Essential CNC Milling Tools Guide To Achieve Precise CNC Machined Parts

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

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.

Benefits Of Precision CNC Machining To Custom Parts For Low – Mid Volume Production

by Norm Grimberg | Jul 14, 2021 | CNC Machining, Custom Machined Parts

Every machinist knows about precision machining or has used it to manufacture ideal machined parts. Precision machining has changed the way industries are working, and it is the right choice for high-volume requirements.

Precision machining helps the machine shops to stay competitive in the market despite the high demand from the customer. If your machine shop is yet to include precision CNC machining in the manufacturing process, then you are missing out a lot.

Our experts at MDA will share the benefits of using precision CNC machining that will help to manufacture your next machined part.

Why is precision machining necessary?

Precision CNC machining is a process where large pieces of materials or parts are shaped into precise forms to meet the specific demands of various industries. Precision CNC machining is finding more relevance in business. In aerospace, it manufactures landing gear parts, manifolds, etc. The medical industry manufactures implants, orthotic devices and other precision instruments via precision machining. So, if a product contains equipment, then it requires precision CNC machining. Here are some reasons why precision machining is necessary:

It improves smooth functionality and operation.
Accurate measurement of precise parts.
Precision machining provides durability.
Conforming to industry standards.

Benefits of precision CNC machining

#1. Fast production of materials and parts

Precision machining is fast and one of the best manufacturing methods available right now. It reduces the manual work by relying on specialized software to create the custom part you need.

It is better than the conventional CNC machining method, which takes around weeks or months to finalize a custom part. In precision machining, you can manufacture a part in days. See the difference? It saves you time, in the long run, helping you to meet the deadlines. Our experts follow the precision machining techniques reducing the human intervention making the parts consistent for low – mid-volume production.

#2. It is cost effective

Fast production of the machined parts leads to a reduction in overall costs. That’s not all. Precision CNC machining helps to reduce the price you need for raw materials and supply chain management. The machine shops now can produce the machined parts in saving on costs and other factors like:

Reduction in labour
Increased manufacturing
Meeting with the delivery rates

Investing in precision machining allows for maximizing the company’s business. When you choose us for the precision CNC machining needs, you will save a lot on your manufacturing costs.

#3. Precision machining is ideal for prototyping

Prototyping is crucial in the manufacturing process. Prototyping allows the machine shop owners to overcome the mistakes in the long run. Precision CNC machining offers rapid prototyping capabilities and helps businesses to tap the smaller markets. The precision CNC machining allows the prototypes to have more functional parts rather than design prototypes.

| Also Read: Why Precision Machining Is The Right Choice For High-Volume Requirements

#4. Compatible with a wide range of materials

Different materials present challenges for manufacturers during the machining process. We all know that to manufacture machined parts for various industries, machine shop owners need to use a range of materials, from titanium to steel to aluminum or copper.

Precision CNC machining is compatible with a lot of materials. There would be no need for the machinist to choose a different manufacturing process as precision machining can do it all. At MDA, our professional experts keep this in mind and manufacture the machined parts in the specific material selected by the client.

#5. Maximizes efficiency

Precision machining is helpful for fast production, as mentioned in point 1. It also allows the machine shop owners to scale up the production needs. The reason is precision machining can create thousands of precision machined parts in no time. Professional machine shop owners can use the manual workforce in other tasks which require more human touch as customer service or post-production.

#6. Safer production

Because the industry is transitioning from manual to automated technology machinery, making it difficult for humans to participate in the manufacturing process. Even though the workforce on the shop floor gets reduced, CNC machine shops will still require skilled employees to be present at the time of production and provide the correct inputs to the machines.

It benefits a business because it reduces the amount of machinery that needs to be maintained and the number of labourers required to run operations. The overall cost of manufacturing a unit will be lower, and profit margins will increase.

Why choose MDA for precision CNC machining?

We are a leading precision company located in Canada. Using advanced manufacturing equipment, our expert engineers and technicians assist businesses in producing high-quality and precise parts. Our production facilities are ISO 9001:2015 certified for quality, and we have a team of quality control experts on staff.

Contact our professionals to get a quote for precision CNC machining parts.

How CNC Machined Parts Can Be Used In The Medical Industry

by admin | Jul 9, 2020 | CNC Machined Parts, Medical Industry

Right now, coronavirus is affecting almost everyone, on every scale. The medical industry is under a lot of pressure and this has led to an increase in the production of medical CNC machined parts. Lots of lives are dependent on the medical industry and to keep them working 24×7, they need high-quality machined parts for the medical equipment. Producing CNC machined parts for medical equipment need accuracy.

