CNC is a cutting-edge technology that has revolutionized the manufacturing sector. Many manufacturers use various CNC cutting operations to create accurate and high-quality components. CNC machining is fast, gives room for production scalability, and results in fewer human errors.
Furthermore, a key benefit of CNC precision machining is the ability to cut both soft and hard materials. However, many often wonder about the thickness limit of CNC machines. If you are one of the many people then this article is for you. Continue reading to understand the types of different metal CNC cutting machines and the thickness level they can handle.
What is CNC Cutting?
CNC cutting encompasses many operations that use programming languages to control the movement of tools and machinery. It is automated and can accomplish accurate and complex cutting tasks. CNC cutting starts with the creation of the 2D or 3D representation of the final part. You do this using CAD software such as AutoCAD and SOLIDWORKS.
Thereafter, the CAD model is converted to a CNC-compatible format in the form of G-code and M-code. G-code tells the cutting tools how to move to carry out specific operations. On the other hand, M-code is for miscellaneous functions like start and stop actions, spindle control, and tool changes. After the codes have been written, you then set up the machine and run the operation.
Factors Affecting Metal Thickness Cutting
Several factors affect the metal thickness level a CNC machine can cut. Some include;
Machine Capabilities
Some machine parameters such as spindle power, torque, and speed affect how thick it can cut. The spindle power determines how much material is removed in a minute. This implies that a machine with a higher spindle power can cut through thicker workpieces and vice versa. Furthermore, a higher torque and faster cutting speed allow for more precise cuts in heavier parts.
Tooling
The tooling type also plays a role. Most CNC cutting tools are made using high-speed steel or carbide. Carbide CNC cutters are capable of cutting thicker materials up to 2 inches. On the other hand, high-speed steel can go as far as 1 inch. Furthermore, the tool length and shape are important factors. Longer tools with linear shapes will create deeper cuts.
Material Type
The type and composition of the material you are working with are also important factors. When cutting harder and denser materials like steel and titanium, the thickness level is usually limited. Going above it can lead to tool breakage and damage. However, for softer metals such as aluminum, you can get deeper cuts in a single pass.
Coolant System
Coolants also affect the thickness level a CNC machine can cut. There are different types of CNC coolants suitable for various materials. Coolants reduce heat and prevent friction between the tool and the workpiece. Furthermore, they help to flush away chips and reduce build-up. Hence, a good cooling system enables the cutting of thicker materials and increases productivity.
Maintenance and Machine Condition
The state of the machine and the cutting tools affect how well they function. Though the machine has innate capabilities, this can decline rapidly with time if not properly maintained. Additionally, wear and damage to the cutting tool will reduce the thickness level it can handle. Furthermore, tool wear generates heat and reduces the effect of the cooling system.
Operator Skill and Training
The metal thickness a skilled operator can handle is considerably different from that of a novice. The operator should be familiar with programming and the use of software. An experienced operator can adapt to different material thicknesses and adjust the cutting parameters to get the best results.
Common CNC Cutting Machines and Their Thickness Limitations
There are many types of CNC cutting machines available. They operate using different principles and have unique thickness limitations. Let’s look at the most common CNC-cutting machines available
CNC Laser Cutters
CNC laser cutters use a highly focused beam of light directed through an optical head to cut through a material. Laser cutting is a non contact process that melts and vaporizes a workpiece to create a clean and accurate cut. The thickness limit of a CNC laser cutter differs and depends on the power of the machine and the type of material. A 3000W laser cutting machine can work on up to 20mm and 10mm of carbon steel and stainless steel respectively. On the other hand, a 500W machine can handle a maximum of 6mm stainless steel and 3mm carbon steel.
CNC Plasma Cutters
This machine uses a deionized gas heated above 20,000 degrees Celsius to create an arc between the electrode and the workpiece. The heat from the arc melts the workpiece and leaves a sharp and high-quality cut. Based on the power of the laser cutter, this machine can cut between 20 mm to 150mm thick steel plate. Going beyond this thickness limit will increase the susceptibility of workpiece damage and distortion.
CNC Wire Electrical Discharge Machining (EDM)
CNC wire EDM involves submerging the workpiece in a dielectric fluid and cutting it with an electrically conductive thin wire. The wire serves as the cathode while the workpiece is the anode. When they get in close contact, an electric discharge occurs and melts the material to create the desired shape. CNC wire EDM is accurate and leaves no burrs or imperfections. Based on the size of the electrode, a CNC wire EDM can cut between 100 mm to 400 mm metal stock.
CNC Waterjet Cutter
A CNC waterjet cutter is an advanced machine that cuts a metal part with a high-velocity jet of water. For softer materials such as plastic or wood, water is used alone. However, it is recommended to mix abrasive materials such as garnet and aluminum oxide into the water when cutting metals. In normal conditions, CNC water jets can cut through 250 mm to 25 cm of most materials accurately. CNC waterjet cutters generate less heat. Furthermore, it is environmentally friendly because you can easily recycle and reuse the water.
CNC Oxy-Fuel Cutter
As the name implies, CNC Oxy-fuel cutters use a combination of oxygen and fuel to cut metal parts. The fuel is usually combustible gasses like acetylene or propane. The CNC technology controls the movement of the touch that contains the mixture of oxygen and fuel. As the touch gets near the workpiece, a high-temperature flame melts it to give a sharp cut. Based on the workpiece properties, a CNC oxy-fuel cutter can handle metal thicknesses between 0.5mm to 250mm.
CNC Punch Press
A CNC punch press is a machine that creates holes by forcing a punch die through a workpiece. This machine is fast and is suitable for high-volume production. After executing the program, the punching tool moves along the X and Y axes over the metal part and cuts holes. CNC punch press is mainly used for sheet metal fabrication. You can use it for thickness ranging from 0.5 mm to 6.0 mm depending on the metal in question.
Techniques for Cutting Thicker Metals
The thickness level that CNC machines can cut is usually a range. When dealing with very thick metals, use the following techniques to get the best results
Using Multiple Passes
Multiple passes will allow you to cut thicker materials. It involves moving the cutting tool from one end to another to refine the cut surface. However, multiple passes may increase the size of the heat-affected zone and the tendency of error occurrence. It also increases machining time and the overall cost of production when using a third-party CNC metal-cutting service.
Adjusting Machine Settings and Parameters
You can also modify the machine settings and optimize cutting parameters to handle thicker metals. Adjust the spindle speed and increase the cutting depth when cutting thick workpieces. Additionally, consider increasing the feed rate and using a higher power to get a good result. However, don’t go beyond the level specified by the manufacturer to avoid burning through the part.
Using Additional Support or Fixtures
Jigs and fixtures indirectly affect the metal thickness a CNC machine can handle. Fixtures securely hold the workpiece and provide stability while jigs guide the movement of the cutting tool. With jigs, the tools cut deeper in one pass. Furthermore, they prevent unnecessary vibrations and elongate the life span of the tool. The tools are sharp, accurately aligned, and can handle thicker workpieces.
Conclusion
CNC machining is an advanced manufacturing process that can cut through both thick and thin materials. However, some factors such as the type of CNC machine, workpiece material, machine specifications, and condition of the cutting tools affect how thick one can cut.
This article has explained the thickness limit of the various CNC machines and tips you can employ when cutting thicker materials. How thick of a metal can a CNC machine cut? What are the techniques for cutting thicker materials? We hope this article has answered all your questions.
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