Out of many beneficial CNC machining services, one of them is CNC milling. Serving to its utmost, this machining service in its full potential is there to make custom machine parts that need a sharp finish. Once treated with a CNC milling machine, the workpiece is attributed to certain characteristics and features that would help fulfill the due purpose. This article is all about the CNC milling services, from its definition to its procedures, machine types and types of milling, industries, and type of raw material used for CNC milling services.
By definition, CNC milling is referred to as a computer numerical-based control milling process that works to remove material from the workpiece and give it a characteristic shape and working feature. All this is done via rotating and cutting tools employed in CNC milling machines. The cutting, removing, and rotating tools produce a final workpiece i.e. a custom machined part. Basically, the CNC milling process is considered a secondary machining technique that is employed to give a perfect finish and shape to the workpiece. The tools i.e. cutting tools can be placed either way, horizontally, or vertically. Moreover, these tools are allowed to move in 5-axis.
While working on the CNC milling machine, there is a four-step procedure. These steps range from designing the blueprint of the process via CAD software, this file is then converted into the CNC milling process with CAM software and according to this file, the milling machine is configured. Lastly, a computer-based software-driven CC milling machine then transforms the raw material to the final machined part. Here is the sophisticated production line:
CNC milling services is not a single regime procedure rather it consists of various CNC milling techniques that are used according to the workpiece/final product. The type of CNC milling applied to raw material also depends on the tolerances in the prototype and the size of production. Here are some of the commonly employed CNC milling procedures.
As the name implies, the type of milling procedure is applied to perform simple cutting or milling purposes. The tool used in this type of process is equipped with teeth on the periphery and it is present on-axis parallel to the workpiece.
This type of milling procedure is performed on the workpiece to create flat surfaces and contours. In this process, the teeth equipped tool is present on the periphery, perpendicular to the workpiece.
If you are intended to create irregular surfaces, curved surfaces or contours on the workpiece then face milling should be your targeted procedure. The process employs fly cutters as cutting tool e.g. convex cutters or concave cutters.
Though CNC milling machine is a computer-operated version of working components that proceed with a command line provided by the software system. Yet this machine is made up of different components that together give it its due functionality. Here are some of those components along with their function in CNC milling services.
As the name implies, it is the part on which the software-based command line is fed i.e. all the information about load, initiate, and execute is given to the machine interface which then commands other parts to work accordingly.
The part of the CNC milling machine where all other components are connected to give one definite structure to the machine. It consists of a base along with other parts involved in the milling procedure.
It is the part connected to the column which further supports two important components i.e. worktable and saddle. Based on the type of milling machine, this component is attached to Z-axis and movable.
The worktable holds the workpiece and it is located on top of the saddle. It is adjustable components and its features depend on the type of milling machine employed for the procedure. It can be adjusted as vertical, horizontal, both, or in neither direction.
It is the main component attached to the spindle. It helps to remove the material from the workpiece during the milling operation. Depending on the type of milling procedure aimed, the machine tools vary on the basis of number, the spacing of teeth, diameter, arrangement, and geometry.
Based on different milling machine components, there are several milling machines which are commonly employed to carry out the procedure in the regime of CNC milling services. Here in this section, milling machines are characterized on the basis of their specific features.
The configuration of the knee type milling machine, it consists of a fixed spindle, vertically adjustable worktable supported by saddle and knee. This knee part can be either lowered or raised on the column to give specific positions to cutting tools to carry out appropriate functions on the workpiece. E.g. floor-mounted plain horizontal milling machine and bench type plain horizontal milling machine.
As the name implies, a specific kind of ram is used in this milling machine. The ram is movable that is housed on the fixed spindle. It is allowed to move in two axes i.e. XY axes. E.g. floor-mounted universal horizontal milling machine and swivel cutter head milling machine.
In this milling machine, the worktable is directly fixed with the machine bed. In this context, the workpiece is not allowed to move in y and z-axis directions. Here the workpiece is placed beneath the cutting tools and rest the movement of the machine depends on its capacity to move in XY and Z axes. These machines are further categorized as simplex, duplex, and triplex. This categorical distribution is based on the number of spindles employed in each machine.
Sharing close resemblance with the bed type milling machines, the planar types have their worktable fixed to the spindle in the Y axis and Z axis, hence giving it a position to move along XYZ axes. It can support multi-tool mount i.e. particularly 4 at a time. This in turn reduces lead time.
Though the CNC milling services provide you with finished machined parts or the porotypes of all materials, yet it is the best machining procedure if the raw material or the workpiece is made up of the following.