We at Machining Design Associated know the value of human life and how difficult it can be for a doctor if they don’t have the proper equipment.

How our CNC machined parts are helpful in the medical industry?

Ideal for surgical equipment

Surgery needs precise medical equipment, and the surgical process is all about attention to detail, a simple miss here and there can lead to complications. CNC machined parts provide the needed precision in surgical medical instruments. The machined parts are also used in devices for cardiac ailments, like pacemakers. The 5-axis machined parts can be used in orthopedic surgery which is a minimally invasive surgery. We know the recent demands of the medical industry and able to create custom machined parts too.

“We at MDA are looking to provide the healthcare frontline workers with the precision machined parts. Our machinists work round the clock to produce medical machined parts.”

CNC machined parts for the laboratory

In a laboratory, it needs accuracy and our machine experts at MDA know this and produce the medical machined equipment accordingly. And the lab technicians can also rely on us for all kinds of devices and medical parts that include equipment used for DNA analysis.

Machined parts for radiology equipment parts

For radiology, the medical team has to rely on manufactured equipment that makes the medical process easier. In cases of fractures, there is equipment that is used during real-time, so the components need to work constantly. The machines need to be durable as they are moved from one place to another. Special radiology instruments that require precision which is guaranteed by MDA.

“Our machine experts are able to produce these parts according to the need of the specifications of the medical industry.”

Materials We Work With

At MDA, we work with the following materials:

● Stainless Steel: This is used extensively in the medical industry. Stainless steel tops the list because of the hygiene benefits. They have corrosion resistance and also durability which is required in the medical industry.

● Titanium: Titanium is useful for building implants because it’s biocompatible. The material also possesses important properties like elasticity, strength, corrosion resistance, flexibility, etc. And we provide CNC machining for medical-grade titanium alloys.

● Plastics: There are various types of plastics that are used in the medical industry. The plastic polymers are easier to process and are robust. Plastic parts are affordable and there is less friction while using them.

Highlights of MDA CNC Machining Services for the Medical Industry

● Machine Design Association Limited can manufacture complex medical machine parts with ease. Manufacturing these machined parts needs high precision and sophisticated machining to create high-tolerances, needed to produce these parts.

● We, at MDA, keep these things in mind and our knowledgeable machinists are proficient at delivering quality components that meet the expectations of our clients.

● At MDA, we offer a wide array of medical components for all surgical instruments and other medical parts. Furthermore, these require highly skilled operators and quality machines

● Our trained professionals keep transparency during the entire process; we also have a dedicated support team that communicates with the client from start to finish.

You can contact us for more details about our CNC machining services for the medical industry. Alternatively, you can request a quote for medical CNC machining.

Benefits of Custom Machined Parts for Business Success

by admin | Jan 22, 2020 | CNC Machined Parts, CNC Machining, Custom Machined Parts

Custom machined parts are manufactured through the process of machining. Machining is a manufacturing process that involves the processing of a work-piece into a part of the desired shape and size by removing material through the use of machine tools. Work-pieces that are machined are made up of materials such as metals, plastics, rubbers, etc. In this blog, we’ll cover the benefits of custom machined parts.

Metal machined parts provide a common example of a machining process. Making plastic machined parts is a very different process than metal machining. For machinists, working with different materials means facing different challenges, which requires the selection of different tools, parameters and techniques.

To get high-quality machined parts, a business can take the services of a CNC machine shop that has vast experience in machining. Custom machined parts offer many benefits such as –

Client’s Requirements Are Fully Met

Customized parts made through the process of machining fully meet the requirements of a business. They are manufactured according to the exact specifications given by a client to a machine shop. An expert machine shop can easily manufacture custom parts having complex shapes.

Extreme Accuracy

Machined parts manufactured using CNC technology are highly accurate in size and shape. All CNC machined parts are highly reliable because of the three characteristics of machining accuracy inherent in CNC technology. These are extreme dimensional, positional and shape accuracy.

Machinists make sure that the machining tolerance is within the allowable range and the highest level of precision is obtained. Tolerance is defined as the acceptable range of a dimension of a part determined by the engineers. The geometry of a part and the type of material that the part is made up of greatly affect tolerance.

