Milling machine for metal: classification and characteristics of equipment

From this article you can find out what features a metal milling machine, which can be used in a home workshop, has: technical characteristics of equipment, classification of tools and their applications. The text briefly describes the capabilities of vertical and horizontal structures, desktop and hand-held milling cutters, as well as drilling-milling, engraving-milling and universal CNC machines.

Types of milling machines: photos and design features

Milling machines are used to process metal blanks. Tools in this category are very popular and widely used in the metalworking field. Moreover, you can buy a metal milling machine not only for production purposes, but also as equipment for a home workshop.

A wide range of milling tools is on sale. Almost all models of machine tools have the same structure and work according to the same principle. Differences can affect only the functional side, which depends on the presence of additional systems and nodal components in the design.

Consumers can buy CNC milling machines for metal of the following types:

• vertical;
• horizontal;
• drilling and milling;
• table-top turning and milling machines for metal;
• universal;
• manual;
• milling and engraving.

The listed modifications are the main ones. Each type of equipment has its own characteristics and functional purpose.

Characteristics of vertical milling machines

Vertical structures are a very common tool category.Accessories for a metal milling machine of this type are represented by cutting elements of a cylindrical, shaped and end type. In addition, the equipment allows you to perform drilling operations.

Purpose of CNC vertical milling machines:

• the formation of grooves;
• processing of frame parts;
• manufacture of gear wheels;
• processing of corners, as well as horizontal and vertical metal surfaces.

The vertical type equipment, due to its structure, has a very rigid structure. This makes it possible to process metal parts at a high quality level. The gearbox is mounted on the spindle head.

There are two categories of vertical metal milling machines:

1. Console-milling.
2. Consoleless.

Note! In those designs where there is no console, the movement of the working table is carried out by means of guides placed on the tool bed.

The machine, in the design of which there is a console, differs only in that its sleeve and spindle can move relative to the axis of the equipment. For the manufacture of parts of complex shapes, 5-axis CNC milling machines are used. Such designs provide very high processing quality and savings. They can have built-in memory and the ability to connect to the Internet, as well as many other additional options. Some options have removable tables.

Features of horizontal milling machines

Horizontal structures differ in that the spindle in them has a horizontal placement. Tools in this category are used to machine small metal parts.

The following types of cutters for metal are used as equipment for horizontal structures:

• shaped;
• corner;
• end;

• end;
• cylindrical.

The standard equipment of a horizontal CNC milling machine does not allow machining workpieces along a helical surface. To perform such an operation, additional equipment is required.

Due to its structure, the horizontal tool allows the table top to be installed in different positions. The table can be positioned perpendicular or parallel to the spindle axis. All nodal and working elements of the structure are mounted on the bed. The speed box for adjusting the rotational speed of the spindle is located inside this area.

Specificity of drilling and milling machines for metal

Drilling and milling equipment allows you to process both vertical and horizontal and inclined surfaces. With this tool, you can form grooves of any modifications on large workpieces. The machine of this type is equipped with a drilling and milling head. It allows machining of surfaces at an angle with respect to the horizontal axis and tilted drilling operations.

A distinctive feature of the table-top drilling and milling machine for metal is its extended functionality. The working head can function in reverse mode. Due to its versatility, this unit can perform at the highest level such demanded operations as drilling and milling.

Note! Due to its versatility, the drilling and milling machine saves money when buying, since the consumer gets several useful and effective tools in one design. In addition, the versatile equipment allows you to save space in the workshop.

Features of universal metal milling machines for home workshop

The capabilities of multipurpose machine tools will be useful for small private industries and workshops that specialize in mechanical and repair work.

Universal milling machines for metal can process various objects:

• vertical surfaces;
• stamps;

• horizontal planes;
• spiral type surfaces.

Given the large number of functions, universal milling cutters differ from standard tools in some design features. Important components such as gearbox, spindle assembly and other working elements are located on the inside of the bed. The tool design provides for the presence of horizontal and vertical guides. They are designed to move the desktop and console.

In addition, the work surface can be additionally adjusted. This element can be installed at any convenient angle in relation to the spindle. This gives the operator the opportunity to process any metal parts. Workpieces with a very complex configuration are no exception.

Features of desktop metal milling machines

Table-top designs are compact in size. Therefore, this type of equipment is suitable for the technical equipment of various objects:

1. Home workshops.

1. Workshops of small industries.
2. Workshops in educational institutions.

For operations such as forming holes, creating threads and machining parts, it is better to buy a desktop metal milling machine. It is easy to use and, due to the presence of various cutters, allows you to perform a wide range of works. The result is quite accurate, since the design of the tool is very rigid (provided that it is correctly mounted).

