CNC milling is a powerful tool for creating titanium parts, but it does have some limitations. Here's a breakdown of some key limitations to consider:

Design Complexity

l Extremely Tiny Features: As mentioned earlier, CNC milling might struggle with parts featuring very intricate details or micron-sized features. The cutting tool diameter itself has a minimum limit, and machining very tiny features becomes challenging.

l Sharp Internal Corners: CNC milling uses rotary cutting tools, making it difficult to achieve perfectly sharp internal corners on a titanium part. Rounded or slightly chamfered corners are generally more achievable.

l Undercuts and Non-Standard Features: Creating undercuts (features where the tool needs to access a recessed area) or holes with non-standard angles might require additional machining processes or specialized tooling, increasing complexity and cost.

Material Properties

l Work Hardening: Titanium has a tendency to work harden during machining. This means the material becomes stronger and more difficult to cut as the machining progresses. Special cutting techniques and tool path strategies are needed to mitigate this effect.

l Heat Generation and Tool Wear: The machining process generates heat, and titanium's high heat resistance can be a challenge. Excessive heat can lead to rapid tool wear and compromised surface finish on the titanium part. Coolant management and proper cutting parameters are crucial.

Other Limitations

l Production Speed: Compared to some high-volume manufacturing methods, CNC milling can be a slower process, particularly for complex titanium parts.

l Cost: CNC machining titanium generally incurs higher costs compared to machining softer metals due to the specialized tooling, slower machining speeds, and potentially more hands-on operator involvement.

Conclusion

CNC milling remains a valuable technique for creating high-precision and high-strength titanium parts. However, understanding its limitations regarding design complexity, material properties, and production speed allows you to make informed decisions. For parts with extreme features or high-volume production needs, alternative manufacturing methods might be better suited. Consulting with a qualified CNC machining service provider or a manufacturing engineer can help you determine the most appropriate approach for your specific titanium part requirements.