CNC Milling - Prototek Parts

What is CNC Milling

CNC milling refers to a machining process that utilizes computer numerical control (CNC) machines to remove material from a workpiece. In CNC milling, a rotating cutting tool moves along multiple axes to create complex shapes and features in the workpiece. CNC milling is a crucial manufacturing process used in various industries, including aerospace, automotive, electronics, and more, for producing precision components and parts with high efficiency and accuracy.

How CNC Milling Works?

Design and Programming

Machine Setup

Machining Operations

Coolant and Chip Removal

Quality Control and Finishing

The Metal Materials of CNC Milling?

铝质
Brass & Copper
钢
Titanium Alloys

6061-T6: One of the most popular aluminum alloys, known for its good mechanical properties and weldability. Commonly used for automotive parts, aerospace components, and consumer goods.
7075-T6: High-strength aluminum alloy, often used in aerospace applications due to its excellent fatigue resistance and strength-to-weight ratio.
2024-T3: Known for its high strength and excellent fatigue resistance, commonly used in aerospace structures and military applications.

C36000 Brass (360 Brass): Known for its excellent machinability, corrosion resistance, and electrical conductivity. Commonly used in fittings, fasteners, and electrical components.
C26000 Brass (Cartridge Brass): Has a good combination of strength and ductility, often used in ammunition casings, radiator cores, and hardware.
C11000 Copper (Electrolytic Tough Pitch, ETP): Highly conductive and malleable, commonly used in electrical applications, heat exchangers, and plumbing.
C17200 Copper (Beryllium Copper): Known for its high strength, hardness, and electrical conductivity. Used in springs, connectors, and precision instruments.

1018 Steel: A low-carbon steel with good weldability and machinability, often used for structural applications.
4140 Steel: A chromium-molybdenum alloy steel with high toughness, strength, and wear resistance, commonly used in manufacturing gears, shafts, and other high-stress parts.
A36 Steel: A standard structural steel grade with good weldability and machinability, often used in construction and structural applications.
304 Stainless Steel: The most common stainless steel, known for its excellent corrosion resistance and good formability. Widely used in kitchen equipment, chemical processing, and architectural applications.
316 Stainless Steel: Offers superior corrosion resistance compared to 304, especially in marine and chemical environments. Commonly used in medical devices, marine applications, and food processing equipment.
17-4 PH Stainless Steel: A precipitation-hardening stainless steel known for its high strength and hardness, often used in aerospace, chemical, and petrochemical industries.

Grade 2 Titanium: Commercially pure titanium with good corrosion resistance and weldability, often used in chemical processing and marine applications.
Grade 5 Titanium (Ti-6Al-4V): The most commonly used titanium alloy, known for its high strength, light weight, and excellent corrosion resistance. Commonly used in aerospace, medical implants, and high-performance automotive parts.

How to select the CNC milling material?

Material Strength: Different applications require different levels of material strength. For example, aerospace and automotive components often require high-strength materials like titanium or steel to withstand high stress and load conditions.

Corrosion Resistance: For parts exposed to harsh environments or chemicals, corrosion resistance is crucial. Stainless steel and certain plastics provide excellent resistance to corrosion.

Heat Treatment Characteristics: Some materials, like certain steels, can be heat-treated to enhance their properties, such as hardness and strength, which is essential for specific industrial applications.

Cost and Availability: The material cost and its availability in the market can significantly influence the overall project budget and timeline. Aluminum and certain plastics are generally more affordable and readily available compared to specialized materials like titanium alloys.

Machinability: Ease of machining affects production efficiency and tool wear. Materials like aluminium and brass are easier to machine, while tougher materials like titanium and stainless steel may require specialized tools and techniques.

Surface Treatment

PURPOSES OF SURFACE TREATMENT

The main purposes of surface treatment are to improve wear resistance, corrosion resistance, surface hardness, and aesthetics.This is crucial for extending the service life of parts and meeting specific application requirements.

COMMON SURFACE TREATMENT METHODS

To enhance the performance and appearance of CNC-milled parts, surface treatment is often necessary. Common methods include:

Anodizing

Primarily used for aluminum, creating an oxide layer through an electrochemical process to improve corrosion resistance and aesthetics.

