Converting a digital design to a physical part could be challenging. You require a process that is exact, dependable, and affordable. For several assignments, CNC (Computer Numerical Control) machining is the solution. In this guide, we will review the two key procedures: turning and milling. When you require custom parts, it is vital to understand cnc turning and milling services. This write-up will help you discover their contrasts, applications, and how to select the right one of them for the best outcomes.
The Key Processes
CNC machining is a process that employs computers to control tools utilized in shaping materials. It basically makes a part by separating material from a solid, geometric form of material, which is the reverse of an additive process. That is the reason that it is called subtractive. We will talk about two main types below.
CNC Turning Described
CNC turning is similar to a potter’s wheel for metal or plastic. The chunk of material gets rotated at a very high speed. A cutting tool does not move, but it stays in one place and presses against it. This chips away material to form a cylindrical or circular shape.
This mode of operations utilizes a CNC lathe. It is perfect for making parts that are round or cone-shaped. Some examples include shafts, pins, rings, and nozzles. A specialized Токарные работы с ЧПУ would be the perfect choice for extremely complicated or very specific round pieces.
CNC Milling Described
CNC milling has an opposite way of working. Unlike the other processes, the workpiece remains still and the tool that usually spins fast. The tool, instead, moves along various cutting paths to get the desired shape that is not round at all. You can imagine it like a finely skilled sculptor using a rotary tool.
The CNC mill is the machine that facilitates this manufacturing. It is more suitable for parts that are not only flat but also designed with pockets or complex geometrical shapes that are not round. These include brackets, enclosures, and molds. Moreover, sophisticated shops are now utilizing 3-axis, 4-axis, and 5-axis milling capabilities to create even the most intricate designs.
Turning vs. Milling: An Overview
Choosing which method, turning or milling, to use depends significantly on the shape of your workpiece. A straightforward table can be used to illustrate the difference between them. Recognizing those is the first step to determining the proper supplier for your cnc turning and milling services.
| Attribute | Токарная обработка с ЧПУ | Фрезерование с ЧПУ |
|---|---|---|
| Tool/Workpiece Motion | Workpiece rotates, tool is stationary | Tool rotates, workpiece is stationary |
| Геометрия деталей | Cylindrical, conical, round | Prismatic, flat, complex curves |
| Axes of Motion | Typically 2 axes (X, Z) | 3 to 5 axes (X, Y, Z + rotational) |
| Typical Parts | Shafts, pins, bushings, nozzles | Brackets, enclosures, molds, housings |
| Лучшее для | Creating round and symmetrical parts | Creating parts with flat faces and pockets |
Both processes are appreciated as they are highly accurate and repeatable processes. Most shops can achieve tolerances between +/- 0.001 inches and +/- 0.005 inches, which means that every piece is more or less the same.
Selecting the Suitable Process
What criteria do you follow in determining the appropriate process for your project? You can apply a simple framework. It would be helpful since it will direct you to a smart choice of the most suitable approach that will save you time and money.
Step 1: Part’s Shape Analysis
Initially, consider the main shape of your part.
Do you think: Is the part mostly round? If so, it will not be unusual that CNC turning is the first option. This will be the most straightforward and affordable way to fabricate a piece like an axle or a custom bolt.
If the part has a mostly flat or block-like form with features cut into it, milling is obviously a better option. Such parts are machine plates or electronic housings.
Step 2: The Features of the Parts
Subsequently, have a glimpse at the smaller details on your part.
Does your cylindrical part call for those that are not on its centerline? For example, besides needing a flat face, it might have to have a slot or holes on its side. If yes, you may necessitate a second process – milling after turning.
Does your block-shaped part have a circular, outer shape, which is not perfect, or a circular shape, or both? In this case, your part might need both the operations of milling and turning to complete it.
Step 3: Consider Quantity and Accuracy
Lastly, give a thought to the number of parts you want and their required precision.
Are you producing a batch of thousands of miniature, complex, detailed round parts? In the case of high-volume projects that associate tiny, complicated parts, an exclusive special procedure may be required. For instance, the Токарные работы с ЧПУ в Швейцарии are designed for manufacturing long and slim parts in bulk while achieving incredible precision.
When Both Are Required: Mill-Turn Machining
Contemporary parts frequently require mill-turn centers which can perform both turning and milling in one setup. These are the most advanced turning and milling machines.
The primary advantage is the increased performance. The reason is that the component only has to be moved one time and accuracy is then increased substantially. This reduces the overall time taken during the manufacturing of one piece. Such an integrated function is a prime benefit of the best cnc turning and milling services.
