What is CNC Milling?
Applications
Benefits of CNC Milling
Produces parts to very tight tolerances, ensuring consistency and high quality.
Can produce a wide variety of complex shapes and designs from different materials.
Automated process reduces the time it takes to produce parts compared to manual milling.
Once set, the machine can create multiple identical parts without variance.
Quick changeover between designs makes it ideal for both high-volume production and custom jobs.
Over time, reduces labour costs and material waste, making it economically beneficial for many businesses.
Metals
Grades Available:
5052, 6061, 7050, 2024-T3
Finishes:
As Machined, Anodized, Hard Coat Anodized, Powder Coated, Bead Blasted, Vibrate Polished
Description:
Lightweight, corrosion-resistant metal widely used in aerospace and packaging due to its versatility.
Grades Available:
1018, 12L14, 1144
Finishes:
Nickel Plated, Zinc Plated, Powder Coated
Description:
A strong alloy of iron and carbon used in construction, automotive, and various industries.
Grades Available:
303, 304
Finishes:
Nickel Plated, Zinc Plated, Powder Coated
Description:
Corrosion-resistant alloy of iron, chromium, and often nickel, known for durability and shine.
Grades Available:
C360
Finishes:
As Machined
Description:
A yellowish alloy combining copper and zinc, lauded for malleability and decorative applications.
Grades Available:
101, C110
Description:
Reddish-brown metal with excellent conductivity, utilized in electrical and plumbing tasks. applications.
Grades Available:
932
Description:
Copper-tin alloy with enhanced strength, conductivity, and corrosion resistance; widely utilized in modern electronics, sculptures, and precision bearings.
Grades Available:
Grade 2, Grade 5
Description:
Lightweight, strong metal resistant to corrosion, common in aerospace, medical implants, and jewelry.
More materials available upon request
Plastics
Colours Available:
White, Black
Finishes:
As Machined, Bead Blasted
Description:
Durable plastic renowned for strength, impact resistance, used in automotive and consumer goods.
Colours Available:
Clear, White, Black
More colours available upon request
Finishes:
As Machined
Description:
Transparent or coloured thermoplastic with excellent optical clarity, lightweight, weather-resistant, often used in signage, displays, and protective barriers.
Colours Available:
White, Black
Finishes:
As Machined, Bead Blasted
Description:
Rigid plastic with low friction, suitable for mechanical parts and precision components.
Colours Available:
Clear, Bronze
Finishes:
As Machined
Description:
Tough, transparent plastic valued for its impact strength, used in eyewear and protective barriers.
Colours Available:
White, Black
Finishes:
As Machined, Bead Blasted
Description:
Ultra High Molecular Weight Polyethylene, a robust, wear-resistant plastic for demanding applications.
Grades Available:
General
Finishes:
As Machined
Description:
High-Density Polyethylene, a strong, chemical-resistant plastic common in packaging and containers.
More materials available upon request
Maximum part size: 30.0″ (762mm) x 16.0″ (406mm) x 20.0″ (508mm)
This is the maximum part size that our mills can accommodate.
Minimum cutting tolerances: 0.001” (0.0254mm)
This is the maximum precision of any dimensions on the part.
Inside corners
When designing parts with inside corners on the XY axis, it is important to consider the size of the endmill. As the cutter removes material by spinning, the sharpest corner possible is equal to the radius of the end mill. A smaller endmill reduces the size of the fillet at the cost of extra machining time, whilst a larger endmill can reduce machining time and thus cost. If a round fillet would cause interference, a possible solution is a dogbone corner, where additional material is removed at the corner to create space where the corner would be.
Fillet generated by round cutter:
Dogbone corners:
Deflection
As the tool cuts through the billet, it can be pushed slightly out of the way of the material. Whilst the effects of this can be almost negligible, it may cause a poor surface finish on very thin walls as they vibrate from the tool’s movements. To accommodate for this, parts should be designed with thicker walls or shorter thin walls.
Tool length
When cutting deep channels, a longer endmill must be used to clear any high walls. This can cause more extreme deflection and thus worse tolerances and surface finish, to avoid this the cutting speed is reduced significantly adding additional cutting time and cost.
When designing parts for CNC milling, considering cost efficiency is crucial. Here are five design considerations to reduce the cost:
Simplify Geometry: Opt for simpler shapes and features. Intricate and complex geometries typically require additional tool changes, specialized tools, or longer machining times, all of which increase costs.
Reduce Depth of Cavities: Shallow cavities are quicker to mill. Deep cavities may necessitate special tooling or multiple tool changes, driving up machining time and cost.
Standardize Hole Sizes: Using standardized hole diameters that match common tool sizes can eliminate the need for tool changes or custom tools. This speeds up the milling process.
Minimize Tight Tolerances: Only specify tight tolerances where absolutely necessary. Tighter tolerances can extend machining time as the mill must move more slowly, and may require additional finishing processes.
Choose Cost-Effective Materials: Material cost is a significant factor. Using common, readily available materials that are easier to machine can reduce costs. Additionally, consider the machinability of the chosen material; some materials can be milled faster or with less tool wear than others.
Incorporating these considerations during the design phase can lead to significant cost savings during CNC milling production.
© 2024 uDesign Manufacturing. All rights reserved.
