NOTE CNC MILLING MACHINE

DEFINITION CNC MILLING

CNC milling, the most common form of computer numerical control (CNC) machining,
performs the functions of both drilling and turning machines. CNC mills are categorized
according to their number of axis and are traditionally programmed using a set of codes
that represent specific functions.

Axis are labeled as x and y for horizontal movement, and z for vertical movement. A
standard manual light-duty mill is typically assumed to have four axis:

1) Table x
2) Table y
3) Table z
4) Milling Head z

CNC Milling Machines

The number of axis of a milling machine is often interpreted in varying ways. A five-axis
CNC milling machine has an extra axis in the form of a horizontal pivot for the milling
head. The end mill is positioned at an angle with respect to the table allowing extra
flexibility for machining. A six-axis CNC milling machine includes an additional
horizontal pivot for the milling head, perpendicular to the fifth axis.

CNC milling machines are traditionally programmed using a set of commands known as
G-codes. G-codes represent specific CNC functions in alphanumeric format.

MEANING OF CNC MILLING MACHINE

CNC milling is a cutting process in which material is removed from a block by a rotating
tool. Cutting tools of various profile shapes are available including square, rounded and
angled. A wide variety of part shapes and geometries are possible. Plouse uses CNC
milling for customers in many different configurations to create a wide variety of parts
and assemblies, including engine components, custom and mold tooling, complex
mechanisms, and enclosures. We can handle CNC milling processes for a wide range
of processes and a large variety of materials. We use vertical milling centers, horizontal
bore mills and other conventional milling equipment.
CNC milling is a specific form of computer numerical controlled (CNC) machining. Milling itself is
a machining process similar to both drilling and cutting, and able to achieve many of the
operations performed by cutting and drilling machines. Like drilling, milling uses a rotating
cylindrical cutting tool. However, the cutter in a milling machine is able to move along multiple
axes, and can create a variety of shapes, slots and holes. In addition, the work-piece is often
moved across the milling tool in different directions, unlike the single axis motion of a drill.

CNC milling devices are the most widely used type of CNC machine. Typically, they are
grouped by the number of axes on which they operate, which are labeled with various letters. X
and Y designate horizontal movement of the work-piece (forward-and-back and side-to-side on
a flat plane). Z represents vertical, or up-and-down, movement, while W represents diagonal
movement across a vertical plane. Most machines offer from 3 to 5 axes, providing performance
along at least the X, Y and Z axes. Advanced machines, such as 5-axis milling centers, require
CAM programming for optimal performance due to the incredibly complex geometries involved
in the machining process. These devices are extremely useful because they are able to produce
shapes that would be nearly impossible using manual tooling methods. Most CNC milling
machines also integrate a device for pumping cutting fluid to the cutting tool during machining.

Computer numeric controlled machining centers are used to produce a wide range of
components, and tooling costs involved have continued to become more affordable. In general,
large production runs requiring relatively simple designs are better served by other methods,
although CNC machining can now accommodate a wide range of manufacturing needs. CNC
milling centers are ideal solutions to everything ranging from prototyping and short-run
production of complex parts to the fabrication of unique precision components.

Virtually every type of material that can be drilled or cut can be machined by a CNC mill,
although most of the work performed is done in metal. As with drilling and cutting, the proper
machine tools must be selected for each material in order to avert potential problems. The
hardness of the work-piece material, as well as the rotation of the cutting tool must all be
factored before beginning the machining process.
OPERATION CNC MILLING MACHINE
Operating a CNC milling machine takes quite a bit of knowledge and formal training. Information
must be input into the machine's computer control for every aspect of the operation. This
includes the tooling location and the dimensions that will be used to cut the raw material. You
must watch each operation during the first machine cycle to make sure that none of the tools
break as that may cause damage to the machine or the expensive raw material. With formal
training or schooling on a CNC machine, you can operate a mill successfully.

