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What is CNC milling and how does it work? CNC milling involves using a cutting tool called a milling machine that is mounted on a rotating spindle to selectively remove material from a dedicated workpiece. The raw material is secured to a table, which moves or rotates on different planes that allow the tool to operate at various angles. The CNC milling process can be used to produce not only shaping but also slots, holes, notches, and pockets. The cutting tool’s edges make several quick cuts to sculpt the raw material’s surface, which is constantly removed as the process continues.
CNC milling accommodates a variety of materials, including metals, plastics, ceramics, and other materials, making it easy for manufacturers to choose a material that suits their exact needs. This material flexibility benefits several industries, including, the following:
- Aerospace and aircraft
- Automotive
- Commercial
- Electronics
- Industrial and OEM
- Maintenance
- Medical
- Technology and security
- Telecommunications
- Transportation
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How CNC Milling Works
The first stage of the CNC Milling process starts by feeding the manufacturing instructions into a CAD system in either a 2D or 3D format. Once this has been completed, the designs are converted into a machine-readable format which is exported to the CNC milling machine. The machine will then relay the instructions to the different tools to recreate the design on the chosen material. Before the process can begin, the machine would have to be fitted with the correct tools to do the job and the raw material needs to be fixed in place with a vice. Once these preparations are completed, the operator will launch the program using the machine interface.
When the CNC milling process begins, the tools spin at thousands of RPM – enabling them to cut through materials with ease. The table will then rotate on several axes to shape the raw material according to the given specifications.
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The CNC Milling Process
The CNC milling process can be broken up into four distinct stages:
- CAD model design: engineers create a 2D or 3D design of the desired part.
- CAD model conversion to a CNC program: the design is exported into a compatible file format and converted into machine instructions using CAM software.
- CNC milling machine setup: the machine operator prepares the machine and workpiece.
- Milling operation execution: the machine operator initiates the machining program.
What are the Advantages of CNC Milling?
#1 Precision
One of the biggest advantages of using CNC milling machines is that they can create parts exactly to specification, whether custom or OEM. Because CNC mills rely on computer instructions to fabricate parts, they eliminate the possibility of human error that is common in manually operated machines. This means you can accurately create complex parts while achieving tolerances as tight as 0.004mm.
#2 Speed and Efficiency
Conventional milling machines often require an operator to manually change cutting tools depending on the cutting operation to be performed. Not only is this time-consuming, but it is also inefficient, as the end results are based on the operator’s judgment.
CNC mills feature rotating carousels that can hold up to 30 different tools. These tools are automatically exchanged on the spindle during machining operations, allowing cutting operations to be performed quickly and efficiently. With CNC mills, you can have your parts ready in a matter of hours, whereas conventional methods may take days or even weeks to complete.
#3 Wide Range of Available Materials
CNC mills boast compatibility with a wide range of materials, including plastics, metals, and composites. So long as we have the blocks of the material, Carolina Knife and our CNC mills will have no problem machining it.
#4 Affordability
We can talk about precision, speed, and a ton of other advantages all day, but nothing beats affordability, especially for businesses that rely on third-party manufacturers. CNC milling is among the most affordable modern-day manufacturing processes. In fact, a CNC milled component would cost you less than a comparable 3D printed part.
