece. The role of the chamfer mill is to eliminate any sharp edges. 

The final result will be a part that is strong and aesthetically pleasing to the end-user. Chamfer milling is ideal for these purposes: 

  • Chamfer mill for beveling
  • Chamfer mill for deburring
  • Chamfer mill for spotting and countersinking

 

#2. End Mills

End milling primarily differs from other milling methods due to the tooling used for wearing out the material. The sole reason they are different is they cut at a 90-degree angle. In simple terms, the mills that can cut axially are end mills. 

The material used in the end mill also makes a difference in the tool you need to use for your final part. Some common materials used to create end mills are: 

  • Carbide
  • Cobalt
  • High-speed steel

In end mills, there are various ways of cutting into the material and how the machinist cut determines the tool used: 

  • Face milling: When the machinist cuts into one surface of the material, it is known as face milling. The surface is the face of the material. 
  • Slot milling: Slot milling creates slots through the material, cutting edges on two sides at once as the end mill will make a groove. 
  • Ramping: Ramping cuts directly down to the surface and at an angle that creates a slanted cut down via the material. 
  • Plunge: Plunging milling is an efficient process in removing a notable amount of material in less time. 

 

#3. Ball End Mills

Ball end mills are ideal for drilling shallow holes. They have a constant radius at the end of the cutting tool. Ball end mills are used for various milling operations like slotting, contouring, pocketing, and profiling. Just because of their shape, they get suited to machining 3D part contours and more. We at MDA offer high-speed ball end mills capable of retaining hardness at high temperatures i.e. perfect for CNC milling tools. 

 

#4. Drill Bits

Drill bits allow the machinists to cut holes in the material. Twist drill bits get used in general repairs. These bits help to create small holes. Similarly, like in end mills, drill bits are made from different materials that impact the strength. If the coating is on the exterior of the drill bits increases the longevity. Here are some common materials: 

  • High-Speed Steel
  • Carbide
  • Titanium Nitride Coating
  • Titanium Aluminum Nitride Coating

 

#5. Fly Cutters

Fly cutters comprise one or two tool bits that are in the solid body. The tool bits present in the fly cutter help to create shallow, broad cuts, and the machinists get a smooth surface finish. The perfect examples are tabletops and counters. 

The fly cutters get a lot of material off the surface quickly. The design of the fly cutters makes the engine of the CNC mill work harder. Some machinists refer to fly cutters as springboards. 

 

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

 

How To Select CNC Milling Tools? 

Selecting the right tools for CNC milling becomes necessary if you desire a quality finish. Using the wrong tools can ruin the finish of your final equipment. Therefore, you need to keep in mind several factors while selecting the ideal CNC milling tools below: 

  • Selection of milling tool body 

The price of the milling tool is costly. A face milling tool body with a diameter of 10mm can cost around $600. 

You have to choose according to your processing needs. You need to consider the number of teeth while considering the milling tool. The size of the tool pitch determines the number of cutter teeth used in the cutting during milling which affects the smoothness of the cutting. Every milling tool manufacturer has a series of dense tooth milling tools. So, choose the tool according to your equipment requirements. 

  • Selection of the milling tool blade

A grinding blade is ideal for fine milling. It has better dimensional accuracy making the positioning accuracy of the cutting edge in milling higher. In other processing operations, it is better to use a pressed blade or a ground blade.

During roughing, it is better to use a pressed blade that reduces the processing cost. Machinists can use a scraping blade to remove any rough machining marks to achieve better surface roughness than using a pressed blade. 

 

Conclusion 

Every milling tool has its own set of requirements and produces a unique result. Before selecting a milling tool, a machinist must consider several factors, including the material to be machined, the desired finish of the part surfaces, and more. 

So, before hiring a CNC machining company, make sure they have all of the necessary tools on hand to machine your parts. 

At Machining Design Associated Ltd, we are committed to providing the best possible custom machined product while providing the best possible customer service. Feel free to contact us with your CNC tool requirements. It is accomplished by:

  • Creating a foundation of trust by being honest and providing excellent service.
  • Performing a thorough inspection of products to ensure that they meet the customer’s requirements.
  • Maintaining flexibility to respond quickly to the changing needs of our customers.
  • Keeping our best practices to deliver the most precise and cost-effective product possible.

Pick Your Right Tool: Ideal Milling Tools To Use For CNC Cutting

by | Feb 25, 2021 | CNC Machine Tools, CNC Turning and Milling

Milling Tools

CNC milling tools are a boon for CNC machinists. Various types of CNC milling tools allow for the customization of the final products. Choosing the right CNC milling tool is a necessary part of the manufacturing process. Machinists have plenty of tools to choose from, and every tool provides different results.

The article is intended for milling operators who can set up and run a milling machine. It will help the machinists to identify ideal milling tools available for CNC cutting and the CNC milling tool materials. And before, choosing the milling tool, it is important to know the materials used in the milling tools.