You should set the machine to zero so that it can use the dimensions in the program to cut the
raw material accurately. When a CNC machine is started, it does not have a reference point.
Place the machine in manual mode by pressing the positive X axis traverse button for one
second. You should follow that by pressing the Y axis button and the Z axis button. This will
allow the machine to set a reference point based on a home position.

You should set the vise or work-holding device on the table. Place a dial indicator on the spindle
and manually move it above the vise. Place the tip of the dial indicator on the front jaw and
manually move the dial indicator along the X axis. If the indicator does not move, the vise is
straight. Tap it in whichever direction to adjust it if the indicator moves and tighten when straight.
Remove the dial indicator and send the spindle back to the home position.

Place all of the needed tools into the tool turret. Place the machine in tool teach mode and call
up each tool individually. The tool teach mode can usually be found on the tool information
screen. The machine will automatically bring each tool to the probe and you will hear a beep
when the tool is taught.

Using any of the tools, touch the top of the raw material and set the Z zero point. The machine
will use this location to determine any depth cuts. This dimension is crucial to machining and
must be as accurate as possible.

Place an edge finder in the spindle and set to 1000 RPM. RPM stands for revolutions per
minute. Place the tip of the edge finder very close to the right side of the material. Slowly bring
the edge finder closer to the material. When it touches the side, you will see the tip of the edge
finder line up with its body. Continue in that direction until the tip becomes misaligned again.
That is the edge of the X axis, set the X zero to this point. Follow the same directions on the Y
axis and set that point as Y zero.

Send the spindle to the home position and start the program. Set your rapids very low. Rapids
dictate the speed of the spindle during tool changes and the approach it takes for cutting. You
can make adjustments to the rapids with the override on the face of the control and set them
anywhere between 0 and 100, which is full speed. Make sure it is coming in at the correct spot
and watch the first piece closely to watch for any mistakes or errors in the setup.
FUNCTIONS OF CNC MILLING PARTS AND COMPONENTS
EXPLAINED

Frame
Frame lies above the ground or foundation of CNC milling machine. It works as a support and
also damper for the machine vibration. The material of the frame may be Cast Iron or granite
filled welded structure. Barely steel is not used generally as a milling machine frame because it
has some spring properties and very less dampening ability. Though steel is very stiff, Cast Iron
is a better choice. Another innovative idea is using epoxy resins with different sizes of stones in a
welded steel container. Epoxy granite mixture is a good damper and when it is confined in a
steel container the strength is also improved.  At times aluminium is also used in the mixture.
There are arrangements for putting foundation bolts on the frame so that it is rigidly connected
to the ground.
Axes
CNC milling machine axes are connected to the frame for providing motion to each direction. As
the machine is computer controlled it is done by the program. It can also be done manually. A
common CNC is called 3 axis CNC. and can move in 3 directions. The components attached to a
CNC axis include motor, different types of ways, table, limit switches and lead screw.  Generally,
the axes move in X, Y and Z directions but sometimes optional 4th Axis is necessary and it is
kept in the list of accessory. 5 axes millings are also seen but not very common. The motor
provides the motion to the table and the ways provide smooth sliding motion. Dovetail ways and
linear ways are frequently used in the axes assembly. Leadscrew provides the linear motion
while it is extracting the rotary motion of the motor.
Table
The table is placed on the top of the saddle. It holds the jobs and also the job holding devices. A

number of T slots are there for holding the workpiece and jigs and fixtures. In CNC milling

operation the table is moved by the motor which gets signals from the program codes.

 Spindle

The spindle is the rotating tool holder. The tools are installed in the tapered part of the spindle.

The spindle has different RPMs. From the main transmission speed, the spindle speed may vary.

The spindle speed is set up according to the properties of the material needed to be machined.