Desktop CNC metal milling machines have a high level of productivity, which makes it possible to use this type of equipment for manufacturing products in small batch batches. Despite the significant efficiency factor and a wide range of functional capabilities, the tool consumes a small amount of electrical energy. In addition, the design has a compact size, making it easy to install in a workshop with limited free space.

The advantages of tabletop designs over standard models:

• light weight and compact dimensions;
• simple operation system;
• mobility;

• low noise level;
• affordable cost.

Note! The size of the workpiece to be processed cannot exceed the width of the table.

Specificity of CNC turning-milling machines for metal

On sale you can find turning equipment for a home workshop, which is capable of providing a full cycle of work to manufacture the required part.

Turning and milling machines for metal are divided according to the accuracy class into the following categories:

• normal accuracy;
• increased quality;
• high processing precision.

Using a drawing for the manufacture of a certain part, it is necessary to indicate all tolerances for linear dimensions, as well as the degree of processing purity. Desktop tool options are virtually indistinguishable from full-size machine tools.

The most common types of metal cutters for a milling machine of this type:

• disk;
• end;
• cylindrical;
• end;
• shaped.

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For certain operations, the appropriate cutting attachment is selected. CNC turning and milling machines are not capable of processing workpieces that are bodies of revolution. If shaped and flat surfaces are used in the work, you will have to move the part in the required direction in relation to the cutting tool. The milling cutter itself is capable of performing exclusively rotational movements.

Features of CNC machines for metal: milling and engraving tools

Milling and engraving equipment has many advantages when compared to standard metalworking tools. Thanks to numerical control, the processing of parts is very precise and accurate. This advantage is especially beneficial in cases where the metal part has a complex configuration, because it is extremely difficult to achieve the same quality on a manual milling machine.

Most often, such equipment is used in enterprises engaged in individual and small-scale production of products. The tool's capabilities will come in handy in industries such as jewelry, furniture manufacturing and souvenir making. The assortment of the metalworking equipment market allows you to choose a milling cutter with the necessary characteristics for cutting sheet metal and applying inscriptions on products.

Why is it profitable to buy a CNC milling and engraving machine:

1. Simple service system.
2. Extensive functionality.
3. High quality metal processing.
4. Reliability and durability.
5. High efficiency factor.

By the type of construction, the following types of milling cutters are distinguished:

• automatic designs, complete with a head with three spindles and a pneumatic clamp;
• desktop milling cutters with mechanical clamping of the workpiece;
• automatic designs with pneumatic clamping of the workpiece.

Note! Milling work on CNC machines has reduced the number of defective products in production to almost zero.

Characteristics of mini milling machines for metal

Mini-models intended for home workshops differ from industrial-type stationary structures in technical characteristics. The power level of such a tool usually does not exceed 400 W. This is enough to carry out high-quality processing of parts made of soft metals or to create products in small batches. If it is necessary to process workpieces made of steel or cast iron, the power of the tool must exceed 600 W.

The dimensions of the table top also differ. The maximum dimensions of the table with which the compact milling machines are equipped is 65x25 cm, the minimum size is 35x15 cm.The parameters are selected taking into account the details that will be processed.

The rotational speed of the spindle determines the level of productivity of the router, as well as its ability to work with certain materials. The harder the metal from which the workpiece is made, the lower the rotational speed should be. Higher parameters are used for soft alloys and aluminum.

Metal milling machine: manufacturing technology

Vertical structures are the easiest to manufacture. It will take a hand drill to assemble, a little time and effort. To work, you will need inexpensive and affordable parts. In addition, a homemade milling cutter can be endowed with additional functions and also turn it into a turning tool.

To make a homemade metal milling machine with your own hands, you need the following materials and tools:

• channel;
• metal pipe with a square section;
• welding machine;
• diamond-shaped car jack;
• metal corners;
• angle grinder;
• file;
• metal pins for making axles;
• drill;
• collet or drill chuck;
• thick plywood sheet;
• Morse taper 2.

DIY metal milling machine manufacturing technology

First, it is necessary to connect the column and the frame from a metal channel by welding. The result should be a U-shaped design. The lower cross member will act as a base for the machine. The guides for the vertical movement of the console are made of a corner. Previously, it must be sanded and attached to the column using bolted connections.

