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Introduction

Working with CNC machines that are not precise and versatile can make the machining process challenging. For this reason, engineers opt for non-cut-and-dried vertical milling machines. However, that does not necessarily mean that selecting any CNC machine cutting tools is restricted to how well they perform in terms of accuracy and precision.

One needs to be mindful of several factors when selecting such tools. Failure to do so may result in a poor-quality end product that no manufacturing unit wishes to produce.

Here are five important considerations when selecting CNC cutting tools. Take a look. 

1. CNC Machining Tool Configurations

A CNC machine features different configuration types. Many CNC machining tools offer multiple features. In other words, many CNC tools can be configured for multiple tasks to be handled by a single cutting machine. This feature further reduces the time needed to complete the entire machining process.

Multi-feature CNC machines can also save considerable time, which may go into changing the tools for different requirements. However, it should be noted that different configurations are designed for different workpiece types and materials. Thus, engineers must know which tool configuration they need for their workpieces.

2. Materials And Features Of The Workpiece

The tool to be used is highly dependent on the material of the workpiece one is operating on. Experts recommend different CNC machining cutting tools for different material types. For example, the Stecker machine works with aluminum, grey iron castings, and ductile iron.

Even within these materials, aluminum tends to have the highest machinability and SFM (surface feet per minute). Therefore, engineers and manufacturers should understand the materials and features of their workpieces.

3. The Capacity of CNC Machines

Tooling machines should be shortlisted depending on the production volume of one's projects. CNC machines can use the majority of cutting tools. However, that does not equate to the enhanced efficiency of those CNC machines. Experts recommend that a higher horsepower machine allows engineers to use multiple combo tools suitable for performing various functions.

In addition, the casting of the machine is also an important consideration. Case in point: smaller castings do not require the help of hosts to move them around, unlike large castings. Running multiple tool parts on a pallet can save considerable time that may go into changing the tool parts.

In other words, selecting the right cutting tool is all about matching the machine's ability and availability to the requirements of projects.

4. Materials Used in the Cutting Tools

Engineers have to work with different materials as per project needs. One must note that the materials used for designing cutting tools can enhance the longevity and finishing of the end product. Case in point: some cutting tools can be developed using materials that are more durable than others. Most cutting tools are made of solid carbide because solid carbide creates a durable cutting tool.

However, polycrystalline diamond-tipped (PCD-tipped) tools can create the hardest and the most reliable cutting tools. It is worth noting that the tool life for a drilling tool made from PCD is around four times longer than that of ones made from solid carbide. The PCD-tipped tools are also known to be 25 times faster than the carbide-cutting tools. In addition, the precision of the PCD-tipped tools is also better.

However, one of the important points to be wary of when selecting materials for cutting tools is the cost. While PCD-tipped tools may seem like the best option for cutting high-precision edges, they come with an expensive price tag. Thus, solid carbide is a less expensive option that costs 75 times less than PCD-tipped tools.

5. Feed and Spindle Speed

The feed and spindle speed are two technical terms that one needs to understand to create better end products. Feed speed is technically the rate at which the work material moves inside the cutter. Feed speed is always dependent on the spindle speed. Failure to use an accurate feed and spindle speed can even burn the workpiece.

Engineers must mathematically determine the optimal feed speed before operating on the workpiece to avoid unwanted results. It is important to note that feed speed is not the same as cutting speed, which is the peripheral speed of the tool. In other words, feed speed is associated with the movement of the cutting tool, while cutting speed is associated with the tools.

Conclusion

Engineers tend to work with designs with higher geometric complexity and different materials. As a result, it goes without saying that when working with computerized cutting tools, accuracy is the utmost priority. However, the tool's accuracy is not the only aspect that makes or breaks the efficiency of CNC machining processes.

One needs to be mindful of various aspects before deciding on the right tools for precise cutting. Awareness of the aforementioned factors is essential to enhance the efficiency and end product.

About the Author:

Vincent Hua

Vincent Hua is the Marketing Manager at TSINFA. He is passionate about helping people understand high-end and complex manufacturing processes. Besides writing and contributing his insights, Vincent is very keen on technological innovation that helps build highly precise and stable CNC Machinery.

We are pleased to announce the expansion of our 3B Thread Gages! Inch plug thread gages are used to inspect pitch diameter and pitch accuracy of internal threads. OSG inch plug gages are manufactured to Class X tolerances per ANSI B1.2. Go and No-Go gages from OSG are ground from premium HSS and hardened to 64Rc to ensure superior wear resistance. Gages are available with short form certifications.

The following list numbers are associated with the NEW 3B Thread Gages:

•        NEW! List #15003   3B Thread Gages

The 3B Thread Gages have the following features:

•        High hardness TiN coating to provide long tool life.
•        Gold coloring to visually analyze the wear condition in seconds.

