The development of CNC (Computerized Numerical Control) technology has revolutionized many sectors of industry, including mechanical production. In this context, CNC milling machines, both vertical and horizontal, have become indispensable tools in workshops and factories around the world. Therefore, the decision between a vertical and a horizontal milling machine is a key question for many manufacturers. In this article, we will make a detailed comparison of these two types of CNC machines, analyzing their advantages, disadvantages, and optimal applications. With our guide, you will gain a better understanding of which of these tools will be the best solution for your specific production needs.
What is a vertical milling machine
Metalworking technology requires specific production and specific tools for each of its processes, and a vertical milling machine is one of the most suitable and fascinating tools for those who are passionate about production, processing, and understanding the properties of metals. Below you will learn everything you need to know about this machine. A vertical milling machine is a machine tool that removes metal from a workpiece using a rotating tool - called a mill, a rotating part with several hard metal teeth, lips, or plates. It is a power tool with longitudinal travel and rotary motion, which operates in the machining process by removing material, both through abrasion and chip removal. In this type of machine, the spindle is set perpendicular to the table, which perfectly facilitates step-by-step or alternating machining to create different parts in a mechanized way, making simple grooves, or shaped grooves or recesses. The vertical milling machine is used for:
- flat surface machining,
- groove making,
- rounding,
- gear wheels,
- slots,
- decorations.
Furthermore, these machines can process various materials, such as:
- wood,
- metal,
- tiles,
- plastics.
What are the functions of a vertical milling machine?
The function of a vertical milling machine is to use a mill for rough machining of materials. Additionally, these cylindrical tools use cutting edges to cut parts or products that are to be produced. According to this principle, virtually any design can be produced, as long as the machine can use the required tools and can move the produced parts in all necessary axes. Thanks to technological progress, the vertical metal milling machine has become a very versatile tool for companies dealing with metal processing, as it provides great flexibility in the production of industrial parts. The term "Vertical milling machine" itself comes from the vertical setting of the spindle, which is the part of the machine that holds and rotates the cutting tool, such as a mill.
Functions of a vertical milling machine
- Milling: This is the basic function of the milling machine, which involves precise removal of material from the surface being machined. The vertical milling machine can mill a wide range of surfaces, including flat, curved, angled, as well as perform grooves and holes.
- Drilling: Thanks to the vertical positioning of the spindle, the vertical milling machine can also perform the functions of a drill, allowing for precise drilling of holes.
- Drilling and threading: The vertical milling machine can drill holes to a specified diameter, as well as perform threading, creating threads for screws and nuts.
- Surface finishing: With this tool, you can smooth the surface, ensuring a high level of finish.
- Programmability: In the case of vertical CNC milling machines, one of the key features is the ability to program tool paths, which allows for automatic production of complex parts with high precision and repeatability.
Depending on the specific model and configuration, a vertical milling machine can offer even more features and capabilities.
What are the advantages of a vertical milling machine?
The vertical milling machine is an easy tool to operate, although it may initially seem complicated. It is undoubtedly intuitive even for an inexperienced operator, who can work with several machines at the same time. This type of machine reduces operator fatigue and provides greater safety, which is an example of simplicity and reliability. In addition, the vertical milling machine helps to achieve better precision, uniformity, and quality of the produced products. Its simplicity allows for flexible changes of designs or models in a very short time, enabling quick execution of urgent orders.
What are the disadvantages of a vertical milling machine?
CNC vertical milling machines have many advantages, but there are also certain limitations and disadvantages that are important to consider:
- Cost: CNC milling machines, including vertical models, can be quite expensive, both in terms of initial purchase costs and ongoing operating costs. This includes the need for regular maintenance and parts replacement.
- Limitations in terms of size and shape of parts: Vertical milling machines have certain limitations in terms of the size and shape of parts that can be effectively machined, especially when compared to horizontal milling machines. For example, long and heavy parts may be difficult to maintain in a stable position in a vertical milling machine.
