limitations of CNC milling

CNC milling is a widely used manufacturing process that involves using computer-controlled machines to remove material from a workpiece. It is known for its precision and accuracy, making it a popular choice for producing complex parts with tight tolerances. However, like any other manufacturing process, CNC milling has its limitations.

One of the major limitations of CNC milling is the effect of material hardness on accuracy. The hardness of a material refers to its ability to resist deformation, and hardness varies greatly between different materials. When milling soft materials, such as aluminum or plastic, the cutting tool can easily remove the material without much resistance. This results in high accuracy as the tool follows the programmed path exactly. However, when milling hard materials such as stainless steel or titanium, the cutting tool faces greater resistance, which can cause some problems that affect the accuracy of the milling process, meaning the dimensions of the final part may deviate from the expected specifications.

Second, the cutting tool may deflect or bend when milling hard materials. This is because the greater force required to remove material from hard materials results in greater stress on the tool. As a result, the tool may not follow the programmed path accurately, resulting in inaccurate dimensions of the final part.

To alleviate these issues, manufacturers often use specialized cutting tools and techniques when milling hard materials. For example, they may use carbide or diamond-coated tools, which are more resistant to wear and stay sharp longer. Additionally, they can reduce cutting speeds and increase feed rates to minimize tool deflection.

Despite these measures, it is worth noting that there are always limits to the accuracy that can be achieved when milling hard materials. Inherent properties of materials, such as hardness and toughness, will always pose challenges to the milling process. Therefore, manufacturers must carefully consider material properties and select appropriate processing strategies to achieve the required level of accuracy.