Milling is a type of machine processing thatallows us to shape complex shapes and cut pieces of different materials like metal, wood, plastic, composite materials and others.
Milling is done with metal cutting machines that are called milling machines. The milling process itself includes the removal of material from the surface of the detail that is being processed. This is realized by feeding the detail for processing to a cutting tool that rotates around its axis (mill). This tool has cutting edges that remove a small amount from the material with each move.
The production of metal parts is impossible without the use of milling machines . The use of these machines offers the same success in both metal fabrication and home workshops. All milling machines work in a similar way and have a similar design.
The different models of milling machines differ in terms of functionality and purpose. Depending on its specific characteristics every type of milling machine is used for different operations.
Where milling is applied?
Milling has a wide application in the metal production industry because it helps us process different types of metals with high precision but milling machines have high efficiency.
Depending on their construction milling machines divide into vertical and horizontal machines and universal and specialized machines.
To be more clear about where milling is applied and what is its purpose we will briefly check the main types of milling machines and what details they can process.
Vertical milling machines
These machines are designed for processing metal billets and they use end, profiled and cylindrical milling tools. Usually they are used in the production of cogged wheels, vertical profiles from cast iron, steel, non-ferrous metals and others.
These vertical milling machines usually don’t have a console and the work panel is moved by the drive motors located on the machine bed.
Horizontal milling machines
The horizontal milling machines are impressive as their mandrel is located on a horizontal plane. These machines are used for processing small metal parts and details.
The machine’s design allows the processing of screw, horizontal and vertical surfaces, angles and grooves.
The processing of the detail happens with disk, cylindrical, end and shaping cutting tools. The characteristic feature about these milling machines is that the work panel can move both perpendicularly and along the mandrel’s axis.
Punching/ milling machines
The punching/ milling machinesare designed for processing horizontal, vertical and slanted metal surfaces. They are also used for making grooves in large metal billets. Because a single machine can perform two operations the production time is considerably reduced. One distinguishing feature of these milling machines is that their heads can function in a reversed mode.
Universal milling machines
These milling machines are used mainly in the production of small metal details and tools. Universal milling machines are often used in private workshops, small factories for metal tools production and mechanical workshops.
Universal milling machines are used in the processing of vertical and horizontal planes, matrix models, spirals and other. The work surface can be set according to the machine’s mandrel in the right angle. This allows the processing of metal parts with a complex configuration.
Billet milling machine
Because of its compact size this milling machine is preferred when we need to punch a hole into a metal detail or when we need to make horizontal or vertical milling at the ends of a detail. This type of milling machine is used for mass production of small metal details designed for the metal industry.
Widely universal milling machines
These milling machines are designed for milling all types of steel, cast iron, alloys and other materials. Unlike the horizontal milling machines, universal milling machines have an additional head on the mandrel that can rotate in every angle in two perpendicular planes. They can also work with one or two mandrels. Universal milling machines have a milling head installed which gives the machine additional flexibility. It rotates and realizes the processing of unusual and complex shapes not only by milling but also by punching,cutting and other operations.
Some types of widely universal machines don’t have a console panel.
Benchtop milling machines
These milling machines are used for milling, punching and making holes in ferrous and non-ferrous metals and plastic. They can perform single detail processing as well as process metal details in small batches. That is why milling with Benchtop CNC milling machines is applied in tent production and the creation of large-scale sketches. Benchtop milling machines have a controller that considerably increases the efficiency of the production process.
CNC machines for metal processing
CNC machines for metal processing and milling are used in industry spheres such as aviation, car manufacturing, instrumental equipment, engineering and other spheres where mass production of high-quality parts is required.
CNC machines are equipped with modern types of driving systems. They are operated by special controllers connected to an IMB computer. These machines allow the realization of different processes with just one setting. We need to point out that one of the systems CNC equipment uses is a Fanuc 0i Mate-MB system.
CNC milling machines
These CNC machines are used in the mass production of high-quality parts in different spheres of the industry sector. The processing of the metal details is done with the latest technologies. That’s why these machines are different from the other conventional milling machines.
What makes them different is that they offer better speed in the processing of metal details, achieve precision and high quality of the end product as well as work in a fully automated way.
A little diversion from the topic … What are CNC milling machines?
CNC is an electronic/computer technology that allows the machine to perform an operation in a fully automated way. In CNC milling an operator enters a set of instructions into the computer that controls the machine. These instructions are called G or NG codes. They determine the geometry of the metal part that is being processed and the trajectory of the operating tool in the form of dots that are easily recognized by the computer.
After the machine is turned on it works completely independently and the operator just needs to control the processing operation. With CNC milling we can process details with an accuracy of 1 micron (1/10th of a millimeter). Traditionally 3 or 5-axis CNC machines are used in the production of complex details with high precision.
You can see that there are many types of milling machines and each type is used for the production of different metal details.
Milling is used in many production spheres because it’s a highly efficient method for processing metal details. Milling offers us the option to manufacture elements in different types and sizes with a high level of accuracy.
What is a milling machine?
A high number of different types of cutting tools are used in the process of milling. These cutting tools are made from hard and durable materials such as fast-cutting steel or other hard alloys.
Milling machines are used for processing metal details of different types and sizes and each milling machine model has a different function. Therefore they fall into different categories depending on different things such as the shape of the cogs, the purpose of the machine, the way the metal details are placed on the milling machine, the shapes of the planes.
- Depending on the shapes of the cogs milling machines can be made from just one material or several different materials;
- Depending on the shape of the cogs’ plane milling machines are classified as discmills, cone mills, worm mills, profile mills, cylindrical-frontal mills, cylindrical mills and frontal mills.
How you can work with milling machines?
As milling machines use cutting tools when they process metal details we need to be careful when working with them. Safety is a top priority and if you need to operate a milling machine, you should follow the following rules:
- Check if the machine is in good working order before turning it on;
- After turning on a milling machine you need to leave it to idle for a while, in order to be sure that everything works fine;
3.During the milling process avoid bending over the machine or trying to repair some part of the milling machine while it’s working.
- While working with a milling machine it’s recommended to wear safety goggles or a face mask as metal shavings can hit you and hurt you.
- Don’t try to clean or grease the milling machine while it’s working.
- Before starting to mill, always check whether the mandrel is set securely in place and it’s balanced.
- Check whether the cutting tools are suitable for work and replace them, if they are worn outor blunt.
- If you have never worked with a milling machine before or you are not completely sure how to work with it, just avoid operating with it.
Applications of milling
Milling is used for processing metal details with asymmetrical shapes or complex shapes such as 3D grooves, pockets, holes and other. The characteristic features of milling makes it perfect for limited batches (small batches), prototypes or custom-made elements. Milling is also used in the production of details and tools used in other industry spheres. Thanks to its high precision milling can be used for additional processing of products that are manufactured with different processes.
We live in modern times where we need to manufacture metal details with high precision and speed. Thanks to milling machines we can manufacture any type of metal detail for our business in a fast way.
Modern CNC milling machines can be used for manufacturing single items of metal details or small or large batches of metal elements and details. They are really helpful to both small and large-scale manufacturing companies specialized in manufacturing elements for different industry spheres- car manufacturing, aviation, machine production, and household items.
