Machinist Tools in Machining: The Must-Have List for Beginners

No machining job can be perfect without the use of proper machining tools. Even a single type of tool can have a lot of variants based on differences in materials and geometries. In order to get precise machining results, the selection of machining tools need to be perfect. In this topic we will be discussing about different types of machinist tools for different conditions. New CNC machinists will hopefully consider this blog particularly useful.

Machinist Tools in CNC Machining

Machinist tools are instruments used for measuring, setup, cutting, holding, and inspection in a machining process. Machinist tools are an integral part of a machine shop. Machinist tools help a CNC machinist to achieve a high level of precision with smoothness in machining operations.

Daily Routine of A Machinist List

Machinist tools are classified according to the stages of CNC machines. Some machining tools are required before machining for setup and alignment. Others are required during machining for cutting, measuring and holding. Finally, some tools are required for inspection and surface finishing. Here is a machinist tools list that every machining shop should have:

Manual vs CNC Shop Needs

There a bit difference between the machining tools need for manual machining vs a CNC shop. A CNC machining shop has a very high level of automation. Apart from the initial setup, almost all other processes are done automatically. On the other hand, a manual machining shop relies heavily on the skills of the machinist. As a result, a CNC machinist emphasizes on precision fixturing, automated tool changers and digital measurement systems. While a manual machining shop machinist requires a lot of setup, alignment and machining tools.

Machinist Tool Types Explained

By Function

Common functions and their respective tools in a basic machining process includes:

1. Measuring Tools: micrometers, calipers, height gauges
2. Setup Tools:edge finders, dial indicators, parallels
3. Cutting Tools: end mills, drills, inserts, reamers
4. Holding Tools: vises, chucks, collets, clamps
5. Inspection Tools: CMMs, surface plates, gauge blocks

By Machine and Operation

A basic machining process has operations like turning, milling, drilling and boring. Here is a machine shop tools list based on specific operations:

1. Lathe Tools: turning inserts, parting blades, tool posts
2. Milling Tools: face mills, ball end mills, fly cutters
3. Drilling Tools:twist drills, boring bars, reamers
4. CNC - specific: tool holders (CAT, BT, HSK), tool presetters

By Precision Class

As machining processes differ in precision, the need for tools precision differ as well. Higher precision tools with a precision of 0.01mm are commonly used for fine machining or high end applications like aerospace parts. Low precision tools with a precision of 0.10mm suffices general machining operations.

By Level of Automation

Machining tools list according to level of automation is presented here

1. Manual Tools:hand micrometers, mechanical dials, analog indicators
2. Semi-Automatic Tools: digital readouts, height gauges
3. Fully Automated Tools: CNC tool changers, laser tool setters, robotic measurement arms

Measuring and Layout Tools Before Machining

Positioning, alignment and scribing are the foundation stones for precise machining. For a good CNC machinist, 6 tools should top his/her machine shop tools list. These machinist tools are very pertinent in the daily routine of setting up the feedstocks. These precise measuring tools are discussed here:

1.Calipers Measuring

Vernier calipers are sort of quick handy tool for a CNC machining. These are used for pre-machining checks and for comparing dimensions. For measuring outer dimensions, close the jaws of the caliper against the object. The main scale shows the reading with 0.1mm precision. Find the lines of the vernier scale and the main scale that coincide. Add the reading of coinciding vernier scale line with the main scale reading. It has a least count of +0.1mm. A quick reading can be taken for outer dimensions, inner dimension and depths.

Digital vs Dial Calipers

Calipers come in digital or dial versions. The digital display gives an instantaneous reading on the screen. There is no chance of a parallel error and the reading remains accurate. Battery limits its use. On the other hand dial calipers do not require a battery. Dial calipers can be used in condition that are not conducive for digital screens and batteries.

2.Micrometers Measuring

Similar to calipers for measuring dimensions, micrometers are more precise measuring tools. They have a least count of ±0.01 mm.

How to Use Micrometers

Micrometer comes in variants for inside, outside and depth measurements. The basic principle of measurement is the same: Close the spindle gently against the part using the ratchet or friction thimble. Add the main scale reading with the thimble scale reading.

