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So, what is a CNC milling machine? CNC milling machine is the name given to machines that remove chips from workpieces by generally making a linear advancement movement with a pocket knife that has more than one cutting edge. This type of bench is used for purposes such as processing flat and angled surfaces, grooving, and making straight and circular divisions. For this reason, they are widely preferred in the manufacturing sector in various fields, from automotive to aviation, from defense to machinery manufacturing.

CNC milling machine parts

CNC milling machine parts can be examined under three separate headings: main parts, headings and accessories.

• Main parts: Body, console, carriage, table
• Heads: Milling machine heads
• Accessories: Mandrels, divisor and striker, rotary table, vises, clamping shoes

Details of CNC milling process

CNC milling machines are highly advanced machines with data processing and evaluation capabilities. For CNC milling, the part is connected to the machine and the reference points of the part are defined to the machine through a precision receiving tip called a probe. In this way, the machine understands the raw size of the piece to be processed and its position on the machine. In CNC milling machines, the necessary cutting tools are placed in a mechanism called a magazine.

Then, the previously prepared program to process the part is entered into the machine using methods such as control panel or memory card. It processes the part by interpreting the program entered into the machine and completely executing the tasks in the program. Here are the details of the CNC milling process and the working principle of CNC milling.

The operations performed on the CNC milling machine are named after the name of the cutting tool used or the name of the milling operation performed. Face milling, slot milling, gear cutting, etc. can be given as examples of these processes.

As we mentioned in the introduction of our article, CNC milling machines are widely used in the machinery and manufacturing sectors today. Thanks to CNC technology, machine parts can be produced flawlessly, quickly and economically in many sectors such as automotive, aerospace, defense, machinery manufacturing and mold making. CNC milling machine enables rapid and error-free manufacturing.

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Aluminum is one of the most used materials, along with steel, in CNC machining. Although the most important reason for this is its very good machinability, many features of aluminum play a role in its preference.

Aluminum (Al) is a silvery, ductile metal with high oxidation resistance. Its ductility and oxidation resistance make it a widely used material in different industries. Aluminum, which is often used by alloying with different metals to obtain stronger but at the same time light and ductile products, is indispensable especially in the automotive and aerospace industries.

Machinability
Aluminum is a material that can be easily processed on CNC machines thanks to its softness and easy machinability. Its density is about one-third that of steel or copper.

In this way, it ensures that both the workpiece itself and the tool tips are less deformed. This feature provides a significant advantage in terms of time, especially in prototype mold production.

Cost
Aluminum is an element abundant in the earth’s crust. Its abundance in nature makes it very cheap in its raw form. In addition, its easy recycling and 95% energy saving compared to its first production is another factor that facilitates its accessibility. For this purpose, aluminum chips that emerge in CNC machining benches can be reused after being brought together and recycled.

High Strength
As we mentioned before, aluminum is a much lighter metal than steel or copper, with its density of 2.7 g/cm3. Its tensile strength of 49 MPa in its pure form can go up to 700 MPa with different alloys. Despite its lightness, its high strength makes it a widely used material, especially in aviation and automotive.

One of the reasons why aluminum is widely preferred in CNC machining is that it has high corrosion resistance. This feature, resulting from the oxide layer on it, enables it to be frequently used in the shipping industry (in different sea and atmospheric conditions).

Suitability for Anodizing
Anodizing process, which increases the wear and corrosion resistance of metals, is carried out by cleaning the product after production and exposing it to artificial oxidation process. Since aluminum is a metal very suitable for anodizing, its already high corrosion resistance can be further increased.

The 7 Most Used Aluminum Alloys in CNC Machining
In addition to the general properties of aluminum, its alloys also have different properties and their usage areas vary according to these properties. Let’s take a look at the 7 most used alloys of aluminum in CNC machining.

AI-2007 Series
The main alloying element of this series is copper with a ratio of 4-5%. It is a durable, lightweight and highly functional short-chipping alloy. It is also suitable for threading, heat treatment and high-speed machining. In this way, Al-2007 series machine parts are widely used in the production of bolts, rivet nuts, screws and threaded rods. However, this alloy has low weldability and low corrosion resistance. Therefore, it is recommended to carry out protective anodizing after processing.