We are pleased to announce the expansion of our PHOENIX® PXM End Mill Offering with the addition of the NEW PHOENIX® PXSH Style Exchangeable Head End Mill! The PHOENIX® PXM is an exchangeable head end mill series for superior surface finish and precision in a variety of applications.

The following list numbers are associated with the NEW PHOENIX® PXM-PXSH Style:

•        NEW! List #78PXSH     PHOENIX® PXM-PXSH (metric)

The PHOENIX® PXM-PXSH end mill offers the following features & benefits:

•        OSG's proven cutting geometries and coatings produces high performance in a variety of applications and materials
•        2-face contact (end face and taper) and buttress thread for fast and highly rigid clamping
•        Radial runout less than 15µm and axial repeatability ±30µm for high accuracy and repeatability
•        End mill style, inch and metric provides a complete offering

We are pleased to announce that inch sizes have been added to the A Brand AE-CR-MS-H End Mill offering! The A Brand AE-CR-MS-H is a multi-flute square type and radius type carbide end mill designed for stable and high-efficiency milling of high-hardness steels. With the addition of the new DUROREY coating uniquely engineered for high-hardness steels, high chipping resistance is made possible even in work materials exceeding 60 HRC, allowing long tool life and high speed milling.

The following list numbers are associated with the NEW A Brand AE-CR-MS-H series:

•        NEW! List #8470             A Brand AE-CR-MS-H (inch)

The A Brand AE-CR-MS-H end mill offers the following features & benefits:

•        Variable index to reduce chattering
•        Cutting edge geometry for stable machining of high-hardness steels
•        DUROREY coating which allows for outstanding performance in high-hardness steels

We are pleased to announce the expansion of our A BRAND AE-VM end mill series with the addition of the NEW A BRAND AE-VTSS End Mill! The A Brand AE-VTSS is a duarise coated advanced multifunctional carbide end mill for ferrous metals. With superb chip handling, this stubby end mill can side mill, slot, ramp, and plunge. 

The following list numbers are associated with the NEW A Brand AE-VTSS series:

•        NEW! List #8233             A Brand AE-VTSS (inch)
•        NEW! List #8333             A Brand AE-VTSS (metric)

The A Brand AE-VTSS end mill offers the following features & benefits:

•        Positive rake angle which reduces cutting force
•        High rigidity to improve milling accuracy
•        New flute form that facilitates excellent chip evacuation
•        Duarise coating to minimize thermal cracks
•        Variable leads which enables stable and high efficiency milling

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There are almost as many distinct variations of CNC tools as there are finished products that could be milled. If you are familiar with the functions these tools perform, it will be much more straightforward for you to select the ones appropriate for the project you are working on. When it comes to the amount of time it takes and the quality of the work to be produced, choosing the appropriate cutting tool for your CNC milling machine, the material, and the type of milling can have a significant impact.

So here is a list of prominent milling tools utilized for CNC cutting.

Top 7 Milling Tools for CNC Cutting 

Different types of CNC milling tools make it feasible to achieve the highest level of product customization. While cutting into and shaping different types of materials, several tools are employed. The tool that should be utilized to cut also gets decided by the finalized design of the cut. 

Aside from these factors, specialists choose their tools based on how well they match the required speed with the desired finish. Depending on the ultimate purpose of the completed product, one of these two considerations might take precedence over the other.

The top 7 milling tools for CNC cutting are: 

1. End Mills

There are numerous kinds of end mills, each of which is designed for a particular kind of cutting. All end mills cut at an angle of ninety degrees.  A center-cutting end mill is what's required to make a vertical cut. These mills can cut both the center and the margins of the workpiece.

Non-center cutting end mills feature a hole in the middle of the tool and only contain cutting edges mostly along the ends of the mill. Since roughing end mills have fewer flutes than standard end mills, they are the tools of choice for making the initial cuts in a workpiece. You will need finishing end mills with additional flutes to obtain a design similar to the part you want to produce. It will enable you to deliver a component that is cut with immense precision.

The tool employed on a project will vary depending on several factors, the most important of which is the number of flutes and the material of its composition. The production of end mills typically involves the use of cobalt, high-speed steel, and carbide as raw materials. More details about the different types of mills (as per their material) are given below.

• Cobalt: Cobalt mills only contain eight percent cobalt, with the remaining construction built of steel.  Cobalt mills can run at a pace that is 10 percent quicker than their counterparts.

• Carbide: The use of carbide end mills is recommended for finishing procedures.

• High-Speed Steel (HSS): It is the go-to material for mills of all kinds. It strikes an optimal balance between tool cost and service life. Since HSS has sufficient flexibility, it can be utilized for cutting iron and other materials.

End mills may perform a wide variety of cuts, the type of tool used depends on the type of cut being made:

• Face Milling

It is the process of just cutting into one surface of a material.

• Side Milling

It is used when chamfer mills are being employed to create beveled edges. To penetrate and smooth off the corner, you move the mill along the material's edge.