- Efficiency during heavy machining: Unfortunately, vertical milling machines may not be as efficient as horizontal milling machines during heavy machining operations, such as deep milling.
- Tool wear: In vertical milling machines, especially those operating at high speed, cutting tools may wear out faster, which increases operational costs.
It is important to carefully consider these factors when choosing a milling machine for specific applications.
What are the types of vertical milling machines?
There are two types of vertical milling machines:
- stationary
- turret.
The vertical milling machine with a fixed axis consists of one part - a table, which supports the worktable, allowing it to move perpendicular to the spindle, which moves parallel to its own axis. Due to the axis layout, this type of milling machine is suitable for grooving and making deep grooves in long-term work.
When it comes to the vertical turret milling machine, its most interesting feature is that the spindle does not move during the cutting or processing of the workpiece. The table has a longitudinal and perpendicular movement relative to the spindle.
How is the vertical milling machine constructed?
In the simplest terms - it is a machine tool with a vertical spindle. In this case, the milling cutter is placed on the spindle, which rotates to produce a cutting motion. The main limitation of this machine tool is the force perpendicular to the axis, which the milling cutter may be exposed to during the table feed. Among vertical milling machines, we can distinguish:
- products with tilting heads - which offer good versatility,
- machines with fixed heads - which lose versatility, but gain in solidity.
In some cases, in vertical milling machines with tilting head, the milling spindle has an axial displacement.
What is a horizontal milling machine?
A horizontal milling machine is a type of milling machine in which the spindle, the machine element that rotates the cutting tool, is positioned horizontally. The above orientation affects the types of operations that can be carried out with a horizontal milling machine, as well as the types of parts that can be effectively machined with it. Unlike vertical milling machines, which are more often used for surface machining and complex-shaped details, horizontal milling machines are typically used for heavier machining operations, such as:
- deep milling,
- especially groove milling,
- pocket milling.
How is a horizontal milling machine constructed?
Now that we've understood the main function a horizontal milling machine can serve, it's time to learn about its construction:
- Table: this is the place where the rough machining part is located. It must be securely fastened to ensure the operator's safety.
- Hand wheels: they provide movement in Cartesian axes and can move the material held on the table.
- Head: this is where the device that holds and secures the cutting element, commonly known as the mill, is located.
- Motor: an essential part of the horizontal mill, where we can find power, rotations and torque. These features depend on the model and application of the horizontal mill.
- Gearbox: depending on the material we want to work with, we will need a certain speed. This part of the milling machine allows us to adjust the speed to achieve the best possible finish.
There are many types of horizontal milling machines and depending on their layout, the above basic elements for creating machining operations may vary.
How to operate a horizontal milling machine?
To operate a milling machine, first and foremost, we need a large, solid piece of material that we want to work with. From this solid block, we can start to give it the desired shape, being able to create any type of element. Then, to be able to make cuts, we need a head in which the mill will be integrated and will be responsible for making the movements. In relation to these movements, various types of mills are available on the market, which are used in different ways. They allow obtaining a range of unique details and shapes during processing. In this case, the horizontal milling machine has the mill extended outward. Therefore, the movements that we will be able to make will be movements above or below the parts that we want to roughly process.
What are the advantages of horizontal milling machines?
Horizontal milling machines are particularly effective in the production of large and heavy parts, such as those used in the aviation or automotive industry. They can also be configured with multiple spindles, which allows for simultaneous machining of multiple sides of a part.
Although horizontal milling machines are less versatile than vertical milling machines, they are extremely efficient in performing their specific tasks, making them a valuable tool in many production environments.
What are the disadvantages of horizontal milling machines?
Just like vertical milling machines, horizontal milling machines also have their limitations and disadvantages that are worth knowing. These include:
- Space requirements: Horizontal milling machines are usually larger than vertical milling machines and may require more space in the workshop. This can be a problem if space is limited.
