CNC Machining Copper: Process, Pros, Cons, Grades & Applications

Copper is a commonly used material that plays a vital role in various industries for its excellent thermal and electrical conductivity. There are various applications of CNC machined copper components. If you are here to learn about CNC machining copper, this guide below features a detailed analysis so let's read.

What is CNC Machining Copper?

CNC machines are known for their excellent working mechanisms and they offer seamless machining applications with different types of materials. Copper machining also is known for its excellent component manufacturing which is equipped with accuracy, speed, and precision.

Copper machining was a challenge before the CNC machining techniques were discovered, however, now machining copper material for manufacturing different components has become much easier. CNC machining is an automated process where the CNC machines are programmed to work according to the given instructions by the software, the cutting tool of the machine makes movements to subtract the material from the workpiece. CNC machining can achieve the desired shapes and cuts on copper workpieces with tight tolerances and a high degree of flexibility.

CNC Machining Copper Process

The three most commonly opted processes for CNC machining copper are as follows:

CNC Milling

CNC milling is equipped with cutting tools which help in carving the copper out of the workpiece. The cutting tools in CNC milling rotate and offer an excellent precision which makes the process suitable for complex and detailed copper components.

CNC Turning

The process of CNC turning copper parts is the rotation of the copper workpiece relative to the fixed tool. The process of CNC turning is used mostly for machining cylindrical components. CNC turning is a versatile and efficient form of machining and is ideal for external as well as internal cutting of the workpiece.

CNC Drilling

CNC drilling helps create holes in the copper workpiece, it is mostly used for machining copper parts that require bolting or fastening. In the process of CNC drilling, the workpiece remains stationary whereas the drilling tool rotates.

Pros and Cons of Using Copper for CNC Machined Parts

CNC copper parts come with various benefits and some of these are as follows:

Corrosion Resistant: Copper offers corrosion resistance and hence suits applications where harsh environmental conditions prevail.

Complex Shapes: Copper is soft and very easy to work with, hence achieving different sizes and shapes during the CNC machining process is easy and it doesn't even crack.

Low Cost: It is much cheaper than other metals and even offers high machinability.

Non-magnetic: Multiple applications need non-magnetic metals and machined copper offers this property making it suitable for defense and military applications.

Antimicrobial Properties: Alloys of copper are well known for their antibacterial properties and therefore are suitable for medical equipment and tools.

Eco-friendly and Recyclable: Copper is environment friendly and recyclable which means it doesn't harm the environment while machined.

Apart from the countless benefits, there are some drawbacks of machined copper too which are as follows:

• Copper is a toxic element and multiple applications that are equipped with ingestion may not find copper a usable material like utensils.
• Copper alloys may have a shorter span of life as they oxidize at high temperatures.
• The alternates of copper are more affordable than copper and may suit some of its applications.
• Copper is a heavy material and may not be suitable for applications like overhead wiring.

Various Grades of Copper are Used in CNC Machining

There are different grades of copper to opt for CNC machining depending on the application requirements. Some of these copper grades are as follows:

Pure Copper

Pure copper is the purest form of copper with about 0.7% of other elements. It is highly malleable and very soft, therefore is used in precise electronic components. In pure copper, some other elements are added to change the mechanical property it has. However, the pure copper grades usually range between C10100 to C13000.

Free-Machining Copper

Free-machining copper is known for its seamless machinability and hence is used in various applications after being machined through the CNC machining process. The copper metal in this grade comprises telluride and sulfur to make copper alloys. These are usually opted for manufacturing welding torches and tips or electrical components. C14700 and C14500 are the grades of copper alloys in this type of copper.

Electrolytic Copper

Electrolytic copper is created through a process of electrolysis. Electrolytic copper is a high-grade pure copper which offers 100 percent electrical conductivity. It works well with hot as well as cold working processes. The electrolytic copper comprises grade C11000 and is used in weddings, wires, cables, and bus bars.

Oxygen-Free Copper

In oxygen-free copper, there is 99.99% purity, copper is heated until its melting point is achieved to remove oxygen. It is one of the purest forms of copper and comprises minimal impurities. The copper grades for the oxygen-free copper are C10100 and C10200. This grade of copper is suitable for machining parts that need corrosion resistance and high electrical conductivity.

Surface Finishing for Copper CNC Machined Parts

• Bead Blasting
• Electroplating
• Electropolishing

Applications of Copper CNC Machining

CNC copper parts are very commonly used in multiple applications and some of these are as follows:

Construction

Copper offers an aesthetic appearance and hence offers suitability in the construction industry. Copper can be used for roofing, gutters, rainwater downspouts, and wall cladding due to its aesthetic look and durability. Copper pipes are also very commonly used in heating systems as they offer corrosion resistance.

Electronics

Copper offers high electrical conductivity and hence is a suitable material for the electronics industry. It is used for electrical wiring and also used in electrical components, generators, and transformers. The PCBs of various devices also are manufactured using CNC-machined copper.

Automotive

The automobile industry makes multiple components for its vehicles using CNC-machined copper. Since copper offers seamless electrical conductivity copper parts like radiators and coolers are manufactured. Moreover, electric motors are also manufactured using copper material. CNC machining helps achieve complex copper components used in vehicles.

Coin Industry

Copper is used widely in many coins from the past many years. Copper offers high malleability and durability which allows manufacturers to stamp the coins easily. Also due to its antimicrobial and corrosion resistance properties, it even suits the circulation purpose.

What are the Factors to Consider When Machining Copper?

There are multiple factors that must be kept in mind when manufacturing CNC machined copper parts and these are as follows:

Consider the Grade of Copper

Every copper grade has different mechanical properties and based on the application requirement, the right grade is important to select. In this case, factors like strength, machinability, and conductivity are important to consider.

Consider the Properties of Copper

Efficient machining is attained when the design is optimized based on the properties of copper, therefore it is essential to optimize the design so that the machining process and copper grade offer compatibility.

Set the Correct Feed Rate

To achieve the desired design and finishing of the final copper component, the speed and precision are required to be balanced, and hence it is important to set the accurate feed rate so that tool wear is minimized.

Choose the Right Tool Material

Tool material for CNC machining copper needs to be chosen based on the characteristics of the selected copper grade to ensure precision.

Conclusion

Selecting CNC machining of copper components proves to be a very suitable process as it is equipped with accuracy and precision which most copper components need. The guide above must have made you learn all the essential aspects of CNC machining copper which are important for designing copper components for different applications.

CNC Machining Copper Service at DEK

If you are looking for a manufacturer that can help you design and produce custom copper parts for your application, you can contact DEK. We'll provide you with high-precision, aesthetically pleasing, durable and cost-effective copper parts. So, get your quote today!

FAQs

Is Copper Easy to Machine?

Machining pure copper can be challenging, however, the alloys of copper are not as hard, and due to the addition of other elements they become more machinable.

How to Choose Tools for Machining Copper?

When selecting tools for copper machining it is suggested to go for carbide-tipped tools as they offer precision and durability. The tools chosen must have high thermal conductivity so that heat dissipation is effective. Also, tools that are equipped with sharp cutting edges help to achieve a smooth surface finish of the component.

What Is the Best Copper for CNC Machining?

Copper 101 is equipped with high conductivity as it offers high purity. However, copper 110 offers high machinability and ensures cost-effectiveness.