Just like other CNC machining services serving their utmost to several industries around the globe, the CNC milling procedures and services are also working to their maximum to facilitate businesses and industries. Depending on the type of machined part, prototype scale, or production line, the following are some of the industries that are directly getting facilitated with the CNC milling services.
Hence, CNC milling services are best to give your machined parts and prototypes a new dimension and fits in the big picture. Being a budding machining service, the CNC milling procedures are now carried out in machine shops to give a reliable, strong, and finished custom machined part.
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The choice of CNC milling machine is mainly depends on the length of the workpiece, size and processing mode, for precision processing, small and medium-sized batch and often periodically repeated production, the use of CNC milling machine is very appropriate, if large parts, large mold precision processing, should choose gantry processing center.The milling machine with high degree of automation replaces common milling machine, reduce the labor of laborer, the trend that raises productivity is inevitable.Our CNC milling machine quality stability,Control quality from the source, completeinspecifications, welcome to inquire.
CNC milling machine is highly automatic milling equipment, can carry out the workpiece unattended processing. The workpiece can be milling, drilling, boring, reaming, tapping and other procedures after only one clamping. According to the shape, size, precision and surface roughness of parts and other technical requirements to develop the processing process, choose the processing parameters. Through manual programming or automatic programming using CAM software, the programmed processing program is input to the controller. Manual incremental movement is adapted to move up the workpiece and align the cutter, continuous movement or manual wheel to move the machine tool. Set the starting point to the beginning of the program and set the tool benchmark. After the controller processing the program, the controller transmits instructions to the servo device. The servo device sends a control signal to the servo motor. The spindle motor makes the tool rotate, and the servo motor in the X, Y and Z direction controls the relative movement of the tool and the workpiece according to a certain track, so as to realize the cutting of the workpiece. Multi-surface machining can increase the fourth axis, on the moving platform to add a 360-degree rotation of the electric dividing head, so that it can carry out automatic dividing bevel hole, bevel milling and other complex space surface high-precision machining, without the loss of precision secondary clamping. CNC milling machine precision, convenient and efficient, It is an essential piece of equipment for accurate metal milling.
1, According to the spindle axis position direction is divided into vertical CNC milling machine, horizontal CNC milling machine, gantry CNC milling machine, vertical and horizontal CNC milling machine. 2, According to the processing function is divided into the ordinary CNC milling machine, CNC gear milling machine, CNC copying milling machine. 3, According to the number of control axis is divided into two-axis CNC milling machines, three-axis CNC milling machines, two-axis CNC milling machines, multi-axis CNC milling machines. 4, According to the servo system control mode is divided into open-loop servo system CNC milling machine, closed-loop servo system control milling machine, semi-closed-loop servo system CNC milling machine
Applicable to mining machinery, automotive, aerospace, printing, packaging, military industry, mold, shipping, textile machinery, agricultural machinery, metallurgical mining, machine tool manufacturing and other industries key equipment.
The first machining center in the world was born in the United States in 1958. The company in the United States added a tool changing device to a CNC boring and milling machine, which marks the advent of the first machining center. Over the past 40 years, there have been various types of machining centers. Although they have different shapes and structures, they are generally composed of the following parts.
It is composed of a bed, column and worktable, which are the basic parts of the machining center structure. These large parts include iron castings and welded steel structural parts. They have to bear the static load of the machining center and the cutting load during machining. Therefore, they must have extremely high stiffness, and they are also the parts with the largest mass and volume in the machining center.
It is composed of a spindle box, spindle motor, spindle and spindle bearing. The start, stop, and rotation speeds of the spindle are controlled by the numerical control system, and cutting is carried out by the tool installed on the spindle. The spindle component is the power output component of machining and the key component of the machining center. Its structure has a great influence on the performance of the machining center.
It is composed of a CNC device, programmable controller, servo drive device and motor. It is the center of the machining center to execute the sequence control action and control the machining process.
This is the core part of CNC milling machine, which is composed of a CNC control system, operation panel, hand pulse generator, driver, servo motor and power cable. Equivalent to the brain of CNC machine tools, all programs and codes are edited in the CNC system.
This part is equivalent to the armor of the CNC machine tool, which can protect the machine tool from external damage, and also protect the operator and working environment from the influence of the machine tool. The system panel and the electrical part need to be installed on it.
The rotation of the servo motor can not directly drive the worktable and spindle to move. It is through the ball screw, the rotation of the motor, converted into a linear movement of the table. The ball screw and the motor are connected by a coupling. The screw and the worktable are connected by nuts.
When the worktable moves on the base, it is bound to produce friction with the machine tool. The linear guide rail plays the role of lubrication and reducing friction. There is ball or roller structure inside. It can ensure the accuracy and speed of table movement.
