Brass is a copper and zinc alloy ideal for producing CNC machined parts, including CNC milled parts. CNC milling of brass involves placing material or a sheet of paper on a die under the spindle, which holds the tool. This rotates, creating two axes of movement. The cutting tool mounted on the rotating spindle removes the raw material, forming the shape. After various surface treatments, such as galvanizing, polishing, heat treatment, nickel plating, zinc plating, tinning, silver plating, and chrome plating, the final abrasive brass product can be obtained. This precision milling service of brass parts machined by CNC cutting is suitable for industrial equipment, smart home, communication, and computer components.
Machining and characteristics of milling brass parts:
- long-lasting,
- high wear resistance,
- good plasticity,
- flexible and rust-resistant,
- easy to shape,
- excellent tensile strength,
- In some cases, there may be no other option, and the work will be done using the materials currently available. If aluminum and brass are such materials and there may be no second choice, here are a few key points to remember when machining them on CNC machines.
Classification of brass as CNC metal machining:
- machine-pressed brass,
- red brass,
- lead brass
- nickel brass.
Types of foundry materials based on brass:
- silicon,
- aluminum,
- tin,
- manganese,
- lead,
- aluminum - a relatively soft, but strong material that is lightweight and malleable. It is non-magnetic, which means it does not ignite easily and is often used in prototyping because it is flexible and durable. However, it tends to stick to the edge of the tool, which reduces performance and lifespan. This should be taken into account when cutting, as the material itself and its coating can already affect the solution to this problem. Chips should also be regularly cleaned, otherwise the tool may break.
Tips for Cutting Materials
- proper lubrication prevents chips from sticking to the cutting edge,
- using a blower and cooling spray helps simplify the process,
- it is necessary to choose a tool with sufficient strength,
- keep in mind that the feed rate and speed are significantly lower for aluminum and other soft metals than for wood or plastic,
- During the machining of aluminum with a CNC milling machine, it is necessary to use an aluminum tool and/or one of small diameter, which is specially designed for cutting this material, as it will help increase the revolutions per minute.
Brass
Brass is an alloy of metals consisting of copper and zinc and is one of the most commonly used materials in the world. It is also one of the easiest raw materials to work with, especially compared to aluminum. Where aluminum often sticks to tools, brass behaves quite properly, better than plastics and guarantees good quality and the desired shape.
Its relatively low melting temperature and fluidity properties facilitate shaping and use in electrical work, medicine, hydraulics, and various industries.
Advantages of Brass
- Brass is cheap and durable, resistant to corrosion and withstands extreme temperatures. Easier cutting at higher speeds and feeds without negatively affecting tool wear, surface finish, and chip formation,
- Moreover, it is 100% recyclable, which minimizes waste and maximizes material utilization. Brass is widely used in the production of musical instruments and electronic components, as it is a highly conductive material,
- Binary brass is the oldest and simplest. Copper is mixed with zinc in various proportions. It was known as early as the 1st century BC, although it was not patented until the 18th century after the discovery of metallic zinc in the 16th century,
- Bronze appeared significantly later and was more of a "domestic" material. It was used for the production of jewelry and vessels, tools and weapons. For centuries, the ability to retain its beauty under a thin layer of oxide allows jewelers to use brass as a substitute for gold, which is why it is called the poor man's gold,
- After the development of navigation, due to its good antimagnetic properties, it began to be used for the production of navigational instruments,
- Good corrosion resistance facilitates the use of water systems (controllers, fittings, nozzles). This is done to add new properties and improve machinability. With the development of the shipbuilding industry, the addition of tin began to be used. In marine conditions, this extends the lifespan of marine hulls by reducing corrosion,
- Silicon and lead reduce losses caused by friction,
- Manganese and nickel, on the other hand, are used for greater strength and resistance to corrosive environments.
Machinability - Milling of Brass
CNC milling of brass is more brand-dependent in terms of machinability. The fewer special additives optimizing chip formation, the worse the material for milling. The closer the physical properties are to pure copper, the harder it is to work with the metal. The addition of lead in brass milling serves to remove the main disadvantage of copper alloys in brass, and during cutting - high plasticity. The brittleness of the cut product helps to remove it from the cutting edge area and ensures a uniform, clean cut. Such alloys are called automatic alloys, as they are specially designed for continuous (high volume) cutting on machine tools.
CNC Processing Error
CNC plotters are equipped with the latest technology, which ensures maximum precision and efficiency in marking, furniture, aluminum and brass processing, and more. But these benefits only appear when we know how to effectively use the existing equipment. CNC machines are very complex devices, so sometimes even experienced operators make mistakes at work, reducing productivity and causing problems they could avoid. If you work on tight deadlines, this loss of efficiency will almost certainly result in a loss of profitability.
From programming to production - here is a compilation of some of the most common mistakes encountered when working with CNC milling machines and how to avoid them in daily work to maximize productivity.
Proper device installation
This is the first step in the process and if not done correctly, it can negatively impact the entire project. There are also many factors that contribute to the overall success of the task - from the choice of tool and feed rate of the material to the spindle speed and cutting depth. Over time, experience gained in using machines in various projects suggests how to effectively configure machines to achieve success. If at any point there is uncertainty about the configuration, it is worth seeking help from an industry expert or a trusted sales representative.
Choosing the Right Tool
This is related to the errors mentioned above, but it is a key factor in achieving the best results. However, it is important to understand that at the very beginning of field research, it is not always easy to find the only correct option. In many cases, the work can be done by many tools at the same time, but it is still necessary to identify one that will bring the highest quality results. Each device provider usually has a product guide that will help you choose the right one for the planned project. If the work is done with new materials, we should not be afraid to make a few trial cuts to see how different knives or blades work.
Proper placement of material
Due to the operation of CNC plotters, it is important to ensure that the material is securely held in place before cutting. Otherwise, inaccurate cutting and excessive losses may occur. You can't process something that isn't in its place! Therefore, before starting work, make sure that the cut material is smooth and clean and there are no leaks around the vacuum system and seals (if applicable), as these are common causes of low final quality. If the cut material is not perfectly flat, it will be harder to fully secure it during the project. The proper size of the vacuum pump is key to effective vacuum application. These numbers should correspond to the size of the canvas used. It is worth consulting with a CNC specialist to make sure that we are using the appropriate size system. Depending on the size of the material or part, mechanical mounting of the material or part may be required.
Proper and regular maintenance
Like any high-performance technical machine, CNC plotters must be regularly cleaned and maintained to ensure continuous operation. Improper maintenance can lead to the accumulation of dirt, dust, and pollutants in the machine, which can lead to malfunctions. The material may start to slip, which can lead to precision errors, etc. In addition to regular cleaning, lubricating moving parts ensures that nothing gets stuck during operation and can move smoothly as needed. Before each use, let's make sure that the plotter is operational. This will help achieve the best results and save unnecessary time and losses when restarting the project.
Brass CNC Machining
Brass strip has:
- good mechanical properties,
- hot ductility,
- good cold ductility,
- adequate machinability,
- welding ease,
- corrosion resistance.
Brass milled parts are machined using computer-controlled machine paths, using high-speed rotary tools, if the material is to be shaped. As the requirements for product size are increasingly high, the machining has gradually changed from the original two-axis machining to three-axis machining, four-axis machining, and five-axis machining centers, and the accuracy can reach 0.001 mm. The rotary motion of the machine tool spindle is 20,000 rpm, which makes the surface of the machined object smooth, and the turning or grinding is very good, maintaining high quality.