Metal CNC machine tools provide high-precision and high-efficiency solutions for processing various metal parts. It is a crucial equipment in modern manufacturing industry. However, there are a wide variety of CNC machine tools in the market with significant CNC machine price differences. For enterprises with different budgets, how to choose the best machine tool that suits their needs has become a key issue.
This article will introduce you to some of the best metal CNC machine tools suitable for various budgets, helping you achieve greater success in the manufacturing industry.
What is a metal CNC machine?
Metal CNC machine tools are specially designed for the production of precise and complex components. They are capable of performing a range of operations, including but not limited to milling, turning, drilling, and cutting, which are crucial for material processing.
When we talk about Computer Numerical Control (CNC) machine tools, we are essentially discussing a highly automated and precise machining tool. These machine tools rely on pre-programmed software to guide their operations and can perform various advanced machining tasks, ranging from three-axis to six-axis configurations.
Compared to traditional manual or semi-automatic machine tools, metal CNC machine tools offer a higher degree of automation and precision. Due to this high level of accuracy and automation, metal CNC machine tools demonstrate exceptional efficiency and accuracy in manufacturing components and finished products.
What are the basic components of metal CNC machine?
Here are the main components of a CNC metal machine:
1.Bed
The bed is the foundational structure of the machine tool, typically constructed from cast iron or welded steel, providing stability and rigidity to the entire machine. It accommodates other components such as the worktable, spindle, and guideways.
2.Spindle
The spindle is the core component responsible for rotational motion to provide cutting power. Usually made from high-strength alloy steel or other special alloys, the spindle is driven by an electric motor. The spindle’s speed and direction can be precisely controlled by the CNC system.
3.Guideway system
The guideway system includes the machine’s guides and guide seats, supporting and guiding the movement of the cutting tool or workpiece. Common types of guideways include rolling guideways, linear guideways, and sliding guideways, chosen based on the machine’s application and performance requirements.
4.Tool changer
The tool changer is an automated system designed to store and interchange cutting tools. It can hold multiple tools and, following instructions from the CNC system, automatically select and replace different types of tools during the machining process, enhancing production efficiency.
5.CNC system
The CNC system serves as the intelligent brain of the CNC metal machine tool, controlling the machine’s movements, speeds, tool changes, and other operations. It typically consists of a controller, programming unit, and input devices such as a keyboard and mouse. It interprets commands from CNC machine operators or computer-aided design (CAD) software, translating them into executable machine actions.
6.Worktable
The worktable is a platform that supports and secures the workpiece, capable of moving along different axes to allow cutting tools to perform various operations on the workpiece surface. The worktable often includes clamping devices to ensure the stability of the workpiece during processing.
7.Coolant system
Metal machining generates high temperatures, and the coolant system is employed to cool cutting tools and workpieces, preventing overheating and extending tool life. Coolant systems typically use cutting fluid or coolant for cooling and lubrication.
8.Fixtures and clamping systems
Fixtures and clamping systems are used to hold and secure workpieces, ensuring they remain stationary and free from deformation during machining. Different machining tasks may require various types of fixtures and clamping systems.
These components work in tandem, enabling CNC metal machine tools to efficiently and precisely accomplish various metal processing tasks.
Metal CNC machine types
The realm of metal CNC machines is vast and diverse, with each type offering specific benefits and limitations. The most commonly encountered categories of these precision tools are as follows:
- CNC milling machines
- CNC turning machines
- CNC lathes
- CNC routers & engravers
- CNC grinders
- CNC-powered plasma cutters
- CNC water jet cutters
- CNC-integrated honing machines
- CNC-controlled electrostatic discharge machines
When it comes to numerical control machine tools, milling machines exhibit the utmost flexibility in applications. Their versatility spans a wide range of operations, from basic drilling and boring to intricate gear cutting and even the construction of complex structures. The precision and versatility of milling machines make them a cornerstone in many manufacturing processes.
Related: Drilling vs. Boring vs. Reaming: Its Process, and Application Difference
CNC lathes, on the other hand, excel in fabricating cylindrical components by rotating the workpiece around an axis. Beyond cylindrical shaping, these machines also perform additional operations such as drilling, tapping, and reaming with unmatched precision. CNC lathes are indispensable in industries requiring cylindrical parts with tight tolerances.
Known as routers, these machines employ a rotating cutter to eliminate unwanted material from the workpiece. Routers are adept at engraving intricate patterns and designs into various materials, including wood, plastic, and metal. The precision and finesse of CNC routers enable them to create intricate works with impeccable detail.
Moreover, this diverse group of machines encompasses numerous subcategories, including waterjet cutters, plasma cutters, and electrical discharge machines (EDMs). Waterjet cutters utilize a high-pressure stream of water to slice through thick materials with minimal heat distortion. Plasma cutters harness the power of an ionized gas to precisely cut through conductive metals. EDMs, on the other hand, employ electrical discharges to remove metal from a workpiece, making them ideal for machining hard and conductive materials.
