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Romina Ronquillo. CNC milling, or computer numerical control milling, is a machining process which employs computerized controls and rotating multi-point cutting tools to progressively remove material from the workpiece and produce a custom-designed part or product.

This process is suitable for machining a wide range of materials, such as metalplasticglass, and wood, and producing a variety of custom-designed parts and products. Several capabilities are offered under the umbrella of precision CNC machining servicesincluding mechanical, chemical, electrical, and thermal processes.

This article focuses on the CNC milling process, outlining the basics professional cnc milling machine quantum the process, and the components and tooling of the CNC milling machine. Additionally, this article explores the various milling operations and provides alternatives to the CNC milling process.

What is milling? It's is a type of machining that uses cutters to shape a workpiece, often on a moveable tabletop, although some milling machines also feature movable cutters. Milling started out as a manual task performed by humans, but most milling these days is done by a CNC mill, which utilizes a computer to oversee the milling process. CNC milling offers higher precision, accuracy, and production rates, but there are still some situations when manual milling comes in useful.

Manual milling, which requires a lot of technical skill and experience, offers shorter turnaround times. Like most conventional mechanical CNC machining processesthe CNC milling process utilizes computerized controls to operate and manipulate machine tools which cut and professional cnc milling machine quantum stock material.

In addition, the process follows the same basic production stages which all CNC machining processes do, including:. Then the completed design is exported to a CNC-compatible file format and converted by CAM software into a CNC machine program which dictates the actions of the machine and the movements of the tooling across the workpiece.

The CNC milling process employs horizontal or vertical CNC -enabled milling machines—depending on the specifications and requirements of the milling application—and rotating multi-point i. When the machine is ready, the operator launches the program via the machine interface prompting the machine to execute the milling operation. Once the CNC milling process is initiated, the machine begins rotating the cutting tool at speeds reaching up to thousands of RPM.

Depending on the type of milling machine employed and the requirements of the milling application, as the tool cuts into the workpiece, the machine will perform one of the following actions professional cnc milling machine quantum produce the necessary cuts on the workpiece:. As opposed to manual milling processes, in CNC milling, typically the machine feeds moveable workpieces with the rotation of the cutting tool rather than against it.

Milling operations which abide by this convention are known as climb milling processes, while contrary operations are known as conventional milling processes. However, the process is also used to shape a stock piece of material from start to finish. In both cases, professional cnc milling machine quantum milling process gradually removes material to form the desired shape and form of the part.

First, the tool cuts small pieces—i. Then, the workpiece undergoes the milling process at much higher accuracy and with greater precision to finish the part with its exact features and specifications. Typically, a completed part requires several machining passes to achieve the desired precision and tolerances. For more geometrically complex parts, multiple machine setups may be required to complete the fabrication process.

Once the milling operation is completed, and the part is produced to the custom-designed specifications, the milled part passes to the finishing and post-processing stages of production. CNC milling is a machining process suitable for producing high accuracy, high tolerance parts in prototype, one-off, and small to medium production runs. The versatility of the milling process allows it to be used in a wide range of industries and for professional cnc milling machine quantum variety of part features and designs, including slots, chamfers, threads, and pockets.

The most common CNC milling operations include:. The process employs face milling cutters which have teeth both on the periphery and tool face, with the peripheral teeth primarily being used for cutting and the face teeth being used for finishing applications.

Generally, face milling is used to create flat surfaces and contours on the finished piece and is capable of producing higher quality finishes than other milling processes. Both vertical and horizontal milling machines support this process. Types of face milling include end milling and side professional cnc milling machine quantum, which use end milling cutters and side milling cuttersrespectively.

The process employs plain milling cutters which have teeth on the periphery that perform the cutting operation. Depending on the specifications of the milling application, such as the depth of the cut and professional cnc milling machine quantum size of the workpiece, both narrow and wide cutters are used. Narrow cutters allow for deeper cuts, while wider cutters are used professional cnc milling machine quantum cutting larger surface areas.

Then, the operator introduces a finer toothed cutter, faster cutting speeds, and slower feed rates to produce the details of the finished part. The process employs single-angle milling cutters—angled based on the particular design being machined—to produce angular features, such as chamfers, serrations, and grooves.

Form milling refers to milling operations involving irregular professional cnc milling machine quantum, contours, and outlines, such as parts with curved and flat surfaces, or completely curved surfaces. The process employs formed milling cutters or professional cnc milling machine quantum cutters specialized for the particular application, such as convex, concave, professional cnc milling machine quantum corner rounding cutters.

Some of the common applications of form milling include producing hemispherical and semi-circular cavities, beads, and contours, as well as intricate designs and complex parts with a single machine setup. Besides the aforementioned operations, milling machines can professional cnc milling machine quantum used to accomplish other specialized milling and machining operations.

Examples of the other types of milling machine operations available include:. Straddle milling : Straddle milling refers to milling operations in which the machine tool machines two or more parallel workpiece surfaces with a single cut.

This process employs two cutters on the same machine arbor, arranged such that the cutters are at either side of the workpiece and can mill both sides at the same time.

Gang milling : What is gang milling? Gang milling refers to milling operations which employ two or more cutters—typically of varying size, shape, or width—on the same machine arbor. Each cutter can perform the same cutting operation, or a different one, simultaneously, which produces more intricate designs and complex parts in shorter production times. Profile milling : Profile milling refers to milling operations in which the machine tool creates a cut path along a vertical or angled surface on the workpiece.