The electronic oil pump delivers the lubricating oil to the lubricating point of the machine tool to lubricate the bearing screw of the machine tool, so as to improve the reliability and service life of the machine tool. The lubrication system is an automatic system connected with the numerical control system and controlled by the numerical control system. The time interval and quantity of lubrication can be controlled.
CNC machining center has the advantages of high automation, high power, high precision, high speed and high reliability, but these advantages are based on certain conditions. A machining center can play the best benefits only under appropriate conditions. The following features are most suitable for machining centers.
The market demand of some products is cyclical and seasonal. If a special production line is used, the gain is not worth the loss. The processing efficiency of ordinary equipment is too low, and the quality is not stable. After the first batch (parts) of the machining center is successfully cut, the program and relevant information can be retained, and the next product reproduction can start production as long as there is little preparation time.
Some parts need little, but they are expensive. They are not allowed to be scrapped. They require high precision and a short construction period. If the traditional machine tool is used to process, it needs multiple machine tools to coordinate work, and it is easy to be affected by human factors to produce scrap. If the machining center is used for processing, the production process is completely controlled by the program, which avoids the interference factors in the process flow, and has high production efficiency and quality The quantity is stable.
The flexibility of machining center production is not only reflected in the rapid response to the special requirements of parts processing but also can quickly achieve mass production and quickly occupy the market.
Some parts have a complex structure and need expensive process equipment to process on ordinary machine tools. The use of CNC milling machine also needs to replace tools and fixtures for many times. Using the machining center, it is possible to complete drilling, milling, boring, tapping, grooving and other multi-process processing at one time.
G code, prepare function. G code is the instruction that makes the machine set up a certain processing mode. Such as linear interpolation, circular interpolation, tool compensation, the establishment of the coordinate system, and so on.
It takes time to learn the code. Its unnecessary to recite all the code. You can query the reference book when you forget it. But the key is to master each application code. There are a lot of notes and tips, when you use to understand a code, you will firmly grasp and remember. Remember, dont memorize the code, its mainly about how skillful the application is. Many of the codes are regular. According to the different foundations of learners, the learning time of CNC programming is also different, which generally takes several months or even years.
Daily inspection: when operating the machine, check the following phenomena one by one. If any abnormality is found, find out the cause immediately and then eliminate it. In case of problems that cannot be solved, please inform our company as soon as possible so as to eliminate the abnormality as soon as possible.
1) Check whether the power line, all lines, and pipe joints are damaged or in poor contact. 2) Check whether lubricating oil must be added to the oil level of the lubricating oil pump and whether the standard oil level of the worm gear box is normal for the vertical tool magazine. 3) Check whether the three-point combination is normal. 4) Check the oil pipe and joint for oil leakage. 5) Check whether the air pressure of the three-point combination is normal and whether the pressure switch is adjusted as required. 6) Check whether the cutting liquid level of the water tank needs to add cutting fluid. 7) Check whether the safety protection device is normal and reliable, and there must be no personnel in the dangerous area. 2.1 after startup 1) Check whether the temperature rise of the spindle is normal and whether there is an abnormal sound. 2) Check whether the following items of the lubricating oil pump are normal. a. The oil supply pressure is between 3kfg / cm2-4kfg / cm2 b. Whether the consumption of lubricating oil is normal (if the consumption is too fast, the oil circuit must be checked for oil leakage). c. Whether the working time of oil pump is normal (3-6cc / time / 5 minutes is recommended). 3) Check whether the processing program is complete. 4) Check whether the machining tool is complete. 5) Check whether the fixture has changed and whether its datum has changed. 6) Pay attention to whether the transformer produces a high temperature at any time. 7) Always put the water in the filter in the three-point combination to ensure that the gas is dry. 8) Whether the spindle blowing is normal.
