Milling is one of many techniques of mechanical subtractive machining, also known as cutting. This process is based on removing subsequent layers of excess material using appropriately profiled blades. Depending on their geometry, number, and shape, this process can be divided into chip machining and abrasive machining. One of the devices used to reduce excess material from a solid block of base material are milling machines. In combination with the constantly developing CNC computer control technology, it allows automating production and ensuring a uniform appearance to all machined elements. What types of CNC milling cutters can be distinguished? How to distinguish a milling machine from a lathe? What materials can be machined with a CNC milling machine? We answer all these questions in the article below.
How to distinguish different types of CNC milling cutters?
During abrasive or chip machining, a CNC milling machine removes excess material from a fixed element using milling cutters. They are primarily used for shaping flat surfaces, edges, and shaped objects. Milling cutters are nothing more than multi-blade cutting tools with a rotary motion. They can be divided based on their shape, the material they are made of, and the geometry of the blades. Based on the first of these criteria, the following types of milling cutters can be distinguished:
– cylindrical
– frontal
– cylindrical-frontal
– angular
– disc
– finger
– pin
– worm
– modular
– shaped
– for threads
Professional milling cutters for CNC milling machines are most often made of high-speed steel (HSS), cobalt (HSS-E or HSS-Co) or cemented carbide (HM), and we also distinguish powder models (PM). Blades with a diamond plate (PDK or DIA) are also very popular in the industry.
Types of CNC milling cutters – division according to the geometry of the blades
Based on the geometry of the milling cutter blades, they can be divided into cylindrical, end-face cylindrical, disc, and angular. The first two types work perfectly for any surfaces, planes with an edge, and T-slots. Disc milling cutters are used for cutting and making slots in a linear range. Angular ones are needed for trapezoidal and angular slots.
Does wood milling require specialized tools?
A CNC milling machine equipped with the appropriate type of cutters is a great solution for machining not only wood, but also metals and plastics. Thanks to CNC technology, wood milling is significantly less time-consuming and demanding. Unlike manual processing, it can also guarantee full repeatability and extremely high precision of machining. In matters such as plywood milling, CNC is also the best solution, because just like solid wood, this material needs to be machined very carefully and accurately. It is also worth paying attention to the aspect related to the optimization of costs of mass, serial or line production. CNC technology allows to transform a three-dimensional virtual model into a ready-to-use or sell product.
What are the advantages of CNC metal milling?
Manual milling of aluminum, non-ferrous metals and steel alloys is an extremely complex and time-consuming process. All these materials can of course only be machined after selecting the appropriate type and kind of milling cutters. Milling metal with CNC is incomparably faster and cheaper than manual processing. A craftsman with even several decades of experience cannot guarantee the same precision of execution as CNC. Numerically controlled machines in the form of CNC milling machines, CNC lathes or CNC grinders are basic equipment in almost every professional machine park or production plant. For this reason, this type of equipment is most popular in almost all branches of industry. CNC was once mainly associated with the automotive, armaments and aviation industries, but now, thanks to the support of professionals, everyone can benefit from this technology. It is useful not only at the stage of serial or linear production, but also in the early phases of the project (e.g. for the production of prototypes).
Is milling plastics more complicated than metals or wood?
Thanks to the support of experienced professionals and CNC technology, the milling of plastics is fast, efficient, and extremely precise. Materials of this type are much easier to process than steel or wood, as they are simply less durable and more susceptible to the action of milling cutters. Milling plexiglass and other plastics using CNC milling machines is an excellent alternative to laser cutting or format sawing technology. Compared to these two methods, CNC milling machines can provide much greater freedom in terms of form, which is particularly useful in the case of less standard shapes and forms. They can also be used to create ornaments and decorations on the processed elements, which significantly increases their market value at a low cost.