Common Materials Used In CNC Milling Tools

Each milling tool has one thing in common which is tool materials. Let’s take a brief look at the materials used for milling tools:

Carbon steel: Carbon steel is an inexpensive material and has 0.6-1.5% of carbon with silicon and manganese. The material is ideal for low-speed operations used in turning, milling cutters, twist drills and more.

High-speed steel: The material has the right proportion of chromium, tungsten and molybdenum that provides HSS with hardness, toughness and resistance better than carbon steel. HSS tools are more expensive than others. HSS tools do last for a longer time frame.

Ceramics: Ceramics are corrosion-resistant that are made via silicon nitride and aluminum oxide. The heat and wear resistance helps the material suitable for heat-cutting environments. The tools are ideally fit for hard steels, superalloys and more.

Solid carbide: The solid carbide is more resistant to wear than HSS. Solid carbide is used mainly in finishing applications with milling machines.

Ideal Milling Tools That Are Used By CNC Experts

The most commonly used milling tools are given below:

  • Reamers
  • Fly Cutter
  • Twist Drills
  • End Mills
  • Thread Milling Cutters
  • Tool Holders

#1. Reamers

Reamer is a rotating tool to enlarge the size of the existing hole. It provides accuracy and a smooth finish. CNC machines require a faster operation. And it has increased the demand for using reamers for CNC cutting. Reamers provide the consistency that is important for machine shops. The accurate holes designed with the reamers help to save time. The common reamers are below:

Single blade reamer: They are highly accurate and used for various special applications.
Multi-blade reamer: They have multiple cutting edges, and the design is like an HSS tool design.

 

#2. Fly Cutter

The reason why CNC machinists use a fly cutter is to get a smooth surface finish in no time. They are used on the milling machine to machine large areas and for flat surface areas. Fly cutters are popular in machining shops without the need for additional arbours. There are various types of fly cutters and including:

  • Point cutter
  • Rotary cutting tool
  • Rotary carving tool

 

#3. Twist Drills

Twist drills get used to creating a hole in the machined part. The machinist must use one that is correct for the application. Frequently the twist drills are made up of high-speed steel. MDA supplies a wide range of twist drills according to the convenience and custom configurations of the customer. We provide a free quote and manufacture machined parts serving the need of the industries:

  • Aerospace
  • Automotive
  • Medical

 

“Machined parts are not just designed for customer satisfaction, but they are designed to exceed itself”


#4. End Mills

An end mill is an ideal tool used by machinists around the world. End mills have cutting teeth at one end that helps to remove large quantities of material with ease. It mustn’t be confused with a drill bit. End mills come in many forms and get used for various milling operations. Here are some types of end mills:

Straight-flute end mills: End mills having straight flutes are single-ended. They help to provide a smooth surface finish. Straight flute end mills are ideal for milling plastics and various milling applications.
Ball-nose end mills: Ball-nose end mills have rounded tips and can be both single or double-ended. It is suitable for 3D contours and curves.

Up and down cut end mills: These are in a spiral shape. An up-cut end mill removes the materials in less time and is ideal for softer materials. Down-cut end mills help to create a smooth surface.

V-bit end mills: V-bit end mills are used by machinists for carving. It is best for sharp corners and edges.

 

#5. Thread Milling Cutters

Thread milling cutters help to cut threads by milling. The thread milling cutter makes it easier for the machinists to produce medium to large sizes. The main benefit of the thread milling cutter is that it can cut external threads. When a machinist needs to manufacture softer machined parts, a thread milling cutter is one of the milling tools for CNC cutting.

 

#6. Tool Holders

The tool holder as the name suggests helps to hold the end mill in one place. Different types of tool holders provide balance, the different tool holders have variations in their durability. The main thing to look at in a tool holder is the time it requires to change end mills.

Here are some CNC milling tool holders used by machinists according to their needs:

Collet chucks: Collet chucks have a lot to offer from a firm grip to alignment compatibility. The chuck design makes it easier to secure a hold on the tool. Collet chucks with a small diameter are apt for machining close quarters.

Tap holders: Tap holders are present in various types to meet the needs of machinists. Some rigid holders are great for horizontal machining centres. There are floating tap holders that help to reduce axial forces on the tap, increasing the lifespan.

End mill holders: These holders are easier on the tools and are a perfect fit for any machine shop. Using end mill holders helps to get less wear and tear.

 

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Choose The Right Tool For The Job

Every tool has different requirements and provides a different finish. There are a lot of factors to be considered by a machinist before selecting the milling tool like the material to be machined, the desired finish of the part surfaces and more. So, before choosing a CNC machining, it’s better to ensure that they have all the necessary tools available with them to machine your parts.

For more details, you can contact our experts that’ll help you choose the right milling tool according to your specifications.

 

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