Ratchet vs Friction Thimble in Tools

Rachet thimble gives a more gentle and repeatable results. But it takes a slightly longer time in adjustment. Comparatively, friction thimble is quicker but results may vary depending on the pressure applied. Friction thimble is recommended for experienced users.

3.Various Indicators

Dial Indicators vs Test Indicators

Dial indicators and test indicators are used to measure small deviations in alignment or runout. Dial indicators check for variation in axial movement of the stylus. It is commonly used to check spindle alignment, parallelism, or part flatness. Test indicators also follow the same basic principle of measurement as with dial indicators. In contrast to axial movement, test indicators detect variations in angular movement. Test indicators are used to check concentricity or squareness. The below video gives an insight about test indicators and drop indicators:

4.Height Gauges and Surface Plates

Surface plate is flat base for layout working. Surface plate acts as a primary reference plane. Height gauges are used measure and mark dimensions from the plate surface. When used in conjunction, height gauges and surface plates are used for height referencing.

5.Layout and Marking Tools

Edge and Center Finders

Edge and center finders are used for precise alignment of workpieces in machining setups. Check out this video to get a quick overview of edge finder:

6.Workholding and Fixturing for Setup

Milling Vises and Soft Jaws

Milling vises are used to hold workpieces firmly for milling. For delicate parts like plastics, soft jaws to prevent damage to the workpiece.

Other Tools for Setup

Clamps, parallels, V-blocks, angle plates, and magnetic bases are some other tools for workholding and fixturing for setup.

Toolholding and Setup Accessories

A robust and vibration free toolholding setup is essential for obtaining precise machining. There are different machinist tools and supplies for this setup. Each one has its own strengths based on factors like changeover time, robustness, precision, cost etc. Here is a quick demonstration of some common machinist tools for toolholding:

1.Collet Systems

Collet system is one of the most common toolholding device in a machinist tools list. Collet is a slotted cylindrical sleeve that fits into a collet chuck or spindle nose. It can hold round shank tools concentrically. Major advantages of collet systems for machining tools are reduced Vibration, high concentricity and quick changeover.

2.Tapered Holders

Precision machined taper forms a connection between the machine spindle and the cutting tool. In comparison to chucks they can handle larger diameter tools. The tapered shank fits into the spindle. A good alignment of taper ensures precise machining.

3.Chucks and Arbors

Chuck is a very common machinist tool for toolholding. It comes in many types. As an example, a 3-jaw chuck opens and closes with a single bolt while maintaining concentricity. It is useful for equiaxial shapes. On the other hand, in a 4 jaw chuck the jaws can be closed independently. So, it is useful in manufacturing eccentric shapes like cam shafts.

4.Presetters and Touch Probes

Tool presetters and touch probes bring automation and precision into the setup phase. These are used to measure tool length, diameter, and offsets before loading machine shop tools into the machine. These are widely used in CNC machining shops to maintain precision and repeatability.

Cutting Tools for Mills and Lathes

Cutting tool is the most functional tool in machinist tools list that effect the actual machining. The characteristics like material, geometry and sharpness have great influence on machining. CNC machinists consider factors like hardness of material, speed and machine capabilities while selecting a cutting tool.

1.End Mills and Face Mills

Cutting tools for end milling and face milling comes in three common designs namely 2F, 3F and 4F. ‘F’ stands for flute. As the number of flutes increase space for chip evacuation decrease. But, higher number of flutes give a better surface finish. For softer metals like Aluminium, 2F an 3F are preferred. While 4F is used for harder metals like stainless steels.

Carbide vs HSS vs Cobalt

A CNC machinist also needs to select the material of a cutting tool. Here is a comparison of three common materials:

2.Turning Tooling and Inserts

Turning tools are most commonly made up of HSS material for general purposes. A more advanced approach it for use inserts of hard materials for longer tool live and faster speeds. Common inserts materials are CBN, ceramics or coated metals. Inserts are place in an applicable tool holder that suffices the cutting angles.

