Flowell Corporation

Computer Numerical Control (CNC) machining has revolutionized manufacturing processes across a wide range of industries, from aerospace to oil and gas. The flexibility and precision that CNC machines offer make them ideal for crafting complex parts from an array of materials. Each material, however, presents its own set of challenges and benefits, making it essential to choose the right material for your specific application.

Metals Machined with CNC

Aluminum

Aluminum is one of the most commonly machined metals in CNC processes. Its lightweight properties, strength, and excellent machinability make it ideal for applications in the automotive, aerospace, and electronics industries. Aluminum is easy to cut, meaning CNC machines can work at higher speeds and reduce tool wear, translating into cost-effective production.

Common Aluminum Grades for CNC Machining:

• 6061: Known for its versatility and corrosion resistance, 6061 is used in structural applications.
• 7075: One of the strongest aluminum alloys, 7075 is typically used in aerospace parts where strength is a top priority.

Aluminum’s ability to be anodized after machining adds aesthetic and protective finishes, further expanding its usability in various industries.

Steel

Steel is another widely used CNC material, offering high strength and durability. There are many types of steel, each suited for different industrial applications.

Common Steel Types for CNC Machining:

• Mild Steel: Known for its machinability, mild steel is popular in many industries, including automotive and construction.
• Stainless Steel: This alloyed steel contains chromium, providing excellent corrosion resistance and strength. It’s commonly used in medical devices, kitchen appliances, and marine applications.
• Tool Steel: As the name suggests, tool steel is used to make cutting and shaping tools. It offers high heat resistance and hardness.

Steel is often chosen for its durability and ability to withstand high-stress environments. However, it can be challenging to machine, requiring more time and more robust cutting tools than softer metals like aluminum.

Brass

Brass is a softer metal, making it highly machinable and ideal for CNC applications that require intricate designs and fine details. Brass is widely used in electrical components, plumbing fittings, and precision instruments due to its excellent corrosion resistance and electrical conductivity.

One of the standout features of brass is its ease of machining. It does not dull cutting tools as quickly as harder metals do, making it a cost-efficient option for parts that require high precision.

Titanium

Titanium is known for its strength-to-weight ratio, corrosion resistance, and ability to withstand extreme temperatures, making it ideal for aerospace, medical devices, and military applications. However, machining titanium can be more challenging than machining metals like aluminum and steel. Titanium tends to work-harden, requiring specialized CNC tooling and cooling systems to ensure high-quality cuts.

Despite these challenges, titanium’s durability and long-term performance make it a top-tier material for applications that demand the highest level of reliability and strength.

Plastics Machined with CNC

Acrylic (PMMA)

Acrylic, also known as PMMA, is a transparent plastic often used as a lightweight and shatter-resistant alternative to glass. It is highly machinable and is commonly used in the production of display cases, lenses, and lighting components. Acrylic offers excellent optical clarity and can be easily polished to achieve a smooth, glass-like finish.

One advantage of machining acrylic with CNC machines is that, unlike some other plastics, it can be cut quickly and efficiently without the risk of breaking or cracking.

Delrin (Acetal)

Delrin, or acetal, is a strong, rigid plastic known for its low friction and excellent machinability. It’s often used in parts that require high stiffness and low wear, such as gears, bushings, and bearings. CNC machining Delrin produces clean, precise cuts with minimal tool wear, making it a popular choice for precision components.

Delrin’s low moisture absorption and resistance to chemicals also make it an excellent choice for outdoor and industrial applications.

Nylon

Nylon is a tough, versatile plastic that offers excellent mechanical properties, including high tensile strength, chemical resistance, and fatigue resistance. It’s often used in the production of gears, automotive components, and conveyor belts.

One challenge with CNC machining nylon is its tendency to absorb moisture, which can cause dimensional changes over time. However, by controlling the environmental conditions and using the right machining techniques, nylon can produce high-quality parts for a wide range of applications.

Polycarbonate

Polycarbonate is a strong, impact-resistant plastic that is widely used in applications where durability and transparency are required, such as protective equipment, machine guards, and automotive lighting. Like acrylic, polycarbonate is easy to machine but offers greater impact resistance, making it ideal for high-stress environments.

Composite Materials Machined with CNC

Carbon Fiber

Carbon fiber composites are known for their exceptional strength-to-weight ratio, making them ideal for aerospace, automotive, and sporting goods applications. CNC machining carbon fiber requires specialized tools, as the material is highly abrasive and can wear down traditional cutting tools quickly.

While challenging to machine, carbon fiber offers superior performance in terms of strength, weight, and rigidity, making it well worth the effort for high-performance applications.

Fiberglass

Fiberglass is a composite material made of glass fibers embedded in a resin matrix. It’s commonly used in applications such as boat hulls, automotive parts, and electrical enclosures. CNC machining fiberglass requires special care, as the material can fray or crack under improper cutting conditions. However, fiberglass can be precision-machined for various industrial uses with the right tooling and techniques.

Machining Exotic Alloys

Inconel

Inconel is a nickel-chromium-based superalloy that is highly resistant to extreme temperatures, corrosion, and oxidation. It’s commonly used in aerospace, chemical processing, and oil and gas industries. CNC machining Inconel is notoriously difficult due to its toughness and tendency to work-harden, requiring special cutting tools and techniques.

Despite its challenges, Inconel’s ability to withstand harsh environments makes it indispensable for critical applications in industries that demand reliability under extreme conditions.

Hastelloy

Hastelloy is another superalloy known for its corrosion resistance and ability to perform under extreme conditions, especially in chemical processing and nuclear industries. It’s difficult to machine like Inconel, but its highly corrosive performance makes it a necessary material for certain specialized applications.

Choosing the Right CNC Material for Your Project

Selecting the right CNC material depends on your specific application, desired performance characteristics, and cost considerations. Metals like aluminum and steel are great for durability and strength, while plastics like Delrin and nylon offer lightweight, cost-effective alternatives. Exotic alloys like Inconel and Hastelloy are vital for extreme environments but require specialized knowledge to machine effectively.

No matter the material you choose, working with an experienced CNC machining partner is crucial to ensuring high-quality, precision-manufactured parts that meet your requirements. Each material has its quirks, and understanding those intricacies can make or break a project.

Contact Us Today

At Flowell Corporation, we specialize in CNC machining for the oil and gas industry and beyond. With over three decades of experience and a team of skilled professionals, we are your go-to source for custom machining and flow measurement products. Based in Tulsa, OK, we offer top-notch services and high-quality products tailored to meet the unique needs of your project.

Whether you’re working with standard metals or exotic alloys, trust Flowell to always deliver excellence. Contact us today to learn more about our services and how we can assist with your CNC machining needs.