
CNC machines are now the mainstay in many manufacturing industries. It delivers unwavering accuracy and precision. These machines are automated and give you total control over the cutting process which improves productivity. Cutting tools are integral parts of a CNC machine. They determine the product quality and how well the machining process goes.
However, there are many types of CNC machine-cutting tools available, and choosing the right one can be a daunting task. You have to carefully consider some factors before making a decision. This article will explain the types of cutting tools you can use and how to select the right one for your project.
Types of CNC Machine Cutting Tools
There are different types of CNC machine cutting tools you can use to make quality parts. They move in predetermined directions and remove material gradually from a workpiece to create the desired component. Though the principle of operation is the same, the cutting tools have unique capacities and applications. Let’s look at them in detail
- End Mill
An end mill is one of the most versatile CNC machine cutting tools available. You can use it for milling, contouring, and pocketing operations. The tool is cylindrical with many flutes. It removes large quantities of material in a single pass. End mills are suitable for cutting 3D shapes and flat surfaces. There are different types of end mills. They have varying shapes, length, diameter, and number of flutes. The most common types are bull nose, ball nose, and roughing end mills.
- Face Mill
A face mill is a popular CNC cutting tool. It has a flat body with many cutting edges. The tool’s main function is to flatten and smoothen the surface of the part before carrying out other operations. Face mills are reusable and you can easily replace the cutters to prolong the lifespan of the tool. They are fast and produce superior surface finish. Additionally, you can use them for both large and small surfaces.
- Drill Bits
The cylindrical body and pointed tip of drill bits distinguish them from other CNC machine cutting tools. They have multiple flutes on the side of the body. Drill bits are mainly used for drilling holes in a workpiece. They make precise holes in a wide range of materials. You can classify drill bits as either twist or insert. Twist drill bits are more common and you can use them for relatively small holes. Insert drill bits, on the other hand, are ideal for large-diameter holes.
- Fly Cutter
Fly cutters are large and flat tools with a cylindrical body. These cutting tools rotate at high speed and are suitable for machining large surfaces. To use fly cutters, you insert the cutter bits into it. These cutter bits can either be single or multi-point. Three main types of fly cutters exist; point cutter, rotary cutting tool, and rotary carving tool. They work in different ways and have unique applications.
- Gear Cutters
Gear cutters have a curved body with multiple cutting edges. They come in varying sizes and shapes. As the name implies, what this type of cutting tool does is to cut accurate and precise gear teeth. This tool cuts with one tooth at a time at a high speed. Gear cutters come as either worm, bevel, spur, or helical.
- Reamers
Reamers are rotary cutters that have a cylindrical body with many cutting teeth around it. Their main function is to enlarge previously drilled holes to get the required size. Reamers come in different styles and sizes with the most common types being spiral fluted, straight fluted, taper pin, and shell.
Key Considerations of Choosing CNC Machine Cutting Tools
There is no standard way of choosing the right CNC cutting tools for your project. You have to carefully consider some factors before making your decision. Let’s look at some important considerations of choosing CNC machine cutting tools.
- Type of Machining Operation
The particular CNC machining operation you want to carry out is a major consideration. Different tools have been matched with various processes such as milling, turning, and grinding. The operation defines the purpose of the tool and influences its geometry, size, and material. For instance, you should go for different milling tools including face mills and end mills when milling flat surfaces. Conversely, drill bits are perfect for drilling operations.
- Workpiece Material
The material of the workpiece you are working with is a major determining factor. Different materials have unique physical and mechanical properties which affects how you can easily cut through. You can’t use a particular tool for both soft and hard metal and get the same results. Ferrous metals are tough and you should employ high-strength tools to get a quality cut edge. Furthermore, nonferrous metals require tools that have superior thermal conductivity to prevent heat build-up.
- Part Complexity
The complexity of the part will determine the tool geometry to employ. The shape and angularity play significant roles. You may need specialized or custom-made tools for complex shapes. Furthermore, there are instances where longer or shorter tools may be the best depending on how curvy the features are.
- Tool Material
You should also consider the material the tools are made of before using them. Common types of tool materials include carbon steel, high-speed steel, cemented carbides, and cutting ceramics. Tools made from carbides and ceramics are durable and perfect for hard workpieces. On the other hand, high-speed steel is less durable and you can use it for small to medium scale production.
- Tool Coating
Most times, cutting tools are further coated to improve their performance, prevent wear, and aid chip removal. Examples of these coatings include titanium nitride, chromium nitride, aluminum-titanium nitride, and diamond-like carbon. The material you are working with will determine the tool coating you use. Tools coated with titanium nitride are general purpose while those made of chromium nitride are reserved for corrosion-resistant metals.
- Number of Flutes
You should also consider the number of flutes the tool has. The number of flutes determines the feeding rate and cutting speed. As a rule of thumb, the harder the material, the more the number of flutes for an effective cutting action. When machining aluminum or softer metals, consider going for tools with less number of flutes. For steel and harder alloys, tools having five flutes and above may be the best option. This is because tools with more flute numbers exert more pressure against the workpiece.
Conclusion
Selecting the right cutting tool is key in any CNC machining operation. Using the wrong tool can lead to tool breakage and damage to the workpiece. You may also experience downtime, increased scrap rate, and loss of productivity. When choosing a tool for your project, you have to factor in the workpiece material, tool material, and number of flutes the tool has. If you are still unsure, reach out to an online CNC machining service provider to leverage their expertise and experience.