The applications of these subcategories are diverse, ranging from cutting thick materials to molding complex designs. Their precision and capabilities have revolutionized the manufacturing industry, enabling faster and more efficient production of components and parts.
How does a metal CNC machine work?
A metal CNC (Computer Numerical Control) machine works by using computerized controls to precisely automate and execute machining operations on metal workpieces. Here is a step-by-step overview of how a typical metal CNC machine operates:
Design and programming:
The process begins with the creation of a digital design using Computer-Aided Design (CAD) software. This design is then converted into a set of instructions, known as G-code, using Computer-Aided Manufacturing (CAM) software. The G-code contains information about toolpaths, speeds, feeds, and other parameters.
Loading material:
A metal workpiece is securely loaded onto the CNC machine’s worktable. The workpiece may be a raw metal block or a partially processed piece, depending on the specific requirements of the project.
Tool selection and setup:
The appropriate cutting tools, such as end mills, drills, or lathes, are selected based on the machining operations outlined in the G-code. The tools are then installed and secured in the CNC machine’s tool turret or spindle.
Related: CNC Lathe Cutting Tools Types, Uses, and Applications
Machine setup:
The CNC machine is set up by entering the G-code program into the machine’s control unit. This involves specifying the workpiece zero point, tool offsets, and other parameters necessary for accurate machining.
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Execution of g-code:
The CNC machine operator initiates the machining process, and the control unit interprets the G-code instructions to move the machine’s cutting tools along predetermined paths. The cutting tools remove material from the workpiece according to the specified design.
Automated precision machining:
The CNC machine precisely controls the movements of the cutting tools in multiple axes (X, Y, Z, and sometimes additional axes for advanced machines like 5-axis CNC). This automation ensures high accuracy and repeatability in the machining process.
Monitoring and quality control:
Throughout the machining operation, operators monitor the process, checking for any anomalies or deviations. Some CNC machines have automated measurement systems to verify the accuracy of the machined features.
Tool changes (if necessary):
If the G-code program requires different tools for various machining operations, the CNC machine can automatically change tools as needed, reducing downtime.
Completion and unloading:
Once the machining process is complete, the finished metal workpiece is carefully removed from the CNC machine. It may undergo additional post-processing steps, such as deburring or surface finishing, if required.
Repeatable and scalable production:
CNC machines are well-suited for repeatable and scalable production. The same G-code program can be used to produce identical parts, making them efficient for both prototyping and mass production.
How to choose a suitable metal CNC machine for oneself?
Choosing a suitable metal CNC machine tool requires considering multiple factors. Here are some key steps and considerations to help you make a decision:
1.Clarify processing requirements
Gain a deeper understanding of the types of metals that need to be processed, as different metal types have different requirements for cutting parameters and tools. For example, the cutting speed and depth required for processing aluminum and titanium are different.
Read this article to gain a detailed understanding of the differences between titanium and aluminum: Titanium vs Aluminum: Which Is the Best for Your Project?
Conduct a detailed analysis of the geometric shape, dimensional accuracy, and surface roughness requirements of the parts to ensure that the selected machine tool can meet these requirements.
Evaluate the mass production requirements of parts, as this will affect the production capacity of machine tools and the required auxiliary equipment (such as material handling systems).
2.Machine tool specifications and configuration
Select the appropriate bed size and workbench size according to the processing requirements, ensuring that it can accommodate the workpiece and allow sufficient cutting space.
Consider spindle power and speed to ensure ability to handle different cutting loads and material types. Meanwhile, select a suitable tool clamping system to ensure the stability and reliability of the tool.
Choose a compatible CNC system to ensure that the control system of the machine tool can meet machining requirements and has sufficient programming and functional options.
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3.Operation interface and software
Choosing a metal CNC machine tool with an intuitive and user-friendly operating interface can improve operator productivity and reduce operational errors. Consider whether CAM/CAD software packages are needed to program and simulate machining processes, and understand their compatibility with machine tools. In addition, ensure that the operating interface is easy to integrate and use to improve overall production efficiency.
4.Tools and consumables
Metal cutting experts believe that the efficiency of a $250000 CNC machine tool largely depends on the performance of a $30 end mill. It can be seen that equipping CNC machine tools with high-performance cutting tools. It is one of the key measures to reduce costs and achieve maximum comprehensive economic benefits.
Generally, sufficient cutting tools should be equipped for CNC machine tools to fully utilize their functions, so that the selected CNC machine tool can process multiple product varieties and prevent unnecessary idle and waste.
