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The milling machine can process various planes (horizontal planes, vertical planes, inclined planes), grooves (keyway, straight groove, angle groove, V-shaped groove, circular groove, T-shaped groove, dovetail groove, spiral groove, etc.) and gears and other forming surfaces, Cutting, and hole machining are also possible. It can process the shape of complex rotating bodies. Milling is fixing the blank and using a high-speed rotating milling cutter to move on the blank to cut out the required shape and features. Traditional milling is mostly used for simple shapes/features such as milling contours and slots. CNC milling machines can process complex shapes and features. The milling and boring machining center can perform three-axis or multi-axis milling and boring, which is used for machining, molds, inspection tools, thin-walled complex surfaces, prostheses, blades, etc. Only by proficiency in CNC milling processing methods and strategies can CNC machines’ advantages and key roles be fully utilized. This article will allow you to fully understand by introducing various processing methods and strategies of CNC milling.
Face milling: the end teeth of the tool mesh to form a flat surface, tool kneading: Ap is small, and Ae is large.
Groove milling: Machining where the tool diameter is fully engaged, Ae is equal to Dc, and Ap is up to 1.5 times Dc, Dc depends on the machining strategy used.
Side Milling: Machining is performed by engaging the sides of the tool. Ap is large, and Ae is small.
Profile milling: The machining where the ball part of the tool is engaged, Ap and Ae, are both small.
Advanced Milling Processing Including ramp milling, thread interpolation, trochoidal milling, push-pull profile milling, plunge milling, contour milling, and drilling.
Ramp milling: Milling a cavity at an angle in the z-axis direction.
Helical interpolation ramp milling: while the z-axis is ramping, the tool makes a circular motion to mill the cavity.
Trochoidal Machining: Partial circular motion in the X or Y axis, slotting using side milling. (turn slot milling into side milling)
Push-pull profiling milling: Machining a 3D profile by making up and down profiling movements along the contour of the profile.
Plunge milling: Drill and mill a deep slot using the (Z) axis.
Contour milling: A surface is machined by a small amount of drilling or ramping in the Z axis, followed by pocket milling along the X or Y axis.
Drilling: move along the Z-axis to machine a hole.
(1) General processing is a general-purpose processing strategy. The ratio of width of cut to depth of cut can vary, depending on the type of operation.
1) Tool characteristics: The tool has a relatively long cutting edge and a small core diameter, and there is no high requirement for precision.
2) Machine tool requirements: no special requirements.
3) Application areas: With basic CNC technology, difficult advanced machining methods are not feasible; metal removal rates can only reach a general level; application areas usually include small batch sizes and a wide range of materials.
(2) High-speed machining is a machining strategy that combines small radial depth of cut, high cutting speed, and feed rate; according to the method used, high material removal rate and low Ra value can be achieved. The typical characteristics of this strategy are low cutting force, less heat transfer to the tool and workpiece, reduced burr formation, and high dimensional accuracy of the workpiece; under high-speed machining, using faster cutting speed than ordinary machining, high metal cutting speed can be achieved: removal rate and good surface roughness.
1) Tool characteristics: stable (large core diameter and short cutting length), clear and well-formed chip space conducive to good chip removal and coating.
2) Machine tool requirements: high-speed CNC control, high speed, and fast feed speed of the worktable.
3) Fields of application: Semi-finishing and finishing machining of hardened steel (48-62 HRC) in the mold industry with short delivery times. This technology can also be applied to other materials using the right tools and advanced machining methods.
(3) High-performance machining is a strategy that can achieve very high metal removal rates. The typical feature of this strategy is that the cutting width is one time Dc, and the cutting depth is 1~1.5 times Dc, depending on the workpiece material; under high-performance machining, using a machining method with a much higher chip load than ordinary machining, Able to achieve extremely high metal removal rates.
1) Tool characteristics: Specially developed chip-containment structure on tool chip flute, tip protected by 45°, facet or tip arc, particularly smooth chip space, coating, with or without side shank.
2) Machine tool requirements: high stability, high power requirements, and high rigidity clamping system.
3) Application fields: In mass production and processing, production efficiency is a key indicator, or single-piece product processing, that requires a high metal removal rate.
(4) High-feed machining is a high-feed machining strategy that combines the full cutting of the entire tool diameter with a small depth of cut. Under high-feed machining, it is possible to achieve a high metal removal rate and good surface roughness by using a faster feed rate than normal machining.
1) Tool characteristics: specially developed tip, extremely short cutting length, coating.
2) Machine tool requirements: the possibility of high stability and high feed speed.
3) Application fields: From mild steel to hardened steel, titanium alloy, and stainless steel, it is very good for pre-processing before high-speed machining, and it can also be used for deep cavity processing. One of the strengths of this technology is the very user-friendly, easy, safe, and fast programming in CAM. It is relatively easy to program complex shapes without extensive programming experience using so-called contour milling strategies.
(5) Micromachining is a machining strategy that uses extremely small tool diameters.
1) Tool characteristics: diameter range from Ø0.1 to 2.0mm, short cutting length, a wide range of outer diameter reduction, high precision, coating.
2) Machine tool requirements: high spindle precision, high speed, CNC, and thermal stability to prevent spindle elongation.
3) Application fields: various cavity processing on many kinds of materials.
1) Check the power and rigidity of the machine tool to ensure that the diameter of the milling cutter used can be used on the machine tool and that the overhang of the tool is as short as possible;
2) The number of teeth of the milling cutter is moderate to ensure that there are not too many blades meshing with the workpiece simultaneously to cause vibration. When milling narrow workpieces or pockets, there must be enough engagement between the insert and the workpiece;
3) Appropriate feed per tooth to obtain a good cutting effect when the chip is thick enough to reduce tool wear. Positive rake angle inserts are used to obtain a smooth cutting effect and the lowest power;
4) The diameter of the milling cutter suitable for the width of the workpiece;
5) Correct lead angle (45 degrees is suitable for general milling);
6) Appropriate milling cutter position;
7) Only use cutting fluid when necessary; dry milling usually has better tool life.
If you need a CNC machining shop to mill your parts, contact Anpllocnc now.
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