Mainly three different types of spindles are seen. These are cartridge spindles, self-contained

spindles, and fabricated spindle

CNC Controller
The CNC controller in a CNC milling machine gives signals to the motor of the machine to move

in CNC axes. It is the electronic control that works as the brain of the machine. This electrical

and electronics equipment executes the code given as the input.

CNC Milling Machine Accessories

Coolant
The role of coolant in CNC milling machine is vital. It improves tool life and ensures smooth

machining of the work. The different coolant used in CNC milling includes Mist Coolant, Flood

Coolant, Cool Air Gun or Air Blast coolant and Dust Collector. Actually, the dust collector is not

a coolant but it creates the initial condition for the coolant to work. It collects the chips and

clears the surface. Mist coolant is used where the machine is not in a closure and requires

pressure. For the closed condition of the machine flooding coolant is better.
Way Oiler
Like any moving engine or machine CNC milling also needs lubrication. The guideways need

lubrication to allow the smooth motion over the table. The leadscrew is needed to be lubricated

as it is getting engaged with gears and motors and also handing heavy loads. In a CNC machine,

oilers are generally automated. But it can be done manually too. Automated oilers are good as

they ensure timely lubrication.

Powered Drawbar
Drawbars are good if you need to change your tool frequently. If automatic tool changer is used

then drawbars are required. Capture and release of the tool holders from the spindle can be

done by the means of powered drawbars. Drawbars include Impact wrenches, Pull Stud and

Tormach TTS Style. With powered drawbars, you don’t need an operator each time when you

want to loosen the drawbar. It reduces the time required by half.

Enclosure
Enclosures create a cover for the machine. A milling machine is always cutting and throwing

cheaps. It can be very messy. So an enclosure comes in very handy and the chips or the chips

mixed with coolant keeps inside and the production floor remains clean.

4th Axis
As the name implies it gives another movement in a direction different from the direction of X, Y

and Z. It is required in many cases. With this, the operator can hold extra parts on the table and

can do some extra work on the workpiece.

 According to the functionality, CNC millings can be small or large. And also according to the
position of the spindle the CNC milling can be divided into two classes. Vertical and Horizontal
milling machines. In vertical milling the tool axis is vertical and in horizontal milling, the tool
axis is horizontal to the WP. In horizontal milling, you can do the up milling and down milling.
We will discuss the different cutting processes of milling machines in a different article. Hope
you have got a good idea about the CNC Milling Machine Parts.
 MATERIAL AND CUSTOM MILLWROK
From the CNC lathe process to specialized milling, grinding, and turning, this style of machining
is ideal for custom work and specialty materials. The technology and sensitivity of these tools
allow them to process specialty parts made from a wide array of materials, including:

 Ceramics
 Composites
 Glass and fiberglass
 Graphite
 Polyester
 Specialty alloys
 Plastic polymers
 Exotic and precious metals
 Industrial and heavy duty metals

Essentially, if a material can be cut, it’s compatible with CNC milling. It’s an ideal tool for
prototyping and custom design, combining sensitivity with affordable tooling costs and efficient
operations.

CNC Milling Tool Types

The most common piece of CNC equipment is the CNC Vertical Milling Machine Center. These
complex tools are the easiest CNC mills to program, and are a key component of many machine
shops.

Both vertically and horizontally oriented CNC milling centers come equipped with specialized
components: an assortment of CNC tools and tool changers, including magazines, carousels,
and specialized CNC tool storage, are incorporated into their design. They also often include
coolant and cutting fluid systems and are equipped with specialty enclosures.

CNC turning tools, such as lathes, can be combined with a milling center for single setup CNC
milling and turning. Other useful milling tools include:

 CNC Router Tools — These specialty tools can perform the tasks of standard panel
saws, boring machines, and even spindle moulders, in addition to tenon and mortise cutting.
They’re just as useful for singular prototype processes as for precise automated production.
 CNC Tool Grinders — Ranging from general applications to specialized micro tool
grinders, these machines can both produce and regrind drills, step drills, woodworking tools,
profile tools and cutters, complex orthopedic implants and instruments, and more.
 CNC Tool Setters — An integrated part of a CNC milling center, tool setters help to
preset tool length and ensure accurate loading of individual tools within the system. They can
also be useful for off-set measuring, as well as detecting wear or breaking of tools in the
machines.