Nickel Plating

Covering the surface with a layer of nickel to enhance corrosion resistance and hardness.

Electroplating

Depositing a layer of metal on the surface via an electrochemical method to improve wear resistance and corrosion resistance.

Sandblasting

Cleaning and polishing the surface using high-speed sand flow to improve surface roughness.

Spraying

Enhancing the appearance and protecting the surface by applying a coating of paint or other materials.

Chemical Plating

Depositing a layer of metal on the surface through a chemical reaction without the need for electric current.

Electropolishing

Using electrolysis to make the metal surface bright and smooth.

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Choosing Surface Treatment Methods

The choice of surface treatment should be based on the type of material, application environment, and usage conditions. For example, anodizing is typically used for aluminum parts, while steel parts may opt for electroplating or spraying.

Precision

Precision is a key performance indicator in CNC milling, including dimensional tolerance, geometric tolerance, and surface roughness. High-precision machining ensures that parts meet design specifications, ensuring their reliability and performance in assembly and use.

Factors Affecting Precision

CNC milling precision is influenced by various factors, including:

Precision of CNC Equipment: The mechanical and control precision of the equipment directly affects the machining outcome.
Tool Selection and Wear: The quality and wear condition of the tools impact machining precision and surface quality.
Characteristics of Workpiece Material: Different materials’ machining characteristics (e.g., hardness, toughness) affect precision.
Machining Parameters (e.g., cutting speed, feed rate): These parameters need to be optimized to achieve the best machining results.

Methods to Improve Precision

To enhance CNC milling precision, the following measures can be taken:

Use high-precision CNC equipment

Reglarly maintain and calibrate the equipment

Optimize cutting parameters

Use high-quality tools

Properly design fixtures and jigs

Quality Inspection and Control

High-precision machining requires strict quality inspection and control. Common inspection equipment includes Coordinate Measuring Machines (CMM) and surface roughness testers. Regular quality checks ensure that parts meet design requirements.

Expanded Market Applications

CNC milling is used across a wide range of industries, each with specific material and precision requirements:

Aerospace

CNC milling is essential for producing complex, high-precision components such as engine parts, structural components, and landing gear. Materials like titanium alloys and composites are favored for their strength-to-weight ratio and durability.

Automotive Manufacturing

The automotive industry relies on CNC milling for producing engine components, transmission parts, and custom interior features. Materials like aluminum and steel are commonly used due to their balance of strength and machinability.

Medical Devices

CNC milling is crucial for manufacturing medical implants, surgical instruments, and diagnostic devices. High-precision materials such as stainless steel, titanium, and certain biocompatible plastics are essential for ensuring patient safety and device performance.

Electronics

In the electronics industry, CNC milling is used to create precise enclosures, heat sinks, and connectors. Materials like aluminum and certain plastics are used for their thermal conductivity, electrical insulation, and lightweight properties.

Consumer Products

CNC milling enables the production of custom-designed parts for various consumer products, including sports equipment, household gadgets, and luxury goods. Materials used can range from plastics and aluminum to more exotic materials like carbon fiber.

Tooling and Prototyping

CNC milling is widely used for creating custom tools, molds, and prototypes across multiple industries. This process allows for the rapid development and testing of new designs, with materials selected based on the specific needs of the prototype or tool.

Why Choose PROTOTEK for CNC milling？

BEST SERVICE

HIGH-PRECISION

PROFESSIONAL TEAM

Choosing Prototek for your CNC milling project means leveraging our extensive range of services designed to support you at every step. Our cutting-edge equipment ensures that parts are machined with exceptional precision and within tight tolerances, guaranteeing top-notch accuracy and quality throughout the fabrication process. Our team of seasoned engineers and technicians is committed to providing outstanding service, offering expert guidance and support from start to finish. Moreover, we pride ourselves on our fast turnaround times, allowing you to meet even the most stringent deadlines. Prototek’s dedication to quality and customer satisfaction makes us a reliable and high-quality partner for your CNC milling needs.