Targeting a tighter tolerance can lead to additional costs due to greater production of scrap, additional fixtures, and the use of advanced measurement tools. To minimize this cost, machinists apply tight tolerances only to critical areas. By making use of CNC machines, tight tolerances can be easily obtained. High machining accuracy and highly-skilled machinists help in creating precisely machined parts that fully serve the desired purpose.

Save Time In Getting Obsolete And Unique Parts

By getting parts that have been machined according to their exact requirements, businesses are saved from wasting time in finding ready-made parts that are not being currently manufactured and are even the old stock is not available.
Businesses may also require customized parts when they have to complete a project with quick turn-around time. When the time is less, it is easier to get custom parts than to search for required parts in the market.

It may also be the case that a business may require some unique parts for certain projects that are not available in the manufacturers’ catalogs. If a business lacks resources, which are unique parts in this case, to carry out these special projects, its clients will turn to its competitor and will probably not return back even in the distant future.

In this case, also, custom parts come to the rescue. By getting custom parts, a business can go ahead and grab these special projects, and earn clients for life. For any project, when parts are available to businesses in time, their business schedule is not delayed. They can readily put these parts to work.

Get Identical Parts Easily

If more custom parts are required by a business, a CNC machine shop can readily provide them. This is because the design is stored on a computer. New parts that are manufactured are identical to the previous batch of parts. This is quite beneficial for manufacturing businesses, for example, if some of the machines of a manufacturer have stopped working and require steel parts to function again, then the custom steel parts that are identical to the previously used steel parts can be readily obtained.

Difficult-to-Process Materials Can Be Used

Some materials cannot be machined easily. For example, plastic, bronze, stainless steel, etc. require sophisticated CNC machining equipment. These materials cannot be just run through standard equipment and processes to get the desired results.
To get machined parts made of these materials, a business can contact an expert custom machine shop that uses specialized equipment to work on difficult-to-process materials.

Custom Parts Can Be Made From Existing Parts

A business may be having a large number of parts that it thinks are of no use. These parts can be modified and customized to bring them into some other use. For example, the parts of discarded machines can be altered and put to use in other machines that need those parts. This saves a lot of time and money for a business.

Streamlined Production

When a business has a tie-up with the manufacturer of custom parts, it does not have to rely on suppliers of ready-made parts. Custom parts are available whenever they are required. So, the production process of business works in a streamlined way as it does not suffer because of the unavailability of parts. With an efficient production process, a business gets the benefit of faster turn-around time.

Moreover, if in case, a business wants some last-minute changes in the parts, these changes can be easily incorporated in the custom parts by a machine shop.

Wide Application

CNC machined parts find use in a large number of industries including automotive, robotics, oil and gas, defense, mining, medical, electronics, etc. As these parts entail extreme accuracy, they are used in highly sensitive fields like defense, aerospace and aeronautics.

It becomes clear from the above discussion that there are plenty of benefits of custom machined parts to businesses. When businesses get parts that fully meet their specifications and are highly accurate, their production process becomes more efficient and they achieve a competitive edge.

Materials 101: Entrepreneur’s guide to selecting the Right CNC Machining Material

by admin | Jul 24, 2018 | CNC Machining, CNC Machining Guides

Right materials make the best applications.

Material selection is a crucial step to get your CNC project right. Think of it as assembling a Subway meal based on your diet plan; you add meats if your diet chart asks for more protein, and greens for a vitamin fulfill. Similarly, selected materials must cover your design prerequisites— hardness, rigidity, thermal stability, and chemical resistance just to name a few. And your budget as well, of course.

Material characteristics are especially important when you require high precision CNC machined parts with complex designs. For instance: amorphous materials like metallic glass and polymers generally hold tighter tolerances than, say, aluminum.

In the following article, we will elaborate more on material types, their characteristics, tips and guidelines on choosing the right materials, and more. Let’s start with the basic: the material selection process.

CNC Materials Selection Process
If you’ve decided to jump the CNC machining wagon, have a valid prototype handy and your budget figured out, it’s time to select the best suitable materials for your project. The basic three steps to material selection are:

Step 1. Define your material requirements: Based on your design, make a high-level list of material prerequisites. Do you need a malleability? Or perhaps a sturdier material? Laser polishing for a surface finish? Consider all the mechanical, physical, environmental, and budget factors.

Step 2. Pin down qualified materials: Identify potential candidates that fulfill your material requirements. Notice, we’re are focusing on ‘candidates’ not ‘candidate’. There’s a solid reason behind it. Have a look:

Here’s what Ronald E. Giachetti, of National Institute of Standards and Technology, wrote in his paper on Manufacturing Process and Material Selection During Conceptual Design:

“The material and manufacturing process selection is performed early in the product development process. At this stage, it is inappropriate to select a single material or process without evaluating all the alternatives. The selection of sets of possible candidate materials and processes allow for greater flexibility in the product development process. The more alternatives, the greater the manufacturing flexibility.”

