Views: 3 Author: Site Editor Publish Time: 2023-02-24 Origin: Site
Manufacturing different components requires various processes; among them, milling is also a common manufacturing process. The process of milling uses subtractive manufacturing techniques.
However, the milling process is divided into two kinds, each of which serves a different purpose. The milling process comprises a tool that keeps rotating in the milling machine, and on the surface, the workpiece is kept over which the tool carries out the cutting.
So, when it comes to the manufacturing process, the manufacturer must decide which kind of milling will be a suitable option, either climb milling or conventional milling.
In the following guide, Kaiao will take you through the differences between the two methods, followed by which is suitable for which applications. So, let's read below.
The process of climb milling is also called down milling. This process uses CNC machining, and the tool keeps rotating in the workpiece's direction.
During the cutting process, the cutting tool teeth jump over the component and keep cutting the material leaving the deposit behind. This process and layout of cutting ensure that no recutting happens again.
There are various benefits attached to the process of climb milling that convince machinists to opt for these, and some of these advantages are shared below:
The workpiece that comes out after passing through the climb milling is backed with excellent surface finishing. The process keeps on decreasing the thickness of the workpiece, and the chops are left at the back of the cutter.
This ensures that there are fewer deflections in the finished component and also there is no recutting of the component.
This process generates less heat because the workpiece starts reducing gradually. Apart from this, the process consists of keeping the direction of forces downward; hence, there is no holding requirement.
The process of climb milling puts little pressure on the workpiece. There are fewer deflections, and the heat generation is quite low, which increases the tool's durability.
The process of climb milling has many advantages; there are also certain limitations, which must be addressed while choosing which process to choose. Some of them comprise the following:
When the climb milling machine deals with thicker pieces, it vibrates a lot. This might cause damage to part of the workpiece. Hence, thicker pieces are always a challenge in this process.
The climb milling process is only suitable for some kinds of materials. Especially when it comes to harder metals like iron and steel. If harder materials are subjected to this machine, there are chances to have damaged finished components.
In conventional milling, the entire opposite thing happens as that in climb milling. The cutting tool in this process moves opposite to the workpiece. In this kind of milling, the cutting direction is upwards.
With conventional milling, the chipping process starts increasing over time, and due to the rotation, the deposits are present in the path of the tool. It comprises an upward force due to the direction of the cutting tool.
Certain pros of conventional milling make this process suitable for many applications. Some of these advantages are discussed below:
In the conventional milling process, the cutting tool moves in the upward direction; therefore, it causes no backlash. Since the table is not lifted due to the movement of the machine and the workpiece, the presence of backlash is eliminated.
In conventional milling, the machine doesn't pull the workpiece towards it, making it more stable and accurate because there are no chances of any deflections in the workpiece. Moreover, the process is less vibrational, and hence there are no excessive movements on the part of the workpiece.
Conventional milling causes an upward force with the milling tool, making it suitable for more rigid materials. Hence, materials like steel and cast iron may easily be shaped using this process rather than climb milling.
There are certain downsides of the conventional milling process, and some of these may comprise the following:
The chip's width keeps increasing over time as the machine cuts down the workpiece. Hence, during this process, the heat generation also keeps on increasing. Therefore the process is known to release a lot of heat while working on the material.
The finishing of the component that comes out of conventional milling needs to be more accurate. You can find deflections at many points, and hence, whereas finishing is a prime concern, there are more suitable approaches than conventional milling.
The process of conventional milling causes a lot of damage to the workpiece. Since the tool forces the workpiece upwards and, at the same time, deflections are caused therefore, the damages are quite prominent in such a situation.
In conventional milling, the pressure is put in the upward direction. Hence a fixture is needed to hold the workpiece in a stable position so that the cutting tool may work over it.
When choosing between the two processes of milling, conventional or climb milling, many things must be focused on. The two processes are opposite to each other hence certain factors will need attention.
The climb milling's finishing, quality, and accuracy are always excellent. However, it needs more application over the harder materials. At the same time, it also lacks stability and control.
Whereas, when conventional milling is considered, it is suitable for harder materials, but at the same time, there are a lot of inaccuracies in the workpiece. Especially when it comes to working, the control and stability are better in conventional milling.
So, when choosing the process, it is essential to consider all these factors and then decide to select the process.
It is essential to consider the right and suitable milling process, but choosing a reputable manufacturer for such parts cannot be ignored. You must contact the KAIAO and have your components milled.
Our team of experts ensures choosing the appropriate milling process for your tools, you will always get the best prices with the optimum quality.