Before the 1940s, shaping metals required a lot of manual effort with tools like hammers and
chisels. Blacksmiths would painstakingly remove parts of metal to form components like the
wheels for horse-drawn carts. However, since the 1940s, we’ve seen a significant transformation with the advent of machines controlled by computers. These CNC (Computer Numerical Control) machines have changed how we manufacture parts, offering unmatched precision and
efficiency.
Today, engineers continually enhance these machines, reducing the human effort and time
needed to produce parts for modern marvels like ships, airplanes, cars, and trains. CNC metal machining is the process these advanced machines use to shape metal parts with incredible
accuracy. In this article, we’ll explore the best CNC machines for metal work, helping you
understand how to choose the right equipment for your projects.
What is a CNC Metal Machining?
Before we understand what CNC metal machining is, we need first to know what machining is. Machining is simply carving a metal or a wood to form something new. Therefore, CNC metal machining is a process of making a new machine part from a plain metal or a metal lump by subtracting parts of the metal using a CNC metal machine. CNC in CNC machines stands for Computer Numerical Control. By definition, a CNC machine is an industrial device controlled by a computer program to make designs for machine parts with an accurate precision of +0.005
0r -0.005.
Type of CNC Metal Machines
In this section, we will talk about the best CNC machines for metal works. We will not just be
telling you about the CNC machines that we think are the best, but based on research, we will explain the best CNC machines for metal.
CNC Milling Machine
This CNC machine is used to precisely remove parts of metal to create the desired component. As the operator places the metal on the machine’s table, the cutting tool, which is connected to a rotating spindle, moves around the metal, shaping it into the planned part. The movement of this cutting tool varies depending on the type of milling machine in use, commonly 3-axis, 4-axis, or 5-axis machines. Recently, more advanced 7-axis CNC machines have also become available.
Before you can use a CNC machine, you need to create a detailed 2D or 3D CAD model using
software like Autodesk or SolidWorks. This model serves as a prototype, containing all the
features, dimensions, tolerances, threading indications, construction lines, and finishing
preferences for the part you want to create. The prototype must then be converted into G-code,
the language that CNC machines understand, as they cannot interpret designs in any other
format. The G-code file instructs the CNC machine on how to execute various movements, including rotational and linear motions, tool paths, cutting sequences, and workpiece speeds. Once
The G-code is ready, the operator sets up the machine by attaching the cutting tool to the spindle and placing the metal on the table. The machine is then programmed to start the milling process, precisely cutting the metal to create the desired part.
CNC Grinding Machine
A CNC grinding machine is a specialized CNC machine that uses a rotating grinding wheel to
remove material from a metal workpiece with high precision and surface quality. As a finishing machine, a CNC grinder typically works on a metal part that has already been shaped by another machine, refining it to achieve the desired surface finish and exact dimensions.
Operating with minimal input from an operator, a CNC grinder follows programmed instructions to create a smooth, precise surface on the metal. Coolant is used during the grinding process to maintain accuracy and ensure a high-quality finish by preventing overheating and maintaining optimal grinding conditions.
A typical CNC grinding machine consists of several key components. The grinding spindle head holds the workpiece, while the grinding wheel removes material either from the side or the front.An exception is the cylindrical grinder, a specific type of CNC grinding machine that includes four main parts: the headstock, tailstock, wheel head, and the grinding wheel, all mounted on a table. This configuration allows for the precise and efficient grinding of cylindrical surfaces, enhancing the overall quality and functionality of the metal part.
CNC Lathe
Engineers use CNC lathe machines to measure a material precisely by computer programming. It uses the old principle of the lathe machine coupled with advanced programming to produce very high accuracy and efficiency in machining. The CNC lathe machine has changed how people manipulate metal, thus making it a tool engineers can use in many industries and machine shops. Its ability to create intricate cuttings and shapes with great precision and accuracy makes it the foundation of the advanced manufacturing process.
Unlike the manual lathe, where the design relies on the accuracy of the hand of the operators, a CNC lathe uses a computerized system to produce better precision and efficiency. Using a lathe machine first involves using CAD software to build a detailed project prototype. The operator changes the prototype into a format that a CNC machine will understand, which is a G-code. The code contains instructions on how the CNC lathe machine will move to create the designed part.
CNC Drills
Unlike manual drills, CNC drills rely on computer programming to make holes in a material,
ensuring better accuracy and consistency. Engineers use this machine in industries where a slight change in specification can cause a severe issue, like in aerospace. The CNC drills turn a digital design into a tangible part through some programmed steps, ensuring it bores every hole with the exact specifications.
The process begins with transforming an idea into a design called a prototype using CAD. The CAD design is then converted into a G-code and fed to the CNC drilling machine. Before the CNC driller begins drilling, the machine is set up by installing the drill bit, securing the metal, and calibrating the machine to ensure accuracy. The CNC drilling machine executes the G-code to drill into the metal using various drilling cycles depending on your needs.
You must monitor the process to ensure that things are going as planned. After drilling, the metal will require extra processing, such as deburring to remove sharp edges and finish operations to get the desired surface finish.
How to Choose a CNC Machine
When selecting a CNC machine, you must look at the money you have because picking a CNC is a severe financial commitment. The benefits you will enjoy from having a CNC machine in terms of productivity, quality, and profitability are worth the investment. We will look at some factors that you should consider when you want to choose a CNC machine.
- Factory Requirement
The type of CNC machine you need depends solely on the nature of the work you want to do. For example, if the parts are simple, a 3-axis milling machine or a CNC lathe would be good for you. However, getting a CNC machine that can machine parts in just one setup becomes sensible as complexity increases. - Machine Cost Optimization
One major thing to consider when choosing a CNC machine is cost. While CNC machine costs vary, they are significantly more expensive than manual machines. The factors that cause a CNC machine to be high in value include bar feeders, cooling systems, chip conveyors, and automatic tool changers. To save money, you should only get the desired add-ons required to carry out your project. - Spare Part Availability
Just like all other machines, CNC machines need you to carry out routine checks on them, so you have to check for spare part availability before purchasing a CNC machine. You have to ensure that local technical support divisions stock the replacement parts of the machine you want. - Power Requirement
The CNC machines require a lot of power to run, so it is essential to ensure you have enough power supply and capacity in your building before getting these machines into it. - Reliable Air Supply
Most CNC machines need clean and dry air to work properly. Therefore, you must have air from a reliable source in your factory. You could install a compressor with a large air tank to allow multiple machines to operate simultaneously. - Material Supplied
When selecting a CNC machine, the machining material is one of the most crucial factors. When you work with hard alloys like Inconel, you need to get an advanced machine with enough stiffness to make machine-accurate parts. Suppose you use the machine to work on softer materials like aluminum or mild steel. In that case, consider getting a cheaper machine to maintain the required tolerance.
Conclusion
As a person or a company that produces machine parts, the best way to go is to use the CNC metal machine instead of the manual metal machine because it will save you a lot of time and increase productivity. When selecting a CNC metal machine, you should consider the type of material you want to work on and what you would like to turn the material into.
While this is the primary factor you should consider, you may also want to look at your budget so that if your work is not very complex, you can go for the cheaper machine to save you the cost of having to buy a machine that you may never use. If you are looking for a “CNC machining company near me”, Zintilon is your best choice. Reach out today to elevate your manufacturing needs!