1.3 after operation 1) Remove all the chips in the table, three-shaft shield, water tank, filter screen and a large shield. 2) The inner hole of the spindle must be wiped clean. 3) The chippings on the handle should be removed at any time and every 8 hours. 4) Move the three-axis to the middle of the stroke to maintain balance. 5) After applying rust-proof oil to the worktable, remove the chips. 6) After the end of the shift, the appearance of the whole machine should be cleaned once. 7) Check whether the safety doors are closed properly. 8) Check whether the power switch is off. 9) Check whether the power source switch is off. 2 regular maintenance 2.1 maintenance instructions 1) In order to ensure the safety of maintenance work, all electrical doors and shields should be closed, especially the control box and operation box. 2) It is forbidden to use an air gun or compressed air to clean the machine tool (to prevent debris and dust blowing into the bearing or slideway). 3) Before carrying out maintenance and repair work above and behind the machine tool in the protective cover, be sure to turn off the power switch on the operation panel, and then turn off the power. At the same time, hang warning signs to prevent others from turning on the machine. 2.2 daily maintenance 1) Remove the chips, dust and sundries on all exposed parts of the machine tool and fixture, and remove the chips, dust and sundries on the tool aligner or other auxiliary tools. 2) Clean the spindle bore. 3) Check whether the oil level of the lubricating oil pump needs to add new oil and whether the oil pressure is within the specified range (3-5kgf / cm2). 4) Check the oil level height of the three-point combination tank to see if new oil needs to be added. 5) Check whether the water of the filter in the three-point combination is completely discharged. 6) Check whether the air pressure of the air circuit is normal (value 6 kgf / cm2). 7) Check whether there is oil leakage in oil circuit and joint, and take appropriate treatment. 8) Clean the clamping part of each handle on the magazine. 9) Check whether the cutting fluid needs to be added and start the machine to check whether the cooling mechanism operates normally. 10) Clean exposed electrical parts and limit switches. 11) Check whether all work lights or warning lights are normal. 12) Keep the environment around the machine clean and tidy. 13) Check the breaker for excessive carbon deposition. 2.3 weekly maintenance 1) Carry out daily maintenance 2) Check the top of the spindle and other running parts for abnormal sound and damage, and clean around the spindle. 3) Check whether the origin of each axis drifts. 4) Clean the filter screen of the water tank, and add coolant when it is insufficient. 5) Clean the three-point combined filter screen. 6) Confirm whether the spindle grabbing and loosening action is smooth. 7) Confirm whether the tool change is smooth. 8) Check whether the lubrication pump works normally (3-6cc / time / 5 minutes, oil pressure 3-5kfg / cm2). 2.4 monthly maintenance 1) Carry out weekly maintenance. 2) Clean the inside of the control box, operation panel and filter screen of heat exchanger. 3) Check the level of the worktable and make sure that the anchor bolts are locked. 4) Check if the three-axis guide strip needs to be adjusted. 5) Check the function of the solenoid valve and limit switch. 6) Clean the brush of the three-axis guide rail and update it if necessary. 7) Check for poor contact when the wire connector is loose. 8) Check whether the oil circuit is unobstructed, and clean the filter screen at the joint where it is not unobstructed. 9) Check whether the interlock device and timer are normal, check whether the breaker has proper pressure and clean it. 10) Drain the cutting fluid, clean the water tank and water pipe, and then install the cutting fluid. 11) Confirm that the NC controller operates normally. 12) Grease the counterweight chain gear shaft once a month. 2.5 half-year maintenance 1) Carry out monthly maintenance 2) Clean NC unit, control unit, and machine tool. 3) Replace the lubricating oil of oil pressure system, lubricate the gearbox of vertical tool magazine and clean the inner cavity. 4) Check the back clearance of the three shafts and adjust it. 5) Check the three-axis grid amount and adjust it. 2.6 annual maintenance 1) Clean all motors. 2) Check whether the control switches on the operation panel are sensitive and normal. 3) Check that the test program runs smoothly. 4) Determine whether the counterweight chain is in normal use. 5) Remove the carbon deposit on the contacts of all disconnectors in the electrical box and wipe it clean. 3 parts replacement and maintenance 3.1 the following work should be done before replacing parts. 1) Write down the machine number. 2) Make a note of the specification and brand of the replaced parts. 3) Mark the position relationship between the part and other related parts, so as to reassemble smoothly. 3.2 maintenance precautions 1) The maintenance personnel must understand the shutdown steps and carry out the repair work after the shutdown. 2) When repairing the interior: a. Cut off the power first; b. If it is necessary to power on for maintenance, lock the machine first and then enter the interior; c. Remove the chips that may trample or touch the area to prevent them from being scratched by the chips; d. Wipe off the lubricating oil and chip liquid at the places where you may tread to prevent slipping. 3) After a new component is replaced, it is not allowed to discard the old component before confirming its normal function. 3.3 maintenance rights and responsibilities 1) Matters allowed to be handled by operators themselves: a. Screw and sheet metal parts that affect the accuracy of machine tools. b. Simple purchased parts, such as fuse, switch, oil circuit, pipe joint, etc. 2) Personnel with professional qualifications are required for the following maintenance work: a. Excessive spindle runout; b. The spindle has abnormal sound; c. Guide screw maintenance; d. Maintenance of three-axis transmission components (transmission seat, nut seat, screw support and bearing, etc.). e. Tool magazine maintenance. f. Handling of knife dropping and collision