CNC Glossary

3-Axis Milling – Milling is the machining process of using rotary cutters to remove material from a piece of metal, wood, foam or plastic, to form the piece into a specific shape. 3-Axis Milling is employed when the cutting requires simultaneous controlled movement of the X, Y and Z axes. Although still used in some milling facilities today, it is the least advanced of the three main axis millings available on commercial markets.

3-Axis VS 4 & 5-Axis Milling

Like 3-Axis milling, 4 & 5-Axis milling machines move along axes. In 4-Axis milling, the machine moves along the X, Y and Z axes but also adds rotation of the X axis called the A-Axis. Rotation of the A-Axis involves moving the piece being worked on whereas in 3-Axis milling the piece remains stationary. Allowing for movement of the piece reduces the number of time employees have to adjust the piece in order to provide the same cuts. 

5-Axis milling as you might have guessed uses 5 axes to create necessary cuts. 5-Axis utilizes the X, Y, Z axes and adds movement along the A and B axes. When moving along the A and B axes, the piece stays stationary and the base the piece is connected to rotates to allow for even more precise cuts. 5-Axis milling greatly improves on 3 and 4-Axis milling and is what we are best at. For any components that other companies would consider "impossible" to make, Owens takes on the challenge using the newest 5-Axis machines with experienced employees who can complete any job. 

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4 Axis Milling—This cutting includes the above axes plus 1 rotary axis movement. There are two possibilities - 4 axis simultaneous interpolation (also known as true 4th axis) or just 4th axis positioning, where the 4th axis can reposition the part between 3 axis operations, but does not actually move during the machining. It is one of the most popular milling options because it allows for more detailed cutting than 3 axis. But, in recent years, its capabilities were passed by the more advanced 5 axis milling.

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5 Axis Milling – During cutting, 3 Axis milling plus 2 rotary axis movements allow a CNC machine to move a tool on 5 different axes. The cutting tool has the ability to move across the X, Y, and Z axes, but rotates on A and B axes as well, allowing the machine to approach a workpiece from every direction possible. With the proper tools attached, 5 axis milling can cut tedious designs in steel, aluminum, granite, and even marble. Often times used with a CAM/CAD system package, this type of milling allows for the most intricate cutting possibilities in modern times.

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Automatic Wire Feed – The automatic wire feed of a Wire EDM machine is responsible for feeding in the extremely fine wire used in cutting. Because the wire is so fine, the automatic wire feeder must apply the perfect amount of torque and pressure to keep a constant feed without breaking the wire.

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CNC Machining – CNC is an acronym for Computer Numerical Control, which refers to the use of a computer to control and monitor the movements of a machine. CNC machines can have several axes of movement, and these movements can be either linear or rotary.

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CNC Prototyping - CNC prototyping is used to create the first model of a component part as a test for design, build quality, and functionality before full production. Prototypes are typically made from aluminum or alloys. Developing a prototype is recommended to anyone planning to mass-produce components or produce components of high value. Industries that benefit most from CNC prototypes are those that require advanced precision parts such as the aerospace industry.

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CNC Turning – CNC turning is a catch-all term for the various forms of CNC lathe work we perform. Depending on the job being done and the machine being used, turning could mean:

• Pinch Turning – The process of using two independent tool turrets on a CNC lathe. Pinch turning allows for faster cuts, and can be used to perform rough turning and finish turning in the same pass.
• Contour Turning – The process of turning a smooth continuous curve on the machine. Contour turning requires specialized bits, and an experienced technician to produce a perfect curve.
• Follow Turning – Any turning process utilizing two independent tool turrets on the lathe. Pinch turning is a form of follow turning. Not all CNC shops can perform detailed follow turning.
• Horizontal Turning – Any CNC lathe which rotates horizontally.
• Vertical Turning – Any CNC lathe which rotates vertically.

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Contour Milling/Profiling – Contour milling produces a continuous curve of various degrees. Contour milling requires extensive knowledge of complex programs and machinery to produce ultra-precise tolerances and angles. Incredibly intricate industrial components and even works of art can be milled from massive blanks using contour milling.

What is Contour Milling used for?

Contour milling is used to machine flat or irregular surfaces. Contour milling is often required to cut details into component parts that most other CNC machines couldn’t achieve. Some of the most popular reasons this machining method is used are to drill, create slots & holes or cut gears into metals or alloys.

Owens Industries has some of the most advanced contour milling machines. We’re able to manufacture detailed parts for almost any application, regardless of the industry. We’ve been able to use our advanced contour milling capabilities to manufacture components for aerospace, medical, military/ defense and many other industries.

Contour Milling at Owens Industries

We pride ourselves on our fast and efficient contour milling services. Countour milling requires the use of advanced technology such as High-Speed Cutting (HSC) and 5-Axis machining to ensure a controlled cut for an accurate product. We use contour milling to create complex parts for a variety of industries, including:

• Aircraft
• Aerospace
• Military
• Medical 
• Optical
• Tool & Die
• Pharmaceutical
• Food Manufacturing
• Oil & Gas

Contour Milling & Other Services

In addition to offering contour milling services, Owens specializes in many other CNC machining processes. Any of or precision milling processes can be used to create complex parts that can then be contour milled on to accomplish complicated jobs that take the utmost care and accuracy. See some of our other CNC machining services that can be used in addition with contour milling to provide your company with the exact part specifications needed:

Owens Industries produces contour-milled components with precision cuts and tight tolerances in our dust-free and temperature-controlled facility. Contour milling is perfect for applications with irregular surfaces requiring complex geometrical cuts and high cutting speeds. Contour milling is a great way to produce parts with curves, concave, convex or any unusual shapes from metals, including:

• Aluminum
• Brass
• Bronze
• Copper
• Steel
• Rhenium
• Molybdenum
• Titanium
• And more!!