• Ramping

Ramping is a way of cutting at an angle into a surface, usually a diagonal cut through the material. It produces an angled toolpath while concurrently milling in the radial and axial directions. Toolpaths for ramping can be either circular or linear.

• Plunge Milling

It causes the end mill to plunge vertically into the workpiece. Like ramping, plunge milling necessitates using a center-cutting end mill to clean out the material from the hole's inside and perimeter.

• Slot Milling

Slot milling creates slots using an end mill to carve a groove in a material while cutting the edges on both sides simultaneously.

2. Face Mills

This tool is primarily used to create a level surface on a solid portion of the material. As the first step in milling, this is often performed on the top of the stock to smooth it out. The cutter inserts in a face mill's sole body can be changed for specialized cutting tasks. You would require more cutters to remove metal at a faster rate.

3. Twist Drills

Drill bits resemble end mills in that they have a conical cutting tip on the end of a shaft with one or even more flutes. Twist drills are often made from solid carbide or High-Speed Steel (HSS). The drill's hardness, wear resistance, and lifespan can be improved by applying a gold-colored coating, such as TiN.

4. Fly Cutters

Fly cutters are considered the best to create a fantastic surface finish.  The clockwise motion of these cutting tools produces a mirror-like finish on the material.

5. Center Spotting Drills

These stocky tools first construct a precise conical hole to avoid the drill bit from drifting during a cutting operation and end up drilling the hole at an incorrect site. Screw clearance holes and counterbores can be drilled with the same tool thanks to multi-function drills that spot and countersink.

6. Reamers

Reamers are mainly utilized to enlarge the existing holes in compliance with the tolerance while providing a superior surface finish. They help you ensure the accuracy of the roundness and diameter of a drilled hole. For reamers to work, a pilot hole of roughly the same diameter as the final product must first be bored.

7. Taps and Thread Mills

Taps are tools used to cut threads into the interior of a material. Yet not every thread is produced by a cutting procedure. By applying pressure, Roll Form taps get inserted into holes, and the surrounding material is shaped to fit them.

Thread mills are similar but can be employed to cut internal or external threads.

Concluding Remarks 

The key to successfully machining products and components is selecting the appropriate CNC tool. Learn how each one functions, and keep in mind the use of the most beneficial ones in your manufacturing facility.

Author Bio

Peter Jacobs is the Senior Director of Marketing at CNC Masters. He is actively involved in manufacturing processes and regularly contributes his insights for various blogs in CNC machining, 3D printing, rapid tooling, injection molding, metal casting, and manufacturing in general.

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We are pleased to announce the release of our NEW OSG PHOENIX® PDZ Flat Drill Series!
The OSG PHOENIX® PDZ is an indexable drill series designed for stable flat-bottom hole making. It is an ideal solution for a wide variety of materials such as carbon and alloy steel, stainless steel and cast iron.

The following list numbers are associated with the new OSG PHOENIX® PDZ Flat Drill series:

• List #52513 OSG PHOENIX® PDZ (inch)
• List #78537 OSG PHOENIX® PDZ (metric)
• List #78PZAG OSG PHOENIX® PZAG inserts for PDZ
• List #7808H OSG PHOENIX® PDZ accessories

This series offers the following features & benefits:

• High Precision finishing on flute improves rigidity, chip evacuation, and reduces cutting force
• Flat bottom cutting edge for machining a wide range of applications including drilling, counter-boring, inclined surface drilling and more.
• Superior chip breaking capability during drilling, counter-boring and turning with enhanced muscle breaker

Check out the new tools HERE

We are pleased to announce the expansion of our A Brand AE-VM series! The new additions feature new lengths & styles ideal for deep side milling and pocket milling of mold parts

The following list numbers are associated with the A Brand AE-VM End Mill Series expansion:

• List #8245 A BRAND® AE-VMFE (metric)
• List #8246 A BRAND® AE-CR-VMFE (metric)

This series offers the following features & benefits:

• High efficiency for deep side milling and pocket milling of mold parts
• Variable Geometry to suppress chatter
• High rigidity to improve milling accuracy
• Positive rake angle which reduces cutting force
• Advanced multilayer DUARISE coating for superior surface quality

Check out the new tools HERE

We are pleased to announce the expansion of our A Brand AE-N series! The new additions to our advanced performance DLC Coated end mills, are designed for non-ferrous materials in a wide range of cutting applications delivering efficient and quality processing.

The following list numbers are associated with the A Brand AE-N End Mill Series expansion:

• List #8830 A BRAND AE-VTS-N (inch)
• List #8930 A BRAND AE-VTS-N (metric)

This series offers the following features & benefits:

• Flat cutting edge achieves higher precision machined surface quality
• Large core design for high rigidity to prevent chattering
• Center cutting edge for plunging
• Three cutting edges at center for high speed milling
• DLC- IGUSS coating that delivers improved durability and effectiveness

Check out the new tools HERE