Posted by: Dani Weinhandl
on February 27, 2024 | 3 min. read
on February 27, 2024 | 3 min. read
Metal milling is a metal finishing service that removes material and shapes metal workpieces. From aerospace components to automotive parts, this versatile machining technique has many applications across industries. Keep reading as we explore everything you need to know about metal milling.
WHAT IS MILLING IN THE METAL INDUSTRY?
Milling is a machining process that uses rotary cutters to remove material from a metal workpiece by advancing against the cutter slowly. This shapes the workpiece to precise specifications suitable for a wide range of applications.
THE MILLING PROCESS
Milling metal on a manual machine takes skill and experience. The machinist must monitor and adjust as the material is removed to achieve the desired results.
The basic milling process involves:
- Securing the workpiece
- Loading the tooling
- Setting the machine speed and feed rate
- Starting the spindle
- Moving the table to feed the workpiece against the cutter
Chip load, depth of cuts, spray coolant use, and more impact the outcome.
CNC MILLING
CNC machines have revolutionized metal milling, allowing for automated, precise, and efficient machining. The integration of computer numerical control enhances accuracy and repeatability. The computer automates movement, allowing for faster, more repeatable production runs.
PURPOSE OF METAL MILLING
Metal milling has many distinct purposes across manufacturing industries, including:
- Reducing thickness and removing material
- Shaping workpieces to precise specifications
- Cutting key features like slots, grooves, pockets, flat surfaces, and drilled holes
- Improving surface finishes
METAL MILLING APPLICATIONS
The uses of metal milling are widespread, ranging from creating intricate parts for machinery to crafting customized components for specific applications. Here are a few common examples:
- Sculpting complex aerospace and aviation components
- Drilling precise holes for fuel injection systems in automotive uses
- Cutting gears, levers, and couplings
- Producing dies, molds, and prototypes
DIFFERENT TYPES OF MILLING MACHINES
There are two main configurations of milling machines, defined by the orientation of their cutting spindles. Both styles can handle various metal milling applications, which we’ll explore in more detail below.
HORIZONTAL MILLING MACHINES
The cutters are mounted horizontally on an arbor extending from the machine. This type often uses endmills and slab mills with cutting teeth on the periphery and bottom.
VERTICAL MILLING MACHINES
Here, the cutters are secured vertically in the spindle nose, with endmills and slot drills being the most common tooling options.
The machine style ultimately depends on the complexity and specifications of the workpiece. Multi-axis CNC milling utilizes computer programming for optimal precision. By integrating software with the mechanical mill, manufacturers achieve tighter tolerances, faster cycle times, and the flexibility to adapt as needed.
MILLING IN A NUTSHELL
Metal milling allows limitless manufacturing possibilities, from rapid prototyping to complex machinery components. Matching the appropriate machine, tooling, and technique enables machining metals within microns of accuracy. With expanding capabilities and precision, metal milling will continue driving innovation across every industry.
NEED METAL FOR YOUR NEXT PROJECT?
When it comes to specialty metal supply, we’re the experts. Mead Metals offers a wide range of metal materials and in-house services like cut-to-length, edge conditioning, and slitting to help expedite project timelines. On top of that, our ISO-certified processes provide a 99.76% quality assurance guarantee and 99.8% on-time delivery.
Click the link below to get a Quick Quote on material in four hours or less.
