How To Choice Better CNC Machining Tools For Hardened Steel

 

Previously, when you do CNC Machining and milling hardened steel, the cutting speed or feed rate was kept low. But the cutting depth & tool walking distance were increased. This approach was slow and prone to leaving deep stepped tool marks on the workpiece, necessitating subsequent semi-finish and finish milling.

Alternatively, some manufacturers would rough mill low-hardness workpieces, heat treat them, or re-clamp the 100 workpieces for semi-finish and finish milling, requiring multiple clamping. Another option is to use EDM for steel, but this process can also be time-consuming & costly.

How to Select the Right CNC Machine Tools?

If you ever wonder how CNC machines are marking our lives easier, then you are thinking right. CNC machines are marvels of innovation and technology which is why these have vast applications in different fields. With CNC machines, your engineering gets an edge. CNC machines cannot work without special tools.

Now don’t be too relaxed to know this. It is because there is a huge range of these tools present in the market. Due to this reason, you need to know the art of finding the right CNC machine tools for your projects. So that you won’t be facing any problems in the future, in this guide, you are going to learn about these tools in detail. So let’s get started without further ado!

• Assess the Existing Setup

When a CNC machine works, you need to understand what tools it needs. So that you will look for suitable tools for this purpose, due to this reason, complete knowledge of CNC machines is important in this regard. For the setup, you need to analyze the performance at the same time. You need to determine the replacement expenditure as well to prevent a dent in your pocket. How reliable is the CNC machine operator also matters? These professionals are your biggest help when it comes to the professional management of CNC machines on all counts.

• Part Design & Complexity

The factors like part design and complexity hold great importance when we are talking about CNC machine tools. These basically set good machines apart from bad machines. Due to this reason, today, the industry is relying on industrial-grade and highly standard CNC machines for different purposes. The nature of the designs matters a lot in choosing the right machine. Basic designs don’t need high-end and intense machines, unlike complex designs. In case you are using inappropriate machines for your designs, it can lead to ultimate failure. Therefore going with the suitable machine type is integral.

• Nature of Raw Material

Sometimes we have to use some special production materials in our designs that cannot work with simple CNC machines. You need advanced and high-end CNC machine tools for this purpose. Well, it does lead to extra expenses for a producer. However, instead of facing trouble with the end result later, it is beneficial to go with the right choice. A CNC machine gives you an edge because it can work with all types of production materials. From soft to hard, everything goes well with these machines. Therefore when it comes to the tools, make sure these are suitable for the nature of the material you are using. Also how tolerant that particular material is also important to find out.

• Types of CNC Control Systems

The CNC control system plays a huge role in the fine performance of these machines. You cannot expect desired results with a defective CNC control system. Therefore you need to determine the nature of this control system and choose tools for it. It completely governs the CNC machines to rule out any chances of possible error. Experts recommend such tools that are durable and last long in the future.

• Average Cost Per Part

You have to be careful with the investment in the CNC machines. The reason is that investing in the wrong machine can lead to mental trauma. Therefore, always determine the average cost per part during production. This also includes the hidden cost. It comes in handy because you don’t have to worry about later. The choice of the tools is also important. If you mainly deal in complex services which are obviously high-end, then the budget will be more. It is clear that the average cost per part varies from one producer to the other.

• Space Available on the Floor

In general, most CNC milling machines take up much space. There are some portable versions also available. There is no doubt that producers are more inclined to rely on space-efficient CNC machines these days. However, when you are going to build a new one, determining the space for it is crucial for you. It should restrict your movement. Moreover, it should not interfere with any pathway, which can be dangerous. It ensures the safety and protection of the CNC machine and the user at the same time.

CNC Machine Tools Materials Selection

CNC machines cannot survive without materials! But how do you find the best materials for this purpose? It is simple; just take a look at the tips below for a better understanding!

• Find out how much material you actually need and make sure not to waste it for the sake of the environment and sustainably. Good CNC materials are those that show exceptional chemical and electrical attributes. Also, you can select production materials based on their quality and endurance.
• Evaluate your needs and find the best fit of materials as per your requirements which means you have to be sure of it before buying.
• Don’t ever settle for the less because the material can only serve you the best if it meets all of your needs in the long run.

Availability of CNC Machine Tools

It is recommended to always go for the readily available materials. If a material is not present in the market or has gone rare, then you have to pay a little extra to get your hands on it. Therefore rely on the available materials for the sake of production. It helps in quick CNC machining with more efficiency as well. In case you cannot find a desired CNC machining material, then you can delay the process.

Hardness & CNC Machine Tools

The typical range of Rockwell hardness for hardened steel is HRC 48-65. But it’s important to note that hardness alone doesn’t determine machinability. For instance, D2 die steel has a hardness of approximately HRC 60-62, but its chromium content (11% to 13%) enhances its toughness. This makes its machinability more similar to a workpiece with a hardness of HRC 62-65. In such cases, cutting parameters by the element supplier & generally applicable to hardness materials should be useful.

Reduce CNC Machine Tool Runout

Tool runout is often an overlooked but crucial factor in milling. If the runout is higher than 0.01mm, the equipment life may be decreased by half. It is particularly significant when using milling cutters with minimal requirements, as a runout of 0.01mm can double the chip load on the single tooth, leading to accelerated damage to the cutting edge. Therefore, it is essential to minimize tool runouts as much as possible. Even though some machining workshops invest in expensive machine tools or high-quality cutting tools, they often neglect the importance of precision tool chucks, leading to various processing problems. By using high-precision tool chucks such as hot fitting chucks or hydraulic chucks, the Detrimental effect of tool runout can be significantly reduced.

Manage CNC Machine Tool Life IN CNC Machining Technology

Regarding high-speed milling, the tool life extends if one carefully considers some factors. These factors include chip load, tool runout, and machine tool rigidity. In the case of milling hardened steel, the application of the milling cutter can contribute to prolonged tool life. However, it is essential to note that the explanation of tool life is subjective. It depends on various factors, including the customer’s specifications for the surface end of the die. It may require replacing the milling cutter before its expected service time.

High cutting temperatures can negatively affect tool life. Therefore, in high-speed milling, the smaller cutting depth can allow for more time between cutting passes. It will let the cutting edge cool down and prolong the tool’s life. When milling workpiece materials with hardness more than HRC 48, one can use air jet cooling or oil mist/air mist instead of coolant to prevent heat shock to the equipment.

Select Appropriate Cutting Tools FOR CNC Machining

As with the overall trend of the industry, mold products are increasingly demanding higher dimensional accuracy. These specifications are imitated in the cutting element useful for manufacturing molds and their components. Several years ago, the radial dimension tolerance of the ball end cutter was 10 micrometers. Nowadays, it has been reduced to close to 5 μ m. Achieving high fitting correctness for parts machined by a ball end with low accuracy can be challenging. In the mold manufacturing industry, where accuracy requirements are stringent, avoiding mistakes by tools is crucial.

Micro milling cutters can use micromachine features previously only achievable through EDM. Today, there are tiny milling cutters that are only 0.1 millimeters wide. Even though they are so small, they are useful effectively for high-speed milling if the groove they cut is not too long.

Balance Various Factors

To optimize production efficiency & machining quality in milling hardened steel, the manufacturer requires a comprehensive approach. It includes utilizing precision tools, advanced CAM software, high-precision tool collections, and high-performance machine tools. It also involves implementing other measures, such as coolant replacement. Suppliers of tools, machine tools, or workpiece materials are typically eager to share their expertise and skills. So it can assist processing workshops in achieving natural process balance and meeting productivity targets.

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