CNC HORIZONTAL MILLING MACHINE

Computer Numerical Control (CNC) technology allows machinists and engineers to control tools
such as mills, lathes, routers, cutters, and more with extremely sensitive computer systems. The
systems convert drawings and designs from CAM or CAD software into codes specific to a
machine’s controls — NC code, G-code, and ISO code being a few examples.

These controls then direct the tool’s operations. The rotating cylindrical cutters in a CNC
horizontal milling or machining center move along up to five axes to create the shapes, slots,
details, and holes of a three-dimensional part. The machine’s horizontal arbor holds a series of
cutters reminiscent of a circular saw blade, though they are thicker and smaller.

Horizontal machining is especially ideal for applications that demand slots, grooves, pocketing,
or facing. Regardless of a machine’s function, a horizontal spindle orientation allows
manufacturers to work quickly and efficiently, especially with projects that create large amounts
of chips. The horizontal layout allows the chips — an inevitable result of high-speed milling — to
simply fall away or be easily removed.
INDUSTRIES AND PRODUCT

CNC milling and machining is especially valuable to the production of large parts that demand
significant floor space, such as aircraft and aerospace panels or components. It also supports
projects for:

 Commercial applications
 Building and maintenance
 Electronics
 Medicine
 Security
 Recreation
 Transportation
 Automotive
 Industrial and O.E.M.
Prototyping and custom design are also popular applications of CNC horizontal cutters due to
their efficiency, flexibility, and increasingly affordable tooling costs

CNC VERTICAL MILLING MACHINE

The process of milling uses a specialized rotary cutting tool to remove material from a
workpiece surface. The process can be used for cutting and creating details, such as holes or
notches, as well as for sculpting a three dimensional piece.

Unlike drilling or traditional cutting, the tool in a mill advances perpendicularly to a workpiece on
a dedicated axis, performing countless unique, small cuts to remove material from a surface in
chips.

With Computer Numerical Control (CNC) technology, machinists and engineers can control
vertical milling machine operations using sensitive computer systems. These systems collect
design information directly from drawings and models in CAM or CAD software, which is
converted into codes (NC code, G-code, and ISO code) and then translated into operational
commands through the system.

A CNC vertical mill machine has cylindrical cutters oriented vertically on a spindle axis. This is
especially useful for plunge cuts and drilling; these tools are considered to be the best for
diesinking applications. With CNC technology, the tools in some vertical machining centers can
be manipulated on up to five axes for the fabrication of custom shapes, slots, holes, and details
in three-dimensional parts.
 INDUSTRIES AND PRODUCT
Vertical CNC milling allows an operator to easily access and monitor cutting operations: they’re
in clear sight. Vertically oriented machining is also best for diesinking work.

The simple setup and programming process of CNC vertical equipment allows for
straightforward operation and work holding, making it an ideal solution for small parts and short
runs. It can be used to produce high-quality precision parts for:

 Electronics
 Medicine
 Security
 Commercial and building applications
 Automotive and transportation
 Recreation
 Industrial projects

Its ease of setup also makes CNC vertical machining an excellent choice for prototype
applications.

Advantages of CNC Milling

 Very good for one-off or geometrically simple objects
 Virtually any material can be milled with a proper cutter, therefore costs are low
 Complex parts can be milled with high detail
 Tolerances of 0.001" to 0.003" are possible
 Weights of parts from a few grams to up to 100 lbs

Disadvantages of CNC Milling

 A more reduced set of features possible
 Certain features are not possible, including internal shapes or parts
 Size limitations depend on the actual CNC machine used
 More material waste than casting type processes
 Quite slow