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!!!

CNC Machine Tools: Types & Functionalities

by admin | Nov 6, 2017 | CNC Machine Tools

Machine tools are, hands down, an essential component of CNC machining.

They make the manufacturing process possible, helping us craft perfect custom-machined parts and products. Simple structure or super-complex, 3D shape or 5D, 2mm piece or 200mm- there is nothing apt CNC machining tools can’t create.

Simply put, if the CNC machine is the brain, machine tools are the limbs- converting instructions into actual action.

While CNC machine tools are fairly new, two-three decades-old- machine tools have existed for a long time. They were there even before CNC or anything computer machinery came into existence.

As everything is machine-related, CNC machine tools have gradually evolved with time. The manually handled tools have now transformed into computerized ones that decrease our workload by a hundredfold.

We can now repeat sequences and create millions of similar pieces with an accuracy of a marksman.

To achieve machined parts of different shapes, a CNC machine utilizes several different types of CNC tools. Additionally, several other types work exceptionally well with certain materials like wood, metal, and more.

Some work on different speeds and feed to get perfect custom machined parts.

All in all, there are several types of CNC machine tools. Let’s look at the types and functionalities.

CNC Machine Tool Types

Milling Machines

Milling machines are used for cutting, drilling, and boring operations. There are two types of milling machines:

Vertical Machining Centers – These machines have a vertically oriented spindle that moves the workpiece vertically. They are ideal for flat parts that require drilling, milling, or tapping.
Horizontal Machining Centers – These machines have a horizontally oriented spindle that moves the workpiece horizontally. They are ideal for complex parts that require 4-axis or 5-axis CNC machining.

Turning Machines

Turning machines create round parts by removing material from the workpiece. There are two types of turning machines:

Horizontal Lathes – These machines have a spindle that is parallel to the ground and hold the workpiece in a horizontal position. They are ideal for creating long, slender parts.
Vertical Lathes – These machines have a perpendicular spindle to the ground and hold the workpiece vertically. They are ideal for creating large, heavy parts.

Grinding Machines

Grinding machines remove material from a workpiece by grinding it with an abrasive wheel. There are two types of grinding machines:

Surface Grinders – These machines grind flat surfaces on a workpiece. They are ideal for creating smooth finishes on parts.
Cylindrical Grinders – These machines are used for grinding cylindrical surfaces on a workpiece. They are ideal for creating precise cylindrical parts.

Others

Other types of CNC machine tools are commonly used in manufacturing:

Electrical Discharge Machines (EDMs) – These machines use electrical discharge to remove material from a workpiece. They are ideal for creating complex shapes or cutting hard materials.
Laser Cutting Machines – These machines use a laser beam to cut through the material. They are ideal for cutting through thin sheets of material, such as metal or plastic.

Invest in CNC machine tools to enhance precision, productivity and efficiency in manufacturing processes. Talk to our expert.

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CNC Machine Tool Functionalities

Precision Machining

Precision machining is one of the primary functions of CNC machine tools. CNC machines can achieve very high levels of accuracy and repeatability in the parts they produce. It is achieved through high-precision sensors and actuators, which allow the machine to precisely control the cutting tool’s movement.

High-Speed Machining

High-speed machining is another crucial function of CNC machine tools. Using high-speed spindles and cutting tools, CNC machines can achieve faster cutting speeds and higher material removal rates. This allows manufacturers to produce parts more quickly and efficiently, reducing production times and costs.

Multi-Axis Machining

CNC machines can perform multi-axis machining operations, which involve moving the cutting tool along multiple axes simultaneously. This allows manufacturers to create complex, three-dimensional shapes and features that would be difficult or impossible to create using traditional machining methods.

Tool Changing

CNC machines are capable of changing cutting tools automatically without the need for operator intervention. This allows manufacturers to use multiple cutting tools in a single machining operation, reducing the need for manual tool changes and increasing efficiency.

Program Storage and Retrieval

CNC machines are capable of storing and retrieving machining programs electronically. This allows manufacturers to easily recall and reuse machining programs for future production runs, reducing setup times and increasing productivity. It also allows for easy modifications to existing programs, making it easy to update part designs or make other changes.

Applications of CNC Machine Tools

Aerospace Industry: The aerospace industry relies heavily on CNC machine tools to produce aircraft components. CNC machines produce complex, high-precision parts such as turbine blades, engine components, and landing gear.

Automotive Industry: The automotive industry uses CNC machine tools extensively to produce vehicle components. CNC machines produce engine blocks, transmission components, and suspension parts. CNC machines are also used to produce molds and dies in automotive manufacturing.

Medical Industry: The medical industry uses CNC machine tools to produce medical devices and implants. CNC machines produce surgical instruments, orthopedic implants, and dental components. CNC machines also produce custom prosthetics and other patient-specific medical devices.

Electronic Industry: The electronic industry relies heavily on CNC machine tools to produce electronic components such as printed circuit boards (PCBs). CNC machines are used to produce PCBs with high precision and accuracy, ensuring that components fit together correctly and function properly.

Other Industries: CNC machine tools are also used in various other industries. For example, the woodworking industry uses CNC machines to produce furniture, cabinetry, and other wooden components. The metalworking industry uses CNC machines to produce various metal components, from small precision parts to large structural components for buildings and bridges. CNC machines are also used to produce plastic components for various applications. Discover an impressive collection of CNC parts produced with a diverse range of materials in our product gallery.

Conclusion – CNC Machine Tools: Types & Functionalities

In conclusion, CNC machine tools have revolutionized the manufacturing industry by providing high precision, accuracy, and efficiency in producing complex parts and components. When exploring CNC machine tools and their functionalities, it is essential to consider reliable service providers like MDA, a reputable CNC machine shop based in Canada and throughout North America.

Our expertise in the field ensures precision, efficiency, and exceptional results for various industries. Whether you require milling, turning, or grinding services, MDA has the capabilities and state-of-the-art equipment to meet your needs. With their commitment to delivering top-notch customer service and extensive knowledge of CNC machine tools, we are a trusted partner for businesses seeking reliable precision machining tools in Canada.

The various types of CNC machine tools, including milling machines, turning machines, grinding machines, and others, offer a range of capabilities to meet the needs of different manufacturing applications.

Additionally, the functionalities of CNC machine tools, including precision machining, high-speed machining, multi-axis machining, tool changing, and program storage and retrieval, enable manufacturers to produce parts quickly, accurately, and cost-effectively.

As a result, precision machining tools are widely used in industries such as aerospace, automotive, medical, electronics, and many others. With ongoing advancements in CNC technology, we can expect to see even more impressive capabilities and applications of these machines.

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.

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