3.Drills, Reamers, and Countersinks

Drilling, reamering and countersinking are done in a sequential manner for high end machining. Chip evacuation and coolant delivery are important in drilling so flute design is important. New approach is to use carbide tools for reamering and countersinking due to enhanced tool life.

4.Threading Tools and Taps

Threading tools have specific thread profiles as per relevant standards. Custom thread profiles with customized depth can pitch can be made in a CNC machine.

Digital Tools for Computer Numerical Control Machining

Digital tools like CAD and CAM are foundation of CNC machining. A fool proof CAD design ensures precise and accurate CNC machining. With the help of modern CAD and CAM software, nearly any level of complexity in manufacturing can be achieved.

CAD Software

CAD stands for Computer Aided Design. Specialized CAD software like Fusion 360, SolidWorks and AutoCAD help designers to create complex designs. The designs can be validated in FEA software to make them fool proof.

CAM Software

CAM software aids in translating the CAD into CNC machine’s language. CAM creates G Codes and M codes that act as instruction for the CNC machine. Almost all other steps are done automatically.

Other Digital Tools for Beginners

Inspection and Calibration After Basic Machining

In order to ensure compliance with quality standards, the QC team inspect articles after machining. Inspection helps to identify issue like machine setup errors and tool wear. Feedback is given to the production team. If any improvement is required machines are recalibrated.

Key Inspection Tools List

Tips for Beginners About Inspecting CNC Machined Parts

1. Always reference the drawing
2. Clean both part and tools
3. Use the right tool for the right tolerance
4. Calibrate frequently
5. Record results at intervals

In Deburring and Surface Finishing Process

After completion of the machining job, parts often need surface finishing. Deburring reduces sharp burrs and improves dimensional accuracy. Surface finishing processes enhance aesthetics and service life of the machined parts.

1.Hand Deburring Tools

Common examples of hand deburring tools include Rotary scrapers, deburring blades, files, and abrasive pads. These machinist tools are used for small features like holes or fillets.

2.Lapping Tools

Lapping tools like lapping plates, compounds, and films improve smoothness of the finished parts.

3.Coolants, Lubricants, and Cleaners

Cleaners clean off the coolants and lubricants that stick onto the surface.

What Is Tool Wear in CNC?

Tool wear is the change in sharpness and dimensions of a tool during service. It happens due to friction, heat and mechanical stress. Tool wear affects the machining process in a detrimental way. Proper machining parameters and the correct tool material helps in extending tool life.

Factors Affecting Tool Wear

1. Too high cutting speed
2. Too high feed rate
3. Improper coolant use
4. Hard or abrasive work material
5. Tool material or geometry
6. Built-up edge (BUE)

How to Identify and Reduce Tool Wear to Improve Quality

Look for visual signs such as dull edges, burn marks, or vibration to identify tool wear. Surface finish deterioration and increased cutting noise is also an indication of tool wear. Correct machining parameter, correct tool material and correct tool geometry prevents tool wear.

TUOFA CNC Machining Shop: Precision and Accuracy

I am Andy, the founder of TOUFA. TOUFA CNC Machining Shop provides a one stop solution for all your machining needs. Here at TOUFA I personally take care that our CNC machinists are equipped with the correct machinist tools for each machining process. We understand that only the correct machinist tools can bring about the required accuracy and precision. If you have any projects requiring custom CNC processing, or any questions, please feel free to contact us. We'd be happy to assist you.

Conclusion

In every machining shop there are a lot of machinist tools for every machining operation. Be it tool holding or cutting, only the correct machinist tools can bring about precision. The skills of a CNC machinist also have an impact on the machining process. The correct settings of machining parameters reduce tool wear for a smooth machining.

FAQs

What tools does a new machinist need first?

Calipers, micrometers, edge finders and deburring tools are must for a beginner.

Which collet system should I start with?

My suggestion is to start with ER collet system.

How often should measuring tools be calibrated?

If operating conditions are not harsh, calibration after 12 months is sufficient.

What is the mother of all machine tools?

Lathe is considered are the mother of all machine tools.