Hack: Make sure you approach readily available materials— it’ll help cut costs and efforts.

Step 3. Now, select the most appropriate material: The third step is the final showdown: choosing the material with maximum functionality in minimum costs. Or, the materials that check most on your prerequisites list.

In the next section, we will talk about the most popular materials and their properties.

CNC Material Selection- Guidelines

Metals
Most common metals in the CNC machining universe are:

1. Aluminum
Most popular of the bunch; used for both mechanical and aspect components.
(a) Physical properties:
● Medium physical strength (<500 MPa) (Note: Aluminium 7075 is one of the strongest metals at >500 MPa; but it’s a bit pricey)
● Corrosion resistance
● Temperature resistance (<400°C)
(b) Mechanical properties:
● High machinability. Can be machined quicker than other metals
● Readily available; inexpensive
(c) Industries:
● Automotive ( gears and shafts etc.)
● Aerospace (aircraft fittings etc.)
● Healthcare (medical equipment)
● Consumer electronics (electronic housings)

2. Cold Rolled Steel
(a) Physical properties:
● High physical strength (Increases the strength of the finished product by 20%)
● Provides perfect precision as it creates smaller products
● Can handle tighter tolerances
(b) Mechanical properties:
● Medium machinability.
● Moderately expensive
(c) Industries:
● Manufacturing (Machinery parts)
● Aerospace (aircraft fittings etc.)
● Construction
● Consumer electronics (electronic housings, Jigs & fixtures)

3. Stainless Steel
(a) Physical properties:
● Hardness
● Chemical resistance
● High strength (>500 MPa)
● Temperature resistance ( Very high >500°C)
● Corrosion resistance
(b) Mechanical properties:
● Good machinability
● Inexpensive
(c) Industries:
● Automotive
● Aerospace (aircraft fittings etc.)
● Healthcare (surgical equipment)
● Consumer electronics (electronic housings)
● Food Industry
● Marine applications
● Chemical Processing
● Marine applications

4. Brass
Used for high volume applications.
(a) Physical properties:
● Medium strength
● Natural Corrosion resistance
● Low-Temperature resistance (<250°C)
● High tensile strength
(b) Mechanical properties:
● High machinability.
● Readily available; moderately expensive
(c) Industries:
● Automotive ( mechanical parts, valves & nozzles)
● Architecture
● Healthcare (medical equipment
● Consumer goods
● Electrical hardware

Exotic alloys

1. Inconel
(a) Physical properties:
● Temperature resistance
● Corrosion resistance
● Medium strength
(b) Mechanical properties:
● Moderate machinability
● Moderately expensive
(c) Industries:
● Automotive
● Aerospace
● Healthcare
● Consumer electronics

2. Copper
(a) Physical properties:
● Highest electric conductivity
● High corrosion resistance
● Thermal conductivity
● Low chemical resistance (especially to acids, halogens sulphides, and ammonia solutions)
(b) Mechanical properties:
● High machinability. Can be machined quicker than other metals
● Readily available; moderately expensive
(c) Industries:
● Automotive (cooling systems and heat exchanger, valves and radiators etc)
● Aerospace Healthcare (medical equipment)
● Consumer electronics (electronic housings)

Outside of this wide range of metal materials, it’s also possible to use plastics, wood, and even fiberglass and foams with CNC machining technology.

Plastics

1. PVC
(a) Physical properties:
● High strength
● Corrosion resistance
● Temperature resistance
● Chemical resistance
(b) Mechanical properties:
● High machinability
● Readily available; inexpensive
(c) Industries:
● Automotive
● Aerospace
● Healthcare
● Consumer electronics
● Food Industry
● Chemical

2. Nylon
(a) Physical properties:
● High physical strength
● Good impact strength
● High corrosion and abrasion strength
(b) Mechanical properties:
● High machinability. Can be machined quicker than other metals
● Readily available; inexpensive
(c) Industries:
● Automotive (insulators, bearings)
● Aerospace
● Healthcare
● Consumer electronics

Now that you know about different materials, you can select the ones that best suit your CNC project. We, at Machining Design Associated Ltd., offer exceptional CNC machining parts with desired tolerances. Get in touch to know more!