Choosing the right CNC cutting tools for your workshop can be a decisive factor in improving productivity and achieving the finest quality in your machining operations. In this ultimate guide, we aim to walk you through the complexities of various cutting tools available and their specific applications. By understanding these tools, you'll be better equipped to make informed decisions that can significantly enhance the efficiency and output of your workshop.
View Details
CNC (Computer Numerical Control) technology has revolutionised precision machining, introducing a variety of cutting tools that cater to diverse materials and production requirements. Whether you're working with wood, composite materials, metals, or foam, selecting the right tool is crucial. Our expertise in manufacturing high-quality PCD, TCT, Carbide and HSS tooling provides us with the unique ability to guide you through this selection process.
This article will delve into the different types of CNC cutting tools we offer, each designed for specific materials and applications. We&#;ll also discuss important factors to consider when choosing these tools, ensuring you select not only the right type but also the tool that offers the best performance and durability for your specific needs. Finally, we'll provide essential maintenance tips to help prolong the life of your tools, safeguarding your investment and maintaining consistent quality in your production line. Whether you are new to the world of CNC machining or looking to refine your tool selection process, this guide is tailored to help you navigate the array of options and find the perfect match for your workshop's requirements.
Understanding Different Types of CNC Cutting Tools
When we consider the extensive range of CNC cutting tools available, it's essential to recognize how each type is uniquely suited for different machining tasks. For woodworking, our tools such as PCD (Polycrystalline Diamond) compression router cutters and straight router cutters are tailored to handle everything from intricate detailing to heavy-duty cutting. These tools are manufactured for precision and durability, offering clean cuts and long-lasting performance on various wood types and composite materials.
In the realm of metalworking and engineering, our Tungsten Carbide and High-Speed Steel (HSS) tools, including end mills and drills, come into play. These tools are designed to withstand the rigours of machining metals, providing high resistance to wear and the ability to maintain sharp cutting edges under high temperatures. Carbide end mills, for example, are perfect for tasks that require high precision, such as creating detailed and complex geometries in tougher materials like steel and titanium.
Key Factors to Consider When Selecting CNC Cutting Tools
Selecting the right CNC cutting tools requires careful consideration of several key factors to ensure you match the tool's capabilities with your specific needs. First and foremost, material compatibility is crucial. Different materials have diverse properties that demand specific cutting tool types and geometries. For example, softer materials like aluminium can be machined efficiently with HSS tools, whereas abrasive materials like hardened steel or composites are best handled by robust PCD, TCT and Carbide tools.
Another vital factor is the machining application. Are you roughing, finishing, or performing detailed engraving? Each process might require different tool specifications to achieve optimal results. Tools for roughing are generally built to remove large amounts of material quickly, while finishing tools are designed for achieving a smooth surface with fine precision. Additionally, machine specifications such as spindle speed, power, and torque should also guide your tool selection process. High-speed machines, for instance, will require tools that can operate effectively at high rotation speeds without degrading.
A Step-by-Step Guide to Choosing CNC Cutting Tools for Specific Applications
Choosing the right CNC cutting tools for specific applications isn't just about understanding the tools themselves but also about knowing the unique demands of each project. Let's break down the decision-making process into clear, actionable steps. First, assess the material that needs to be machined; different materials will require different cutting tools based on their hardness and abrasiveness. For instance, when working with composite or engineered wood, a PCD cutter might be the best choice due to its ability to handle harder materials more effectively than standard carbide cutters.
Next, consider the type of machining operation. Are you engraving, cutting, shaping, or finishing? Each of these operations might benefit from specific types of cutters or drills. For detailed engraving in metals, using fine-grained tungsten carbide end mills could be ideal as they offer precision while maintaining a good edge under challenging conditions. By aligning the tool choice with both material and operation type, we ensure optimal performance and efficiency from your CNC machinery.
