Rapid prototyping technologies today are indispensable in the process of manufacturing a prototype of a product and creating molds from metal. 3d milling is one such technology. Milling is one of the main methods to quickly and efficiently produce a 3d model. In the process of 3d milling, milling machines with and without CNC are used.
3d milling is a technologically complex process in which a milling machine, based on the data obtained, processes a workpiece and creates a three-dimensional model of a product from it.
In the process of milling, the machine carries out 2 types of passes
- Rough pass – creation of the main lines of the object and its shape.
- Finishing pass – sharpening the clear shape of the product according to the given 3D model.
This Rapid Prototyping technology uses tapered end mills with ball or flat nose. These cutters are optimal for the production of complex 3D models.
Types of milling machines
Depending on the method of controlling the milling machine, there are: a milling machine with and without numerical control. The control of a CNC machine is carried out by a computing device, usually a computer. The cutter is moved by a special signal. The signal is fed to special controllers, which process it with the selected power, and then feed it to the motors.
Machine control without software control requires direct human intervention in the milling process. This significantly complicates the process, makes it more time-consuming and costly.
The principle of operation of CNC milling machines:
In the milling process, a workpiece and a router are involved. A workpiece is a material from which the machine creates the desired object, as a result of its processing. Rotation of the cutter is provided by a special spindle that sets the rotational speed and trajectory of the cutter. Numerical control converts the incoming signals and is responsible for the operation of the machine with a text file that contains control codes. Such a file is created in advance by an experienced engineer in CAM programs.
Types of CNC milling machines
From the level of complexity of building a 3D model, various milling machines are used:
Stages of 3D milling
The 3D milling process is carried out in several stages.
- Building a 3D model of the product.
- Preparation of the resulting model for the milling process (selection of tools, writing an operation algorithm for a cnc machine).
- Trial milling of a workpiece made of plastic (in order to save money).
- Milling of a finished 3d model of a product (made of metal).
As materials for 3D milling use materials such as:
- plastic (ABS, PLA, polycarbonates, polyethylene, etc.);
- ferrous and non-ferrous metals (copper, duralumin, steel, aluminum, etc.);
- composite materials;
- stone, etc.
Application of CNC milling machines
- Industry – creation of molds for casting, design and development of a master model of a product, production of a trial batch of goods, small-scale production. As well as the manufacture of auto parts and tuning elements for cars.
- Advertising production – production of advertising signs, with volumetric patterns or “carvings”, production of POS-materials and souvenirs.
- Instrumentation – production of printed circuit boards, instrument panels, holes in electrical and radio equipment.
Benefits of cnc milling
CNC machines have a number of undeniable advantages:
- high speed of work performance;
- high-precision control based on a computing device;
- the possibility of using for engraving on various materials;
- the ability to work with large surfaces;
- saving human resources.
If you need custom-made milling, KLONA will be happy to cooperate. High-quality technical equipment and qualified specialists of the KLONA company allow us to carry out milling work of any complexity.