Al-5083 Series
This series, which is not heat treated, is famous for its excellent resistance to harsh conditions. This alloy, which contains 4-5% magnesium and small amounts of chromium and manganese, is frequently used especially in marine and chemical applications with its high corrosion and wear resistance. It is not recommended for use in applications involving high temperatures.

Al-5754 Series
This alloy, which has a magnesium content of 2.5-3.5%, is the alloy with the highest aluminum content. Al-5754 series is a rollable, wrought and extrudable alloy. Cold processing can be done to increase the strength of this series, which is not heat treated. It has high corrosion resistance and strength like the 5083 series. Considering these properties, it can be understood that 5754 is one of the most popular aluminum alloys used in CNC machining. It is commonly used in welded structures, flooring applications, fishing equipment, vehicle bodies, food processing and rivets.

Al-6060 Series
It is a wrought aluminum alloy containing magnesium and silicon. This heat-treatable alloy has average strength. It is well weldable and formable. It is also highly resistant to corrosion and its resistance can be further increased by anodizing. The 6060 series is commonly used in the construction/architectural, food processing, medical equipment and automotive industries.

Al-6061 Series
It is an alloy containing magnesium, silicon and traces of copper. With its high tensile strength of 180 MPa, it is very suitable for high-load structures such as scaffoldings, railway wagon parts, machinery and aviation parts.

Al-6082 Series
This alloy, produced by rolling and extrusion processes, has medium strength, high weldability and high corrosion resistance. It is frequently used in container parts, ship construction and bridges.

Al-7075 Series
This series, whose main alloying element is zinc, has average machinability and low weldability, but is frequently used in military and aerospace industries, climbing equipment and nuclear applications with its high strength, excellent resistance in atmospheric and marine environments.

Conclusion
Apart from all these, many more aluminum alloys formed with different metals in different proportions are used in CNC machining. With its easy machinability and low cost, it is a metal that you can easily choose both in the prototyping phase and in mass production.

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Copper
Copper, which has been actively used since ancient times in human history, is a pure metal suitable for direct processing. Copper, which is antimicrobial in nature, is very soft in its purest form and can be easily hammered. In addition, it offers high electrical and thermal conductivity as well as high corrosion resistance. The electrical and electronics industry frequently benefits from these properties of copper.

Copper is one of the cost-effective CNC machining metals with its very high machinability rate. With excellent thermal and electrical conductivity, C101 and C110 copper alloys are widely used for CNC machining.

C101, also known as “oxygen-free copper”, is an extremely high purity alloy with a Cu content of 99.99% and shows excellent electrical conductivity and is therefore also called “HC (high conductivity)” copper. In addition, C101, which has good strength values and high ductility, is an indispensable alloy in the electrical-electronics industry. With its effective corrosion resistance, it is used in various engineering applications such as cables, motor components and transformers.

C110, also known as “electrolytic hard pitch (ETP)”, although not as pure as the C101 alloy with its 99.9% Cu content, is a very pure alloy and shows high electrical conductivity. It is more cost-effective and easier to process than the C101 alloy. In addition, C110 alloy can be easily formed by cold forming methods. C110 alloy is also frequently preferred for electrical-electronic applications.

Brass
Brass, a metal alloy consisting of a combination of copper and zinc, is among the preferred CNC machining metals thanks to its high machinability, although its raw material cost is relatively high. In addition, the high scrap yield brass offsets the raw material cost. Brass is widely known for its medium hardness and high tensile strength. Particularly, zinc concentration improves the strength and ductility values of brass and provides flexibility as well as strength to the alloy. The color of rice changes from red to yellow with increasing zinc concentration.

C260 and C360 alloys with high zinc concentration are often preferred in CNC machining. These alloys have a gold appearance and exhibit superior mechanical properties. They show good corrosion resistance and are highly machinable alloys. They are also ideal for applications requiring low friction.