Maintenance and Care Tips for Extending the Life of Your CNC Tools
Maintaining and caring for your CNC tools is crucial for ensuring they perform effectively over their lifespan and deliver the best possible return on investment. Regular maintenance not only extends the life of the tools but also guarantees the quality of your machining projects. Always start by following the cleaning guidelines provided, which usually involve removing any residue or particles that could affect the tool's performance. Proper storage is also essential; tools should be kept in a dry, clean environment to prevent corrosion or other wear and tear.
Additionally, routine inspections are vital. Check for signs of wear such as bluntness or damage to the cutting edges. For PCD, TCT and Carbide tools, consider professional re-tipping or sharpening services when performance begins to drop, as this can substantially extend their useful life compared to replacing them entirely. By adhering to these maintenance and care protocols, the tools retain their precision and efficiency, ensuring that your CNC operations always run smoothly.
Conclusion
Selecting, using, and maintaining the proper CNC cutting tools are essential steps in maximising the efficiency and output of your machining processes. By understanding the different types of tools available, considering key factors for selection, and applying detailed care and maintenance, we ensure our workshop operations are both cost-effective and of high quality. Remember, the longevity and effectiveness of your CNC tools don't just depend on the initial purchase but also on how well they are maintained. A disciplined approach to tool selection and upkeep not only protects your tools but also enhances your overall production capacity.
For more insights and help selecting the right tools for your CNC projects, reach out to us today at Prima Tooling. We are dedicated to providing you with top-quality CNC tools and expert advice tailored to your specific needs and applications.
What do you need from CNC tooling?
How you want a tool to perform is straightforward. What&#;s challenging for many CNC machine shop engineers is selecting the right tool to ensure the job gets done properly.
From the list above, performance of the tool is vital, but it&#;s not the only thing to consider. The experience of your CNC machine shop plays a part. And, cost is also a big factor, which we&#;ll address below.
You will get efficient and thoughtful service from Guangzhou Ruiyi Technology Co., Ltd..
When selecting CNC tooling, engineers should consider:
- Workpiece Material and Features
- Production Volume
- Combo Possibilities
- Machine Capacity
- Tool Material
- Toolmaker Selection
- Planning
- Experience of the Shop
1. Workpiece Material and Features
The material of the workpiece drives tool selection. For instance, a shop may primarily machine aluminum, ductile iron, and gray iron castings (which describes Stecker Machine), so there are likely favorite CNC machining metal cutting tools for each material. Engineers choose proven standardized tooling first, helping to reduce risk, inventory, and costs.
CNC tooling &#; drills, mills, taps &#; are required to machine different features, and there&#;s standard tooling for each tool type and material. Again using Stecker as an example, we have three different standard 90° square shoulder face mills, one each for machining aluminum, ductile iron, and gray iron. Of these materials, aluminum has the highest machinability, so the aluminum tooling has higher surface feet per minute (SFM) specifications, so they can run faster.
2. Production Volume
Specialty, high-end cutting tools are usually selected for high-volume projects, while low-volume jobs use more economy-level tooling. It comes down to economy of scale, with the cost of high-end, feature-specific tooling being justified by the high quantity of parts to be made by that tool.
Like much of manufacturing, CNC machining is a production-focused business, with machining centers playing a large role in a machine shop&#;s efficiency.
3. Combo Possibilities
Multiple-feature tools can be huge cost- and labor-savers in CNC machining. If multiple tasks &#; three or four or more &#; can be completed by one tool, it cranks up cycle time while also reducing the time needed to change out the tooling.
For instance, when designed properly, an insertable combo tool can drill and chamfer possibly three different ways, getting the job done in one pass with one tool, instead of six tools (and six passes). Yes, that custom-made, multiple-feature tool may cost upwards of $3,000, but the savings add up quickly to offset the costs, especially on a high-volume project.
4. Machine Capacity
Most CNC tooling can be used in most CNC machines. That doesn&#;t always mean those machines are the most efficient, however. Engineers and operators know that a greater horsepower machine &#; with a bigger taper &#; provides opportunities to use combo tools (mentioned above) that can perform many functions.
Whereas large castings require the help of hoists to move them, smaller castings don&#;t have that challenge. In fact, there may be opportunities for increased efficiency by designing a fixture that can run two or three small parts at the same time on a larger machine. That&#;s an example of when large machine = large casting doesn&#;t necessarily hold true.