Gear cutting : Gear cutting is a milling operation which employs involute gear cutters to produce gear teeth. These cutters, a type of formed milling cutters, are available in various shapes and pitch sizes depending on the number of teeth necessary for the particular gear design.

A specialized lathe cutter bit can professional cnc milling machine quantum be employed by this process to produce gear teeth. Other machining processes : Since milling machines support the use of other machine tools besides milling tools, they can be used for machining processes other than milling, such as drilling, boring, reaming, and tapping.

The CNC milling process employs a variety of software applicationsmachine toolsand milling machinery depending on the milling operation being performed. Despite professional cnc milling machine quantum wide range of milling machines available, most machines largely share the same basic components. These shared machine parts include the:. Machine interface : The machine interface refers to the machine component the operator uses to the load, initiate, and execute the CNC machine program.

Column professional cnc milling machine quantum The column refers to the machine component which provides support and structure to all other machine components. This component includes an affixed base and can include additional internal components which aid the milling process, such as oil and coolant reservoirs. Knee : The knee refers to the adjustable machine component which is affixed to the column and provides support to the saddle and worktable.

This component is adjustable along the Z-axis i. Saddle : The saddle refers to the machine component located on top of the knee, supporting the worktable. This component is capable of moving parallel to the axis of the spindle, which allows the worktable, and by proxy the workpiece, to be horizontally adjusted.

Worktable : The worktable refers to the machine component located on top of the saddle, which the workpiece or workholding device e. Depending on the type of machine employed, this component is adjustable in the horizontal, vertical, both, or neither direction. Spindle : The spindle refers to the machine component supported by the column which holds and runs the machine tool or arbor employed. Within the column, an electric motor drives the rotation of the spindle.

Arbor : The arbor refers to the shaft component inserted into the spindle in horizontal milling machines in which multiple machine tools can be mounted. These components are available in various lengths and diameters depending on the specifications of the milling application. The types of arbors available include standard milling machine, screw, slitting saw milling cutter, end milling cutter, and shell end milling cutter arbors.

Ram : The ram refers to the machine component, typically in vertical milling machines, located on top of and affixed to the column which supports the spindle. This component is adjustable to accommodate different positions during the milling operation.

Machine tool : The machine tool represents the machine component held by the spindle which performs the material removal operation. The milling process can employ a wide range of milling machine tools typically multi-point cutters depending on the specifications of the milling application—e. Machine tools can vary based on the number, arrangement, and spacing of their teeth, as well as their material, length, diameter, and geometry.

Some of the types of horizontal milling machine tools employed include plane, form professional cnc milling machine quantum, staggered tooth, and double angle mills, while vertical milling machine tools employed include flat and ball endchamferfaceand twist drill mills. Millings machines can also use drillingboringreaming, and tapping tools to perform other machining operations.

In general, milling machines are categorized into horizontal and vertical machine configurations, as well as differentiated based on the number of axes of motion. In vertical milling machines, the machine spindle is vertically oriented, while in horizontal milling machines the spindle is horizontally oriented. Horizontal machines also employ arbors for additional support and stability during the milling process, and have professional cnc milling machine quantum capabilities for multiple cutting tools, such as in gang milling and straddle milling.

Controls for both vertical and horizontal milling machine are dependent on the type of machine employed. For example, some machines can raise and lower the spindle and laterally move professional cnc milling machine quantum worktable, while other machines have stationary spindles and worktables which move both horizontally, vertically, and rotationally.

When deciding between vertical and horizontal milling machinesmanufacturers and job shops must consider the requirements of the milling application, such as the number of surfaces requiring milling and the size and shape of the part.

For example, heavier workpieces are better suited for horizontal milling operations, while die sinking applications are better suited for vertical milling operations. Ancillary equipment that modifies vertical or horizontal professional cnc milling machine quantum to support the opposing process is also available.

Most CNC milling machines are available with professional cnc milling machine quantum to 5 axes— typically providing performance along the XYZ axes and, if applicable, around rotational axes. The X-axis and Y-axis designate horizontal movement side-to-side and forward-and-back, respectively, on a flat planewhile the Z-axis represents vertical movement up-and-down and professional cnc milling machine quantum W-axis represents diagonal movement across a vertical plane.

In basic CNC milling machines, horizontal movement is possible in two axes XYwhile newer models allow for the additional axes of motion, such as 3, 4, and 5-axis CNC machines. Table 1, below, outlines some of the characteristics of milling machines categorized by the number of axes of motion.

Depending on the type of milling machine employed, the machine tool, the machine worktable, or both of the components can be dynamic. Typically, dynamic worktables move along the XY-axes, but they are also capable of moving up and down to adjust the depth of cut and swiveling along the vertical or horizontal axis for an increased range of cutting.

CNC milling machines with greater degrees of freedom allow for greater versatility and complexity in the milled parts produced. There are several different professional cnc milling machine quantum of milling machines available which are suitable for a variety of machining applications. Beyond classification based solely on either machine configuration or the number of axes of motion, milling machines are further classified based on the combination of their specific characteristics.

Some of the most common types of milling machines include:. Knee-type : Knee-type milling machines employ a fixed spindle and vertically adjustable worktable which rests on the saddle supported by the knee.

The knee can be lowered and raised on the column depending on the position of the machine tool. Some examples of knee-type milling machines include floor-mounted and bench-type plain horizontal milling machines.

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