- Cost: Unfortunately, horizontal milling machines are usually more expensive than vertical milling machines, both in terms of initial purchase costs and operating costs. In addition, the tools used in horizontal milling machines may be more expensive to replace.
- Access limitations: In horizontal milling machines, access to the workpiece may be hindered due to the position of the spindle and table. This can make it difficult to precisely position the workpiece.
- Efficiency in delicate machining: While horizontal milling machines may be more efficient in heavy machining, they may not be as precise as vertical milling machines in delicate and detailed CNC machining.
Just like with vertical milling machines, it is crucial to understand the specifics of a given machining operation and choose the appropriate type of milling machine.
What is the difference between a horizontal and a vertical milling machine?
The main difference between horizontal and vertical milling machines, as the name suggests, is the orientation of the axis. Horizontal milling machines have cutters on a horizontal axis parallel to the milling table, while vertical milling machines have an axis perpendicular to the milling table.
Due to this difference, each of the milling machines is used for different machining tasks.
On the one hand, the horizontal milling machine is used for grooving with a wide range of combinations in terms of types and depths of grooves. On the other hand, on the vertical milling machine, we can work on parts with offset machining and they may include rotating parts, which in continuous finishing are ideal for low production output jobs. As you can see, the difference between these two machines is tangible, just look at the types of finishes each generates, as well as the cuts made, to which each strives. Both can accept components or accessories that give them additional features, but they cannot be used for the same tasks, as they were created for different areas in the CNC industry.
Which milling machine generates higher costs - vertical or horizontal?
Both vertical and horizontal milling machines are key elements of most CNC machining workshops, however, they differ in terms of costs. When choosing between these two types of machines, it is necessary to consider several factors related to this aspect.
Purchase cost
Vertical milling machines are usually cheaper than horizontal ones. They are often chosen by small and medium enterprises that are just starting their activity in CNC machining or have a limited budget.
Maintenance Cost
Horizontal milling machines may generate higher maintenance costs. Due to their complex construction, they may require more frequent inspections and servicing. The replacement of tools for horizontal milling machines can also be more expensive.
Operating costs
Vertical milling machines are usually more energy-efficient, which translates into lower operating costs. Horizontal milling machines, although they may be more efficient in terms of production, often consume more energy.
Profitability
Although horizontal milling machines are more expensive to purchase and maintain, they can provide higher profitability in the long run. Thanks to their ability to conduct heavy machining operations and make precise cuts, they can speed up production and increase efficiency. The ultimate choice between a vertical and horizontal milling machine depends on many factors, such as the type of machining, available space, budget, and long-term goals of the company.
Trends and future of milling technology
In the world of CNC machining, there is no shortage of technological trends. Both vertical and horizontal milling machines continue to evolve, adapting to the changing requirements of the industry. Which type of machine is worth choosing due to market development and what trends are currently shaping it?
Automation
Increased automation is a trend that affects both types of milling machines. With technological advancement, milling machines are increasingly equipped with advanced control systems and robots that can automate the milling process. Although automation can be costly at first, in practice it can significantly increase efficiency and reduce errors in the long run.
Digitization
Digital tools, such as CAD/CAM systems, are increasingly used in milling machines, enabling precise design and programming of milling operations. Both vertical and horizontal milling machines benefit from these modern technologies, allowing for quick and accurate creation of complex parts.
Sustainable Development
In the face of growing ecological awareness, milling machine manufacturers strive to create machines that are more energy-efficient and less harmful to the environment. This includes both vertical and horizontal milling machines.
Hybrid Technologies
Another important trend is the emergence of hybrid milling machines, which combine vertical and horizontal milling functions. It is these machines that are capable of performing various machining operations, providing greater flexibility and efficiency.
In conclusion - both vertical and horizontal milling machines have a bright future in the world of CNC machining. Both types of machines are evolving to meet the growing demands of the industry, and the choice between them depends on specific needs and production goals. Each of these products has its advantages and disadvantages, but before we start using it - we need to outline the goal we want to achieve.