In the world of precision CNC machining, the materials and tools used in the production process play a key role in achieving optimal results. From mild steel and stainless steel to aluminium – choosing the right raw material and tools is the foundation for the quality, durability and functionality of the final products.
In this article, we will walk you through the variety of materials and tools used in CNC machining, with particular emphasis on popular steel grades and the applications of aluminium.
Types of steel used in CNC machining
Mild steel: S235 and S355 in the spotlight
Mild steel is often the material of choice in CNC machining due to its mechanical properties and economic efficiency. Grades S235 and S355 are especially valued for their versatility – from machine construction to structural components. The choice is driven not only by an attractive price, but also by ease of machining, which translates into a wide range of applications.
Mild steel, also known as carbon steel, contains carbon as the main alloying element, which determines its properties. One interesting fact is that the amount of carbon in steel has a strong influence on its hardness, strength and also its susceptibility to corrosion. Steel with a low carbon content (below 0.3%) is soft and ductile, whereas steels with higher carbon content (up to around 2%) are much harder but also more brittle. Another interesting point is that mild steel is magnetic, which makes it useful in many specialised applications, such as components for electric motors or transformers.
Stainless steel: Durability and corrosion resistance
Stainless steel is chosen wherever high corrosion resistance and durability are required. Thanks to its unique properties, it is used to manufacture machine parts and components in the food and medical industries, among others. Stainless steel is somewhat more difficult to machine than mild steel, which means it requires the use of specialised CNC tools – key to maintaining its properties.
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Galvanised steel: Protection against corrosion
Galvanised steel, thanks to its zinc coating, provides additional protection against corrosion, which is invaluable in many outdoor applications and high-humidity environments. It is often used in structures that must offer long-term resistance to weather conditions.
Aluminium: Light and strong
Aluminium is valued in CNC machining for its low weight combined with high strength, which makes it ideal for aerospace, automotive and modern design applications. CNC machining of aluminium allows the creation of complex shapes and precise components that are impossible to achieve with many other materials.
Aluminium is a metal with exceptionally low density and high corrosion resistance, thanks to a thin but very durable aluminium oxide layer that forms on its surface. One fascinating fact is that aluminium is the third most abundant element in the Earth’s crust and the most common metal. Despite its abundance, it was isolated in pure form relatively late – in the 19th century – due to the difficulty of separating it from other elements. Today aluminium is a key material in the aerospace, automotive and construction industries due to its low weight, strength and corrosion resistance.
CNC tools: Precision in every detail
Choosing the right tools is just as important as selecting the material. High-quality milling cutters, drills and cutting tools are essential for efficient and precise machining of selected materials. CNC technology requires tools capable of working with very high accuracy and matched to the specifications and hardness of the workpiece.
Laser cutting machines
Laser cutting machines use a concentrated beam of light to cut materials with exceptional precision. The key to optimal operation lies in the correct laser parameters such as power and wavelength, which must be matched to the thickness and type of material being cut. Thanks to the ability to program precise patterns, laser cutters are ideal for complex projects that require accuracy.
Tools:
Focusing lenses: different focal lengths for cutting materials of different thicknesses.
Cutting nozzles: different nozzle diameters for different pressures and types of assist gas.
Tool selection:
The choice of focusing lens depends on the material thickness; thinner materials require lenses with a shorter focal length for precise cutting.
The choice of nozzle and gas (e.g. oxygen, nitrogen, air) depends on the material; stainless steels are often cut with nitrogen to achieve clean, oxide-free edges.
Laser cutting machines are devices that use a concentrated beam of light to cut a variety of materials, including metals, plastics and fabrics. The fascinating part is that laser cutting accuracy can reach tolerances in the range of tenths of a millimetre, which makes this method indispensable in precision machining. The laser can be programmed to perform complex patterns and fine details, making it ideal for producing complex components such as aircraft parts, microprocessors or jewellery.
Plasma cutting machines
Plasma cutting machines, used to cut electrically conductive materials such as steel and aluminium, use a hot plasma jet to rapidly cut through metal. Choosing the correct nozzle type and plasma pressure settings is crucial for obtaining a clean cut and minimising the heat-affected zone in the material.
Tools:
Plasma electrodes and nozzles: specific to the type and power of the cutting system.
Shield caps: protect nozzles and electrodes from damage.
Tool selection:
The choice of electrode and nozzle depends on plasma power and type of cutting. High power is used for thick materials and requires more robust electrodes.
Shield caps are selected according to cutting conditions to ensure optimum protection and cut quality.
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Guillotine shears
Guillotine shears are used to cut sheet metal and require high-quality blades designed for a specific material type and thickness. Regular maintenance and sharpening of blades are essential to ensure smooth and precise cuts every time.
Tools:
Guillotine blades: different blade profiles for different materials and thicknesses.
Tool selection:
Blades are selected based on the material and required cutting precision. Harder blades are used for harder materials.
Regular maintenance and sharpening ensure consistently high cut quality.
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Press brakes
Press brakes used for bending sheet metal require the right dies and punches to form the material into the desired shapes. The choice of tools depends on the type and thickness of the sheet, as well as the bending angle. Accurate tool selection ensures consistent bend quality and prevents material damage.
Tools:
Dies and punches: different shapes and sizes for different angles and bending radii.
Tool selection:
Choosing the right combination of dies and punches is crucial for accurate bending. Material type, sheet thickness and bending angle must be taken into account.