5.Supporting equipment and accessories
Select necessary fixtures, fixtures, and measuring equipment according to processing requirements to ensure accurate fixation of parts and accurate measurement after processing. These devices should be compatible with machine tools and improve overall machining efficiency. In addition, consider whether additional accessories such as protective covers, chip conveyors, etc. are needed to ensure safety and comply with environmental requirements
To fully utilize the function of CNC machine tools and enhance their processing capabilities, it is necessary to equip necessary accessories and tools. Do not purchase a machine tool that costs hundreds of thousands or millions of yuan and cannot function properly due to the lack of an accessory or tool that costs tens of yuan. When purchasing the main machine, purchase some vulnerable parts and other accessories together.
Recommended best metal CNC machine
The optimal choice of metal CNC machine tool depends on specific processing requirements, budget, and other specific requirements. Here are some suggestions, but please note that the best choice may vary depending on the specific situation:
| Brand | Machine Types | Price Range | Pros | Cons |
|---|---|---|---|---|
| Yamazaki Mazak | Lathes, Turning Centers, Milling Machines, Machining Centers (Horizontal and Vertical), Laser Cutters, Flexible Manufacturing Systems (FMS), CAD/CAM Programs, Control Systems | $50,000 – $1,000,000+ | – Leading in CNC machine industry – Diverse range of machines and equipment – High precision and automation | – Possibly higher prices depending on configuration |
| DMG MORI | Vertical Machining Centers, Horizontal Machining Centers, Three-Axis Machining Centers, Four-Axis Machining Centers, Five-Axis Machining Centers, Turning and Milling Compound Machining Centers, Ultrasonic/Laser Machining Centers | $100,000 – $2,000,000+ | – Combines the histories of DEMAGESEN and MORISEIKI, leading in technology – Wide product range, catering to high-end manufacturing needs – High precision and automation | – Possibly higher prices depending on configuration |
| Trumpf | Industrial Laser Machines and Systems | $100,000 – $2,000,000+ | – Pioneer in Germany’s Industry 4.0, leading in technology – Widely used in industrial laser cutting and processing fields – Strong market position and reputation | – Focuses primarily on industrial laser machines and systems |
| MAG | Machine Tools and Automation Systems | $100,000 – $2,000,000+ | – Conglomerate of world-class machine tool manufacturing and control system companies, offering customized machining solutions – Serving diverse needs in durable goods market | – Possibly higher prices depending on configuration |
| Hardinge | Metal Cutting Machine Tools and High-Precision Tools | $50,000 – $1,000,000+ | – Over a century of experience in manufacturing high-reliability metal cutting machine tools – High precision machining equipment, synonymous with the Hardinge brand | – Possibly higher prices depending on configuration |
| Haas | CNC Machine Tools | $20,000 – $500,000+ | – Founded in 1983, with a good brand reputation – Large production capacity, producing over 12,500 units annually – Relatively lower prices, suitable for small and medium-sized enterprises and startups | – May not be suitable for high-end, specialized machining needs, relatively lower brand recognition |
| Okuma | CNC Lathes, Turning Centers, Vertical, Horizontal, Gantry (Pentahedron), CNC Grinders | $50,000 – $1,000,000+ | – Nearly a century of machine tool manufacturing experience – Japan’s largest machine tool producer – High stiffness, great cutting efficiency, high precision, and long lifespan of products | – Possibly higher prices depending on configuration, mainly targeted at industrial manufacturing field |
Metal CNC machine manufacturer:
- Yamazaki mazak corporation (Japan)：Leading producer of CNC equipment since 1919, offering a wide range of machines including lathes, milling machines, and laser cutters.
- Trumpf (Germany)：Pioneer in industrial laser machines and systems since 1923, contributing to German Industry 4.0.
- MAG (USA)：Michigan-based conglomerate offering tailor-made machining solutions for the durable goods market.
- Hardinge (USA)：Established in 1890, renowned for high-reliability metal cutting machine tools and precision tools.
- Haas automation (USA)：Founded in 1983 by Gene Haas, known for its production base in California manufacturing a large number of CNC machine tools annually.
- Okuma (Japan)：Japan’s largest CNC machine tool producer since 1898, offering a wide range of CNC lathes, machining centers, and grinders known for their precision and efficiency.
- DMG Mori (Germany + Japan)：Joint venture between Demag (Germany) and Mori Seiki (Japan), known for precision machining centers and turning/milling compound centers.
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FAQ
CNC machines are programmed using G-code, a language that defines toolpaths and operations. Programmers use CAM (Computer-Aided Manufacturing) software to generate G-code based on the design specifications.
Maintenance frequency depends on usage and the specific machine. Regular checks on tool wear, lubrication, and calibration are common. Manufacturers usually provide maintenance schedules in the user manual.
Metal CNC machine tools have a wide range of applications and can be used for a variety of metal working tasks, providing highly precise and automated machining capabilities. Through the appropriate program and control, metal CNC machine tools can be milling, turning, drilling, cutting and other processing operations.
Tagged: CNC Machining Guide
This article was written by engineers from the BOYI team. Fuquan Chen is a professional engineer and technical expert with 20 years of experience in rapid prototyping, mold manufacturing, and plastic injection molding.