Finding the best efficiency is mostly about selecting the right tool to match the project needs and the machine&#;s ability and availability to run it. If a machine can run multiple parts at the same time and the operator changes out three instead of one, that&#;s a no-brainer.
Running multiple parts on a pallet saves time by reducing the number of pallet and tool changes per part. For example, running three parts simultaneously, compared to one, saves 1/3 the tool change and pallet change time per part, plus it increases rapid motions between the three parts in the machine center.
5. Tool Material
The same cutting tool can be made from many different materials, some more durable (and expensive) than others.
Solid carbide is reliable, yet PCD-tipped tools reach even higher durability. PCD, or polycrystalline diamond, is the hardest modern cutting tool made by sintering diamond particles with a metallic binder.
A PCD-tipped drilling tool has approximately 4 times the tool life of a solid carbide tool (2,500 pieces versus 10,000) and can run 25% faster, offsetting the cost difference between the two (around $180 for carbide versus $960 for PCD) and resulting in production savings.
PCD tools can be retooled multiple times, unlike solid carbide tools that lose diameter after a few regrinds. CNC machine shops often use cutting monitors, tool life counts, and experienced operators to predict and prevent tool failure, ensuring proper cutting.
An economical alternative to solid carbide is a steel tool body with brazed carbide inserts, reducing costs up to 75%. Other options include high-speed steel tools and carbide-tipped tools, preferred by smaller CNC machine shops for cost-effectiveness.
6. Toolmaker Selection
Like any vendor partnerships, a toolmaker and CNC machine shop thrive on familiarity. A large shop&#;s strategic investment in around seven to eight toolmakers &#; each specializing in specific challenges such as solid carbide, combo tools, PCD-tipped tools &#; fosters trust and creates benefits (increased buying power, expedited projects, or a willingness to go the extra mile to satisfy a customer). Again, the larger, more experienced CNC shops have the advantage here.
Engineers in large CNC machine shops may concept and design over ¾ of all tooling needed within that shop. For instance, if the project requires an insertable combo tool, the engineer sends the part print and model to the toolmaker rep and, together, they complete the design. That hands-on connection results in a more reliable overall project. Small CNC machine shops must completely rely on their toolmaker rep for design and engineering expertise.
7. Planning
When engineers determine how a new project will be completed in the shop, they often create a best-case scenario (best tooling, aggressive cycle times, high-end fixturing), and then also
have a &#;Plan B&#; (less expensive tooling, less powerful machines, etc.). The temptation is to stay competitive by choosing a less expensive option, which usually means the tooling suffers.
The flaw in that thinking overlooks potential tooling challenges, which not only match the cost of the initial best-case scenario but also include the added expense of wasted time. That&#;s why high-end, experienced, confident CNC machine shops don&#;t seriously consider &#;Plan B&#; options. Leadership understands the value of immediately selecting high-quality materials and using the best processes to complete a job, staying ahead while the competition chases.
8. Experience of the Shop
Some CNC machine shops have more experienced staff than others. Nothing can replace the insight gained from decades of successful projects using CNC machines. These frontrunners are familiar with handling projects from design to assembly. They have the correct processes in place as well as a lot of the right CNC tooling.
So, how does an up-and-comer join an experienced CNC machine shop? After all, selecting tools is not a skill taught in even the best higher education CNC classes or training sessions. In this case, it&#;s an example of tribal knowledge: expertise passed down from engineer to engineer, usually within high-end CNC machine shops.
How can you evaluate a shop&#;s capabilities when it comes to selecting CNC tooling without seeing their work on your project? It&#;s a difficult task. Look for experience first and ask for references. Also, review these three signs that a CNC machine shop knows how to choose the right tools for complex parts.
Now you know what CNC tooling can do and what engineers should look for when selecting CNC machining cutting tools. Next, learn how to maximize your CNC tooling practices by reading CNC Tooling Improvements and Partnerships: A Guide to Solving Specific Tooling Issues. Click the link below for your copy.