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Deburring – A finishing method used in industrial settings and manufacturing environments. Many processes in order to create pieces of specific shape and size, and it may be welded, molded, cast, trimmed, slit or sheared. These procedures often create ragged edges or protrusions. The raised particles and shavings that appear when metal blanks are machined are referred to as burrs, and the process by which they are removed is known as deburring. 

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Dielectric fluid – Dielectric fluid can be anything from oil to de-ionized water, and limits electric discharges. When used for Wire EDM, dielectric helps cool the work piece, limit the spread of excess electrical discharge, and wash away any material that’s been cut off.

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Electrical discharge machining (EDM), sometimes referred to as spark machining, spark eroding, burning, die sinking, wire burning or wire erosion, is a manufacturing process whereby a desired shape is obtained using electrical discharges (sparks). EDM can cut small or odd-shaped angles, intricate contours or cavities in pre-hardened steel.

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Electrodes vary greatly depending on the job being performed. Every EDM job has two electrodes, the first being the workpiece which must be a conductive metal. The second being the thin wire of the EDM machine. This electrode can be hollow for small hole EDM, contain multiple chambers for RAM EDM, or solid wire for standard EDM. Most electrodes are made of brass or copper. Brass electrodes should not be used when cutting tungsten, carbide, or exotic materials. 

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Flush cups are essential for Wire EDM equipment. The flush cup is a small plastic nozzle placed roughly 0.004” from the top of the part. This nozzle enables more accurate cutting, and helps to force dielectric fluid between the electrode and the work piece.

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Machine shop is a room or a company where machining is done. In a machine shop, machinists use machine tools and cutting tools to make parts, usually of metal or plastic (but occasionally of other materials such as glass, wood, stone, etc.).

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Medical machining is as simple as it sounds: CNC machining services for medical parts manufacturing. Primarily used for medical devices, implants, and surgical components, medical machining can range from the use of one, or a combination, of the following:

• 3-,4-, and 5-axis milling
• Wire EDM
• Sinker EDM
• Lathe/Turning

Owens Industries, like many other Machine Shops in the U.S., specializes in medical machining. However, our machines, controlled facility, and industry leading CNC programmers set Owens apart from others offering similar services. We are dedicated to high quality, precision results that can improve lives across the globe. Every piece of our process adheres to strict standards allowing us to meet your needs exactly.

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Micromachining – When the milling is done by an action other than that of a sharp-edged tool, like with an electron beam or lasers. This process is used to make tiny features in parts - measured in micrometers or millimeters. The work is completed via pulsed lasers, depositing very small, finite amounts of energy into a material, resulting in extremely precise and reproducible material removal.

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The tightest tolerances possible, micron tolerance is the epitome of accuracy. While many projects require accuracies as tight as 1/25^th the thickness of a human hair, some project require accuracies as tight as a few microns! Micron tolerances are achieved through a process called micromachining, and require the care of an experienced technician.

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The ability to consistently and continuously produce components with ultra-tight tolerances. Repeatability is critical when reproducing replacement parts.

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Sinker EDM, also called “Ram” EDM or “Plunge” EDM, consists of an electrode and workpiece submerged in an insulating liquid such as oil or, less frequently, other dielectric fluids. The electrode and workpiece are connected to a suitable power supply. Relying on spark erosion, this process relies on pressure to form indentations over time.

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Similar to RAM EDM, small hole EDM uses a hollow electrode to pump high pressure dielectric fluid to remove eroded particles. Small hole EDM behaves like a drill, it even rotates, but spark erosion allows for ultra-tight tolerances. A relatively stress free process, small hole EDM is simple at heart, but requires extensive knowledge of complex equipment.

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Spark Erosion – Essential to Wire EDM, spark erosion is the process of removing material from a work piece with a series of rapidly recurring current charges between two electrodes. The first electrode is the ultra-thin wire, and the second is any electrically conductive material. Spark erosion allows for ultra-tight tolerances, up to 1/25^th the thickness of a human hair.  

More information about Electric Discharge Machining >>

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A special lathe design, Swiss Lathes are made specifically to provide precision accuracy down to a few micrometers. Swiss Lathes hold the work piece on the Z axis using a collet and guide bushing. The tools sit at the Z axis, and the workpiece moves. This is different from many lathes where the tool moves and the work piece stays stationary.

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High Precision” in traditional machining refers to tolerances of microns in the single-digits. Ultraprecision Machining, using the cutting power of diamonds, is capable of producing such accuracy that the tolerances can reach “sub-micron” level with the use of tiny machine parts known as “Nano tools.”

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A non-traditional machining process that uses electricity to cut any conductive material precisely and accurately with a thin, electrically charged copper or brass wire as an electrode. When the wire gets close to the part, the attraction of electrical charges creates a controlled spark, melting and vaporizing microscopic particles of material. The process happens quickly, with hundreds of thousands of sparks per second, but the wire never touches the workpiece, so the result is a part with an excellent surface finish and no burrs regardless of how large or small the cut.

More information about Wire Electric Discharge Machining (EDM

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