A diamond-shaped car jack will be used to enable the console to move vertically. The distance in this case will be 10 cm. To create the guides, you will need to insert pins with screwed threads into a metal pipe with a square cross section. As a result, the tabletop will be able to move back and forth within a segment equal to 9 cm, and the lateral amplitude will be 13 cm.

Helpful advice! Before assembling a home-made structure, it does not hurt to get acquainted with the principle of operation and the device of the factory equipment, study the drawings and carefully prepare the parts necessary for work.

The table top is made of plywood sheet. For fixing, screws are used, the heads of which must be recessed. After that, you need to install a vice on the tabletop. They can be homemade: the structure is welded from a pipe with a square profile and a metal corner, through them it is necessary to pass a threaded pin. Self-tapping screws can be used as fasteners to fix the vice on the tabletop.

Next, a drill is fixed in the bed. This is done so that the spindle eventually points down. The fixation is carried out using the screw connection method. For this, you must first weld special jumpers. Then a Morse taper 2 is attached to the spindle, followed by installation of a collet or drill chuck on it.

On the resulting homemade machine, you can process workpieces made of soft metals, such as aluminum or bronze. In this case, the arm moves during work, while the router remains stationary.The structure can be made in another way, so that the workpiece is fixed, and the router with the carriage moves. This requires an elevator.

How to make an elevator for a homemade metal milling machine

By means of a lever or a crank, the lift will move smoothly along the router. At the same time, there is no direct contact between the master and the equipment. For this reason, it is advisable to accurately calculate in advance all the dimensions of the grooves to be formed and quickly change the cutters.

Elevator manufacturing technology:

1. A plate is cut from a piece of PCB and fixed on the tabletop. It will be used as a support.
2. Two posts are attached to the base plate. Be sure to make sure that they are parallel to each other.
3. The stands will be used to move the carriage on which the router is mounted. The movement will be provided by a pushing mechanism.

Note! The structure of the elevator must be stable and rigid. In the presence of even the slightest backlash, the processing operation may be disrupted and a defect on the part may appear.

The efficiency of processing metal parts is influenced not only by the quality of the machine, but also by the coordinate table on which the workpiece is fixed. It is presented in the form of a flat slab and can have from 1 to 3 degrees of freedom. If it is intended to machine flat parts, it is sufficient that the table moves horizontally. Working with bulky products also requires vertical movement. The same goes for constructions in which drill fixed motionlessly.

How to create a coordinate table with your own hands: selection of materials and components

The structure of the XY table can be moved by electricity, mechanics or CNC. You can take aluminum, steel or cast iron as the material for making the base. The choice depends on the weight of the workpieces that will be processed on the machine. The base of the aluminum frame is assembled and fixed by means of threaded connections. The result is a simple and lightweight design that is affordable.

Cast iron structures are made of cast iron. They turn out to be very heavy, but they allow to carry out large production volumes. The cast structure is installed permanently on the foundation.

It is better to make the bed from metal using a welding machine. In this case, it is very important to reduce the weld stress of the material by releasing. Otherwise, the high rotational speed of the equipment will cause cracking. The table can be gantry (for flat products) or cross (for three-sided processing of bulk workpieces).

When making a coordinate table, special attention must be paid to the correct choice of guides, as well as the method of their fastening. For work, elements of a cylindrical or rail type are usually used. They have the possibility of a carriage superstructure and have already installed bearing units.

When choosing guides, you should also consider the type of drive. If the work requires high precision, it is better to give preference to sleeve bearings. Rolling bearings are suitable to reduce friction, but they will create play.

Taking into account the technical features of the carriage, two types of guides can be distinguished:

1. With an oversized flange - the element is attached to the bottom of the table.
2. Flangeless - fixed in the usual way through threaded holes.

For a homemade table, a ball screw (6-12 microns), a rack-and-pinion (up to 10 microns) or belt drive (50-100 microns) can be used. Each of these systems has both advantages and disadvantages, so the choice depends on the type of work that will be performed on the machine.To increase the service life of all driving mechanisms, it is advisable to timely clean the assembly elements from debris and dust, as well as lubricate them.

In general, making a home router and a table for it is very simple. The main thing here is to take into account the working conditions and comply with safety requirements. All mechanisms present in the structure must correspond to each other in terms of parameters: service life, load, cooling and heating time. If these indicators coincide, the tool will give good results in the process. This requirement is of particular importance if home workshop equipment is self-made.