CNC machining is a cutting-edge manufacturing method that uses computer-controlled machines to make precise and intricate parts. The wide range of cutting tools available for CNC machining makes it a versatile technique.
Each tool is designed for a specific task. Stick around as we dive deep into the different types of CNC machining and the critical factors to consider when selecting CNC machining tools. Let’s get started!
Ten Common CNC Cutting Tools That Empower SME Manufacturers to Create Top-Quality Parts
Drill Bits
The first in the list is drill bits – these tools have a cylindrical shape and a conical cutting point to aid initial penetration. The cutting point angle is usually 120 degrees, but there are also spiral flutes along the shaft for easier chip evacuation.
These bits are typical of high-speed steel, carbide, or cobalt. However, they come in 3 varieties (center, twist, and ejector), each specialized for a specific purpose. For instance, the center drill bits can be used when one is aiming to create small spots on the workpiece, which are further refined using the twist drill. On the other hand, the ejector drill can be strategically used to cater to the needs of deep hole drilling.
End Mill
End mills allow manufacturers to perform advanced operations.
Compared to the drill bits, which have one or two flutes, end mills have 8 sharp flutes both on the ends and sides. This feature makes it easy for them to remove large amounts of materials in a limited amount of time. The roughing end mill should be your top choice if you want to cut through the entire workpiece and remain with an excellent surface.
Face Mill
As a manufacturer, you have to prepare the workpiece for quality results. Part of these preparations involves making the workpiece straight and flat. With a face mill, this should be the least of your worries. This CNC cutting tool has a bigger diameter and a high speed, allowing you to make the flat section of the workpiece before other cutting operations are made. The interchangeable cutter inserts make the cutting tool more suitable for challenging surfaces.
Reamers
The last thing you want to do is drill an oversized hole that will ruin your workpiece, and this is where reamers step in. You see, when creating holes in a workpiece, always opt for a small drill bit; this way, you can slowly adjust the size depending on the desired needs. If you drilled a big hole, it’s impossible to make it smaller. However, with a small hole, you can use a reamer to expand the size. The result? Dimensional accuracy and tight tolerance parts.
Gear Cutters
Gear cutters are highly demanded CNC cutting tools because of their ability to cut accurate and precise gear teeth. Gear cutters have varying teeth forms and pitches making it easier for manufacturers to fabricate various gears from spur, bevel, screws to helical gears. If you belong to the automotive or robotic industries, gear cutters are indispensable tools you should not miss having.
Hollow Mill
Hollow mills are more like end mills, but the difference is that they have a central hole that revolves around a cylindrical workpiece. With over three cutting edges, this piped-shaped CNC cutting tool revolves around the workpiece, cutting it downwards. Hollow mills are most preferred when working with a cylindrical workpiece to create a consistent pre-thread diameter.
Thread Cutting Mill
If your manufacturing processes mainly revolve around cutting threads, threading cutting mills should be your topmost priority CNC cutting tool. As the name suggests, the threading mill cuts both internal and external threads. While it’s possible to use taps, they are only suited for cutting internal threads. Thread mills, however, can cut both even when penetrating hard metals.
Countersink Mill
Countersink mills are mainly used for the creation of canonical recesses in workpieces. With a fluted cutting head, this tool is adept at chamfering or deburring drilled holes. If you decide to use the countersink mill to enhance the finish and functionality of your components, ensure that you reduce the rotation speed for quality results.
Slab Mill
Slab mills are found to be most suitable for horizontal milling, owing to their broad and flat cutting surface. Also sometimes called slab cutters, these tools come in various sizes and configurations to accommodate diverse machining needs.
With teeth on their periphery, they can be readily used to create wide and narrow cuts on the workpiece without much ado. Other tasks of this CNC tool include slotting and contour milling.
Fly Cutter
Unlike slab millers, which are used to create wide and narrow cuts, fly cutters make broad or shallow cuts through their single-point rotary tools, thus producing a smooth surface finish. Additionally, fly cutters are much more affordable and offer a better surface finish than face millers. So, if your goal is to achieve a top-notch surface finish, these CNC cutting tools should be your go-to.
Important Factors to Consider When Selecting CNC Machining Tools For Your Needs
Now that you know how each CNC cutting tool operates, you are ready to make an informed choice. Below are important considerations that will help you choose a tool that gets the job done correctly and lasts you for several years to come:
● Tool Material
If you are on the hunt for a tool that will serve your industry for several years, you ought to be cautious of the type of material you choose. You see, CNC cutting tools are usually made of various materials, including solid carbide. Some are more durable and expensive than others.
Solid carbide is perfect for anyone looking for a reliable cutting tool. However, if you are ready to splurge your money to make a solid investment, a PCD-tipped tool will serve you well. These tools are usually made of diamond materials with metallic binders, thus making them hard and durable.
While the PCD-tipped CNC cutting tools are a bit pricey, they are cost-effective. Once you buy this tool, you increase your production rate 25% faster, thus saving labor and extra feed rate.
● The Material and Features of the Workpiece
Workpiece material and features play a significant role in determining the tooling selection. The stecker machine is known to work wonders on aluminum, ductile, iron, and gray ironwork pieces. CNC cutting tools can be used on each of the materials. However, it’s essential to go for standardized tooling to reduce risk and costly damages.
When it comes to using CNC cutting tools like drills, mills, and taps, pay good attention to the features of the workpiece. The Stecker machine, for instance, is better suited for aluminum. The machine has 3 different standard 90-degree square shoulder face mills, which run faster on aluminum surfaces.
● Combination Possibilities
Frankly, relying on different CNC cutting tooling can cost a lot of time and money, and the combination can save you the hassle. Let’s get technical for a minute. If you need 6 CNC cutting tools to get the job done right, you will have to pass the workpiece for many cycles plus, let’s not forget the cost of buying each tooling.
However, the good news is CNC cutting tooling is customizable, meaning one can make necessary adjustments to perform various functions in one workpiece. When designed properly, a combo tool can drill and chamfer, thus reducing the number of cycles compared to using different tools. While combo tools have high upfront costs, they are definitely worth it in the long run.
● Machine Capacity
While most CNC cutting tools can be used on CNC machines, you just can’t jump to the conclusion that they are all robust and performant. Machines that feature greater horsepower provide opportunities to use combo tools. However, those with relatively smaller horsepower can find this endeavor challenging.
In regards to the size of the casting, large casting requires the help of hoists to move them. On the flip side, smaller castings don’t need it. In the real sense, they even increase efficiency. How, you might ask? Well, all engineers have to do is design small parts that can be fitted into a larger machine to perform various functions. With the right tooling, you can increase your machine’s efficiency.
● Expertise
You are making a huge investment, so you have to choose the right CNC machine shop. Buying your tools from an experienced staff puts you in a much better position to gain insights into what would work best for your project. They can also help design combo tools to get you started. So, if you are ready to begin your fabrication journey, get help from an accredited CNC machine shop.
At Sunrise Metal,we have the right expertise to guide you through the entire process,from selecting the right tool to designing and assembling.Our engineers have been in the industry for over X years and deeply understand every CNC machining project;thus,all your needs will be accounted for.
Contact us today, and let us partner to achieve your manufacturing project goals!