C260, also known as “yellow brass” or “cartridge brass”, is among the most preferred and cost-effective brass alloys. The most ductile yellow brass, C260 offers good mechanical properties along with superior corrosion resistance. C260 alloy, which has non-hard machinability, can also be cold formed. It is widely used in ammunition components, hinges, fasteners and radiator equipment.

C360, also known as “free machining brass”, has excellent machinability, as its name suggests, thanks to its high lead content. Known as a soft and ductile alloy, C360 brass is also a strong material that exhibits good strength values. Additionally, this alloy has good resistance to corrosion, making it an ideal choice for parts requiring low friction. It is widely used in various machine parts such as nuts, bolts, shafts, bushings, screws and connectors.

Choosing Between Copper and Brass Alloys
Copper offers you excellent electrical and thermal conductivity. With high purity copper alloys C101/HC (99.99% Cu) and C110 (99.9% Cu), you can meet the requirements of your designs that require conductivity while also obtaining the necessary mechanical properties in the parts you produce. In addition, with their high machinability properties, these alloys can be easily processed on CNC machines.

Brass offers you the best machinability of all copper alloys. The copper content in its structure gives brass electrical and thermal conductivity. However, thanks to its zinc content, brass exhibits superior mechanical properties than copper and is a lower-friction material. In summary, brass shows better wear and corrosion resistance than copper. Lead, another alloying element, gives brass excellent machinability.

You can achieve superior mechanical properties and high corrosion resistance in your design with C260, the most ductile yellow brass, and C360, the best machinable alloys. Thanks to their excellent machinability, these alloys can be easily processed on CNC machines, thus saving time and energy. C260 and C360 brass alloys are ideal for fittings that require low friction and high strength.

Copper and brass, known for their electrical conductivity, show significant differences in terms of electrical conductivity values. Superconducting copper, which is considered to be absolutely 100% conductive, is a reference measure by which the electrical conductivity of other materials is evaluated. Brass, which is an alloy of copper and zinc, has an electrical conductivity of approximately 28% of copper.

Conclusion
Choosing materials according to the usage areas of your parts is very important in terms of efficiency and cost in the long run. The alloys of the two metal materials we examined are often used in the production of fasteners with their high machinability and corrosion resistance properties. You can contact us to have your parts produced with copper and brass alloys, which differ from each other with minor differences.

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When a three-axis milling machine was first used in 1952, it was perfect for solving some of the manufacturing problems of that day. These systems applied to milling machines are later used in lathes, grinding machines, etc. also applied to machine tools. Today, CNC is used in almost every field of manufacturing.

The main areas where CNC is used are;

• Machining.
• Fabrication and welding.
• Press works Inspection and control.
• Assembly.
• Transportation of materials.

CNC MACHINES:
A- CNC LATHE MACHINES:
In numerically controlled lathes, there are generally two basic axes, X and Z axis. Many profile turning operations should be possible on such machine tools. These are done with the linear interpolation and circular interpolation process features. In addition, the number of revolutions and cutter changing, determining the feed rate, etc. They have functions.

In CNC lathes with larger processing capacities, the number of axes can be 3 or more. The third axis can be the axis movement of the machine turret. The areas of use of CNC in the industry are to increase the structural resistance of the machine and to perform more precise manufacturing, especially in industrial type CNC lathes. In order to remove the emerging chips from the cutting area, some design changes have been made in the structural details.

As a result, CNC Milling machines are the machines with the most processing capabilities after machining centers in terms of the diversity of operational capabilities. These types of machines have the ability to operate on at least 3, 4-5 or more axes.

All types of these machines are equipped with continuous path control. In addition, automatic cutter change (Automatic Tool Change) is another feature. In addition, Cutter compensation provides great convenience, especially in curved milling operations and mold making.

It successfully processes three-dimensional (3D) workpieces with ideal profiles and optimum properties. The cutters used are hard metal and titanium coated tips with radiused tips and high cutting speed.

B- CNC MACHINING CENTERS:
These types of CNC machines are equipped with point to point and continuous trace control (CPC). The manufacturing of workpieces with such complex and multiple operations is carried out in one assembly.
a- Horizontal machining center
b- Vertical machining center

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