CNC milling is a key subtractive manufacturing process that allows manufacturers to shape a workpiece to create a desired design. As opposed to manual milling, where operators directly control the machine’s movements to shape the workpiece, this computer numerical control-driven process relies on pre-programmed instructions to guide the cutting tool.
This form of milling lends unparalleled precision and repeatability to the manufacturing chain, and it can unlock a wealth of benefits for businesses in various fields. Find out everything you need to know about CNC milling and precision machining with this quick Revelation Machinery guide.
CNC Milling: A Breakdown
3D printing has, in many spaces, taken over the limelight and overshadowed the benefits of CNC machining. The two processes are, however, incredibly distinct. 3D printing is generally an additive process that creates the final output piece-by-piece, while CNC milling arrives at its output by chipping away at the original workpiece.
We can break down CNC milling into its key elements:
- Computer Numerical Control (CNC): This is effectively the ‘brains’ of the milling operation. CNC precision machining operators use CAD/CAM software to create programs that dictate the movements of the milling machine along its rotational axes. These instructions dictate the cutting tool’s
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- Path
- Speed
- Cut depth
- Feed rate
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- Cutter: Cutting tools can come in many different shapes and sizes. The average cutting tool is a multi-edged instrument that can rotate to remove material while traveling along its pre-programmed path. Operators need to choose well from tool options like end mills, face mills, and drills to unlock the benefits of CNC machining.
- Workpiece: This is essentially the raw material that the machine works on. This can be anything from metal, plastic, or wood to composite materials. The workpiece is held securely in place on the worktable by vices or clamps.
The Benefits
CNC milling represents a massive leap forward in precision machining compared to traditional manual processes. These advantages generally flow from automation, advanced tooling, and computer control. Let’s break these down.
- Precision and Repeatability: CNC milling machines operate on pre-programmed instructions. This minimizes–if not removes–the scope for human error and inherent inconsistencies in processes like manual machining. This benefit of CNC machining allows for very tight tolerances and repeatability, which is critical when manufacturing complex components and managing larger production runs. Since CNC precision machining movements are precise to within a few micrometers, manufacturers can ensure consistent quality and minimize variations between each output.
- Intricate Designs: CNC milling is an excellent choice for manufacturers looking to create complex shapes featuring intricate details. This functionality is powered by the machine’s ability to follow multi-axis paths, allowing operators to create complex 3D contours and undercuts accurately.
While this is useful for mass production, it’s especially handy for those in R&D spaces who regularly need to create prototype designs for testing before entering mass production.
- Reduced Waste: Milling and machining processes are rarely cheap. The benefit of CNC machining is that the optimized toolpaths and precision cutting are excellent at reducing material waste and ensuring efficient material utilization. This is particularly useful for operators who regularly work with expensive metals like titanium.
- Safety: Automating the many dangerous tasks involved in traditional milling can reduce risks to human operators. CNC milling typically happens in an enclosed machining environment, and the pre-programmed, automated tools avoid erratic movements. Additionally, modern CNC machines also come with key safety features and interlocks to further reduce the scope of errors that could result in injury or damaged equipment.
- Flexibility: Success in today’s competitive landscape hinges on a business’s ability to pivot and adapt to new changes. CNC precision machining gives businesses that agility, allowing them to respond to evolving market demands and customize production whenever needed. Traditional milling, on the other hand, involves a slow and comprehensive retooling process. This benefit of CNC machining stems from how easy it is to reprogram and repurpose machines for different tasks. For instance, CNC programs can be easily modified to accommodate iterative design changes, allowing operators to quickly test and refine prototypes.
- Run Times: Manual milling processes are powered by human workers and expertise, and both of those things have their limits. In other words, traditional milling stops once workers have to go home or take a break. CNC milling doesn’t suffer from that limitation. Aside from maintenance breaks, CNC mills can effectively run for nearly 24 hours a day, every day. Additionally, newer CNC machines require minimal maintenance to run effectively, reducing the total ownership cost for businesses. Manufacturers can even buy used equipment to save even more on production costs.
- Lower Costs: A key benefit of CNC machining is that it allows operators to scale down their reliance on manual workers. Manufacturers that rely completely on CNC machines can employ a few AI engineers and machine operators instead of hundreds of human milling workers for their production floors and cut down significantly on costs.
CNC precision machining is already a staple in many industries, including aerospace, manufacturing, medical, and automotive. New advancements like hybrid machining technologies and improved data integration are set to improve CNC milling even further as we look ahead at the future of manufacturing.
Get The CNC Advantage
The benefits of CNC machining paint a clear picture of its importance. If you’re ready to upgrade your production floor with used CNC machinery from top brands, head over to Revelation Machinery today. Our nationwide inventory covers a wide range of used machinery, and we can also help you sell your used CNC equipment quickly and safely.