CNC milling is one of the most versatile machining operations. It helps create flat surfaces, complex internal geometries, and slots. Typically, these operations require straight cuts. But what if your geometry requires beveled edges or angled surfaces? Can milling handle this? Yes, angular milling is a specialized technique for these geometries. This article explains everything about angular milling, including the process steps, types of angle milling cutters, best practices, and applications.
How does angular milling differ from flat milling?
Angular milling is a milling technique that cuts material at a specific angle (other than 90°) to create angular features such as beveled edges, chamfers, or inclined surfaces. Conventional or standard milling uses a cylindrical cutter with teeth located on the cutter’s periphery, milling a horizontal plane parallel to the cutter axis. The milling process essentially removes material from the workpiece surface, creating a smooth line. In contrast, angular milling requires the workpiece or cutter to be tilted at an angle, or the cutter to have beveled teeth to remove material along the slope. Sometimes, the feed path can be curved, depending on the requirements. This is essentially how it achieves precise angles and shapes from the original workpiece.
Angle Milling Workflow
Angle cutting is a precision machining process that requires careful planning and execution. Here’s the basic process:
- Workpiece Setup: The first step is setting up the workpiece. Based on the specific requirements, the engineer will need to determine if the desired geometry can be achieved by tilting the workpiece. If so, the workpiece is clamped in a vise at an angle. An angle block or fixture can be used to ensure precise angle alignment.
- Tool Selection: If you need chamfers or bevel grooves, you may need a specialized bevel milling cutter. Single-angle milling cutters are best for chamfers, while double-angle milling cutters are suitable for bevel grooves and grooves. You can choose a carbide milling cutter or a high-speed steel milling cutter, depending on the material being cut.
- Setting Up the Machine and Cutting Parameters: In some cases, machine tools feature a tilting cutting head that can be adjusted to the desired angle. Other cutting parameters, such as speed, feed rate, and depth of cut, are set based on the material being machined. It’s recommended to start with conservative speeds and feeds to avoid tool deformation or overheating.
- Inspection: After cutting, inspection is required using an angle indicator or other gaging available in the machine shop. For applications requiring tighter tolerances and higher precision, a coordinate measuring machine (CMM) is more effective.
Advantages and Disadvantages of Angular Milling
Angular milling is a unique process with many advantages. However, like any process, it has limitations.
- Advantages: By combining angled tool positioning with controlled machining paths, tight tolerances (±0.1° or better) can be achieved. Unlike manual grinding or secondary machining, it offers the same accuracy as conventional milling, but for angled features. Furthermore, by adjusting the tool or workpiece angle, this method unlocks complex geometries such as bevels, chamfers, dovetails, and V-grooves, which are cumbersome or impossible to achieve with standard milling. Parts with beveled edges or chamfered holes can be created in a single setup, eliminating the need for post-machining grinding or finishing. Because precise cutting and machining are accomplished in a single operation, material scrap is significantly reduced.
- Disadvantages: Bevel cutting increases tool engagement and friction, accelerating wear. Furthermore, aligning workpieces or tools at different angles requires specialized fixtures (such as sine bars and angle plates), meticulous measurements, and skilled labor, all of which complicate matters and increase costs.
Types of Angled Milling Cutters
Milling cutters come in different shapes (various angles), each suited to specific applications. There are two main types of angled milling cutters: single-angle and double-angle.
- Single-angle milling cutters: Single-angle milling cutters are characterized by a tapered or beveled face with cutting teeth. They are typically manufactured with single right and left angles of 45° and 60°. Most often, they are used for dovetailing, chamfering, or beveling along the sides or edges of a workpiece.
- Double-angle milling cutters: Double-angle milling cutters have two symmetrical beveled faces, each with cutting teeth, allowing them to create V-grooves or slots in a single pass. These cutters are available in standard configurations of 45°, 60°, and 90°. They can create grooves and dovetails in a single pass, whereas single-angle cutters require multiple passes to create symmetrical slots.
What materials can be cut at an angle?
Angle milling processes are suitable for most common industrial metals, but specific process parameters vary depending on the material’s characteristics. Therefore, you must adapt and adjust them for each material.
Metal Materials Suitable for Milling
- Aluminum Alloys
- Stainless Steel
- Mild Steel
- Tool Steel
- Brass
- Copper Alloys
- Titanium Alloys
- Magnesium Alloys
Plastic Materials Suitable for Milling
- PC
- ABS
- PA
- PMMA
- POM
- PEEK
- HDPE
- PVC
Best Applications for Angle Milling
Grooving or chamfering may seem like simple tasks, but angle milling cutters play a key role in complex and high-precision applications across various industries.The table below illustrates key applications for angle milling.
- Aerospace Industry: Milling processes enable the manufacture of durable, lightweight aerospace parts from materials such as aluminum and titanium.
- Automotive Industry: Products manufactured for the automotive industry must be efficient and precise. Therefore, CNC milling is suitable for producing interior panels, driveshafts, cylinder heads, transmissions, exhaust components, suspension parts, and more.
- Medical Industry: Medical and surgical tools often feature unique designs that require high precision. Therefore, CNC milling is one of the best methods for manufacturing these components. This approach improves efficiency and productivity while maintaining precision.
- Consumer Products: CNC milling operations also facilitate the production of common components such as nuts and bolts, gears and shafts, flanges, and more. This process is suitable for both short-run and large-scale production.
How Can Xtproto Help?
If your product design requires precise angle cuts to achieve the final shape, Xtproto’s CNC milling services can make your vision a reality. Our CNC milling services support both prototyping and mass production, offering precision machining with tolerances up to 0.008mm. Whether you need angle milling for complex bevels, flat milling for flat surfaces, or face milling for smooth surfaces, we ensure precision and consistency every time. Our experienced team of engineers and advanced 3- to 5-axis CNC milling machines can easily handle even the most complex angular geometries. From aerospace components to automotive parts, you can trust Xtproto with its expertise and cutting-edge technology to get your milling tasks done. So upload your design here and get an accurate quote for your milling project today!