Materials and Finishes
CNC machining is a highly flexible process used for a variety of materials. Once the component is available, you can also select from myriad surface finishes to achieve the desired look and functionality.
Metals Generally Utilized in CNC Machining
- Металлы: Aluminum (6061 and 7075), Stainless Steel (303, 304, 316), Mild Steel, Alloy Steel, Brass, Copper, and even Titanium.
- Пластмассы: ABS, Polycarbonate, Nylon, Delrin (POM), and PEEK.
Each of the materials is distinctive as per their properties and individual suitability. For instance, aluminum is considered lightweight while being easy to machine, meanwhile, stainless steel is the best option for strength and corrosion resistance.
Common Surface Finishing Techniques
A surface finish serves as protection for a part or can also enhance its appearance.
- As-Machined: This is the default raw finish with clear impact tool marks.
- Обработка бисером: This operation generates a non-reflective uniform surface that has a matte finish.
- Анодирование (тип II и III): A process that involves the addition of a colored hard and corrosion-resistant layer on aluminum parts.
- Порошковое покрытие: This applies to an array of colors in a durable form like paint.
- Покрытие: The application of a very thin coating of metal such as nickel or chrome can be carried out for wear and tear problems or just for design.
Collaboration with a CNC Service
Collaboration with a manufacturing partner should be simple. From experience, we have seen that implementing the following steps can ensure that you are on your way to getting the best out of the cnc turning and milling services.
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Prepare a Complete Tech Pack. A 3D CAD file (like a .STEP or .IGS file) is a must. But for true precision, you also need a 2D PDF drawing. This drawing should show all critical dimensions, tolerances, material type, and finishing notes. A complete pack leaves no room for error.
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Understand Tolerance. A tolerance is a set of allowable variations of a dimension. Standard tolerances are suitable for the majority of features. Specifying tolerances that are very tight where they are not needed will increase the costs of a part dramatically. Use them only on the most critical features.
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Design for Manufacturability (DFM). A few small design changes can save a lot of money. We often advise clients to:
- Avoid making deep and narrow pockets, they are hard to reach for tools and take a long time for machining.
- Use standard drill sizes and thread types whenever possible. Custom tools add cost and lead time.
- Design internal corners with a generous radius. Sharp internal corners require special, slow processes.
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Assess Your Partner’s Expertise. Merely a machinery list won’t do. You need a partner who has the experience and who is committed to quality and additional requirements that your solutions impose. Seek out a proven name in the industry with quality certifications, like ISO 9001, for transparency in communication.
Why Mekalite?
The key to your project success is selecting the proper partner. We bring to you precise cnc turning and milling services that are designed to make your ideas come alive with quality and precision. Our focus is on giving you the best possible design feedback resulting in the optimization of your parts for manufacturing at the same time saving you time and money. We possess the manpower as well as technology to manage a broad inventory of jobs that range from simple prototypes to complex production runs.
На сайте Mekalite we draw on our many years of experience and the best machines to make sure that every piece is exactly what you were hoping for. Get in touch with us now to tell us about your project.
FAQ on CNC Turning and Milling Services
What differentiates CNC turning from milling?
In CNC turning, the part is rotated, while the cutting tool stays fixed. This is ideally suited for circular parts. In CNC milling, on the other hand, a tool rotates and moves across the fixed part. This is why it is most appropriate for flat, and complicated shapes.
Can a part be turned and milled?
Yes, that is a very common case. A part might get turned to make a round shaft on it. Then it is milled to put in a flat area or a keyway. The Advanced cnc turning and milling services use mill-turn machines to do both in one setup. This boosts accuracy and goes easy on time.
What do you need to know to quote CNC services?
To get a quotation that is accurate and speedy, you are expected to provide a 3D CAD model (.STEP format). It should also be really useful to attach a 2D drawing to it. This should include materials, quantities, critical dimensions, tolerances, and any surface finishes that are required.
How does part complexity affect CNC machining pricing?
One of the most important factors that determine cost is complexity. High costs are always related to factors such as extremely tight tolerances, sharp internal corners, and long pockets. The features that need several different machining setups cost more too. Unusual materials or non-standard tools also generate extra costs.
What makes 3-axis different from 5-axis milling?
3-axis milling moves the tool in three directions; X is left-right, Y is front-back and Z is up-down. It is best for simpler parts. But in 5-axis milling, two rotational axes are added to this. So, the tool may approach the part from any angle. Consequently, it is possible to make very complicated geometries with a single setup.