Soft materials such as aluminium require different tools than steel to avoid damage.
Press brakes are machines used to bend sheet metal. One interesting fact is that modern press brakes are equipped with advanced CNC systems that allow sheet metal to be bent with very high accuracy. Thanks to CNC technology, the operator can program the press to perform a series of complex bends, which minimises the risk of errors and increases production efficiency. In addition, some press brakes are equipped with crowning systems that automatically adjust the bending force to ensure uniform quality along the entire length of the bent part.
Lathes
CNC lathes require specialised turning tools that must be selected according to the material and type of operation, such as turning, threading or drilling. High-quality carbide or ceramic tools ensure longer tool life and allow machining at higher speeds.
Tools:
Turning tools: carbide, HSS and ceramic tools for different turning operations.
Toolholders: ensure stability and precision of cutting.
Tool selection:
The choice of tool depends on the machined material and type of turning (boring, threading, etc.). Carbide tools are preferred for hard materials.
Toolholders must be properly matched to the machine and tool to ensure maximum precision.
Milling machines
CNC milling machines use a wide range of milling tools, including end mills, cylindrical mills, angle mills and forming cutters. The choice of milling tool depends on the type of machining (e.g. slotting, profiling) and the material. Coated cutters (e.g. with titanium-based coatings) offer better performance and durability when machining hard materials.
Tools:
Mills: end, cylindrical, angle, form and modular cutters with various coatings (e.g. TiN, AlTiN).
Milling toolholders: precision, hydraulic and mechanical holders.
Tool selection:
The choice of milling cutter depends on the material and type of operation. Coatings increase tool life and performance.
Toolholders must ensure stable clamping, which is crucial for machining quality.
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Plate rolling machines
Plate rolling machines are used for bending and forming sheet metal into cylindrical or conical shapes. The key here is the use of appropriate rolls adapted to the width, thickness and type of material being processed. Precise settings and regular maintenance are essential to ensure uniform bend quality and avoid material deformation.
Tools:
Rolls: for cold and hot rolling, matched to the dimensions and shapes being formed.
Tool selection:
The choice of rolls depends on the type of bending (cylindrical, conical) and the material. Rolls must be precisely matched to material thickness and type to ensure consistent bending results.
CNC plate rolling machines are advanced systems used to form metal sheets by gradually bending them between rolls. An interesting fact is that these machines use numerical control to precisely adjust the distance between rolls, which allows the required curvature or shape of the sheet to be achieved. Thanks to CNC, plate rollers can automatically adapt to different thicknesses and material types, making them extremely flexible in production. What’s more, modern CNC rolling machines can be equipped with additional functions such as cutting and perforation, enabling complete sheet metal processing in a single work cycle. This makes them a key element of production equipment in the automotive, shipbuilding and household appliance industries.
Optimising production processes through the choice of tools and materials
In the era of advanced manufacturing technologies, where precision, efficiency and innovation are the key drivers of success, CNC technology is setting new standards in material processing. A crucial aspect in achieving optimal utilisation of CNC machines is an informed and precise selection of tools and materials – not only compatible with a given machine type, but also tailored to specific design and production requirements.
A strategic approach to material selection
Material choice has a fundamental impact on the entire production process. Steels such as S235 and S355, thanks to their strength and ductility, are widely used in applications ranging from light structures to advanced engineering projects. Stainless and galvanised steels, offering excellent corrosion resistance, are used where high durability and aesthetics are required, while aluminium, due to its low weight and resistance, is preferred in the automotive and aerospace industries. Understanding the properties of each of these materials allows for their effective use, maximising the durability and functionality of finished products.
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Tool selection tailored to CNC machines
Success in CNC machining also depends on the precise selection of tools that must match the machine specification and the material being processed. Laser and plasma cutters, guillotine shears, press brakes, lathes, milling machines and plate rollers – each of these machines requires specific tools to ensure precision, efficiency and machining quality. From focusing lenses and plasma electrodes and nozzles to dies, punches and milling cutters – accurate selection of these items enables production processes to be optimised, waste reduced and productivity increased.
Tools for press brakes – such as dies and punches – are crucial for the bending process because they are the elements that give the workpiece its final shape. One fascinating fact is that there is a wide range of specialised tools designed for different types of bending, including air bending, radius bending and step bending. Interestingly, the materials used to manufacture these tools must be extremely durable to withstand the enormous forces involved in bending, which is why they are often made from high-speed steel or carbide. An innovation in this field is the use of nanotechnology-based coatings that can significantly increase tool life and reduce friction, enabling faster and more efficient production.
Integration of materials and tools in CNC processes
Effective use of CNC technology requires integrating material knowledge with expertise in cutting tools. Understanding how a material behaves when processed by different methods makes it possible to adapt the process to get the maximum potential out of the machine. Cooperation between designers, engineers and machine operators is essential for continuous improvement and innovation in production.
Conclusions for industry
CNC technology is the driving force of modern industry, enabling the implementation of advanced projects with unmatched precision. Optimal selection of materials and tools tailored to design specifications and production requirements is key to maximising production efficiency and quality.
Investing in knowledge and development in CNC technology allows companies not only to achieve their production goals, but also to remain competitive in a rapidly changing market environment. As this technology evolves, the importance of informed selection and integration of materials and tools grows as well – opening up new opportunities for innovation and continuous improvement of production processes.