CNC Turning is a manufacturing process considered to be the backbone of modern industry. It is possible to produce accurate and fully round parts through computer control using the technology proposed. To accomplish that, CNC turning operates by the method of a rotating part. In parallel, a separate tool takes away from the material. A similar method is known as the subtractive manufacturing process. Making parts to high standards for many businesses is a process of making it widely.
This tutorial will reveal the whole wrapper of CNC turning. It will start with be the introduction and the machines used. Then, we will look at operations with the greatest importance. We will compare turning and milling and also provide design advice. We will discuss also the new trends. Furthermore, we will help you find the right service.
The Core Principle: How CNC Turning Works
If you divide it, it is much easier to learn how CNC turning works. CNC turning is primarily running on a machine known as the lathe or turning center. The machine is where the raw material is held and is rotated. The term used for this material is workpiece.
The machine’s principal components coordinate with each other. A chuck or collet is clasping the workpiece very firmly. The spindle spins the workpiece chuck at a significant rate. A turret has several cutting tools attached to it. Among the turret is where the tool automatically changes. A controller is a computer that gives the movement of the tool. It reads a set program.
The CNC turning procedure is clear-cut which is why it is easy to follow:
- Design & Programming: First, a 3D CAD model is made of the part by an engineer. CAD is an abbreviation for Computer-Aided Design. The model is then imported into CAM software. CAM is the acronym for Computer-Aided Manufacturing. The CAM program prints a set of directives called G-code. The CNC machine understands this code.
- Machine Setup: The workpiece is firmly installed in the machine’s chuck by a qualified worker. They insert the correct cutting tools into the turret. They ensure that everything is in the correct place.
- Execution: The machine operator initializes the program. The CNC controller interprets the G-code and begins the work. It adjusts the speed to the required level to rotate the workpiece.
- Material Removal: The cutting tool is introduced directly into the spinning workpiece. The tool moves in the direction of the part and across its end. It is careful in carving away material to make the workpiece match the design manually. The workpiece takes a specific form after each step.
Key CNC Turning Operations
One single turned part is commonly made by several different operations. Each of these operations can involve a specific tool and motion. It creates a certain feature. Combining these fundamental CNC operations can produce sophisticated 3D shapes.
The most frequent operations in CNC turning are as follows:
- Drehen: It is the most primary operation. A tool goes along the side of the workpiece. Thus removing its excessive outer width.
- Facing: A tool moving at the end of the workpiece. It makes flat and smooth surfaces. It also sets the part’s length.
- Grooving: The tool goes straight inside the workpiece. It makes a channel or void of specific width and depth. Necking or recessing is another term for this process.
- Parting: A special type of tool is used to cut the finished part from the larger bar of stock material.
- Bohren: The hole is made by the drill bit parallel with the axis of the spinning workpiece.
- Langweilig: This process enlarges a hole. The hole was previously drilled. Its purpose is to define inside diameters more accurately.
- Threading: A tap tool makes threads in parts by cutting them on the inside or outside. This operation is for creating mechanics, such as screws and bolts.
CNC Turning vs. CNC Milling: Which Do You Need?
The two most common types of CNC machining are CNC turning and CNC milling. It is easy to mix them up. However, they differ in fundamental ways that determine their strength. The decision is made based on the shape of the part.
The elementary difference is that simple. The workpiece in CNC turning revolves while the cutting tool moves in a straight line. The position is vice versa in CNC milling where the tool is the one that rotates while the workpiece is generally stationary.
The main distinctions are shown in this table:
| Merkmal | CNC-Drehen | CNC-Fräsen |
|---|---|---|
| Workpiece Motion | High spinning rotation | Mostly Not Moving |
| Tool Motion | Linear (2-axis) | Rotating and on multiple axes |
| Best for… | Cylindrical or cone-shaped parts | Flat surfaces, complex shapes, pockets, and holes |
| Typical Parts | Axles, screws, nozzles, flanges, pins, shafts | Enclosures, brackets, molds, complex 3D parts |
| Kosteneffizienz | Round parts are more cost-effective | It is more cost-effective for blocky or prismatic parts |
A smart rule is to examine the main part’s figure. If it is mainly round, start with CNC turning. If it is a square shape or it has different complex features on many faces, CNC milling would be a better alternative.
Design for Manufacturability (DFM) for CNC Turning
Based on our experience of manufacturing thousands of turned parts, just a few small design choices can make a huge difference. The right Design for Manufacturability (DFM) tips can help you in two ways: getting lower costs and shortened lead times. Good design results in making the CNC turning process faster and more efficient.
Here are five tips that would keep your costs down while also saving time for your next project:
- Look After Your Tolerances: These are the limits that define how much a size can vary. Do not apply tight tolerances where it is not necessary. Tight tolerances entail slow machining, additional measurements, and special tools which eventually cause higher costs.
- Eliminate Inner Features Complexity: A long and narrow hole is difficult to make. The tools are prone to breakage. The clearing chips out may become impossible too. It is also good not to have sharp internal corners. Always add a small radius. This way the tool can make the corner without stopping or changing tools.
- Standardize Round and Chamfers: If your part has several corner radii, you should try making them the same size. Using one tool for all corners is a time-saver. The machine does not need to stop for a tool change.
- Avoid Thin Walls: If walls are too thin they might bend or vibrate while machined. This causes a bad surface finish. Besides, it makes it difficult to achieve tight tolerances. It is better to keep the wall thickness above 0.04 inches for metals.
- Think About the Stock Material Size: Raw materials are supplied in standard bar sizes. When you select the largest dimension of the part to be just under a standard stock size you will cut waste. This addition also reduces the time needed for the initial rough cutting.
The Spectrum of Turning: From Standard to Advanced
Turning in CNC is a wide world with numerous incredible machines. The simplest is a 2-axis CNC lathe but is just a good option to cut basic shafts and flanges with it. However, technological advancement has gone beyond these machines.
Presently, many shops are benefited from using modern CNC turning centers. These machines are more flexible and powerful than lathes of the past. They are mostly equipped with futuristic parts. Therefore, they can make tougher parts in a single setup.
Let’s see a few of the advanced features these machines can offer:
- Live Tooling: This is the feature that enables a turning center to use tools that rotate, such as end mills and drills. The machine can drill, mill flats, and cut slots on the part with live tooling. Consequently, it attaches a second operation on the milling machine, there is no need for it.
- Multi-Axis Turning: Sophisticated turning centers come with the addition of an axis of motion, for instance, a Y-axis. This allows the tools to go up and down. It is not only in and out. There are also sub-spindles that can catch the part from the back that works on both ends without a need for flipping by hand.
- Swiss CNC Turning: This is one type of CNC turning that is extremely special since it is used for parts that are long, small, and complex. The material goes through a guide bushing that holds it near the cutting tool. Consequently, the part does not bow. It helps to make parts with great qualities at extremely small scales. For highly complex and tiny parts, special processes like those offered by Schweizer CNC-Drehdienstleistungen are often the best solution.
Materials & Applications: Where CNC Turning Shines
CNC turning is the manufacturing process applied throughout almost all major industries. Performing the tasks of producing strong, accurate parts makes CNC turning indispensable in important applications. As per reports, the CNC machine market is anticipated to reach a huge value of USD 128.85 billion by 2028. These innovations are largely driven by the automotive and aerospace sectors.
CNC turning is a technology that can be used with a wide range of metals and plastics. The selection of the material is made based on what is the part’s function, its budget, and the manufacturing environment.
Metalle:
* Aluminum (e.g., 6061, 7075): It is very lightweight and has a good strength-to-weight ratio. It is mainly used in aerospace parts and consumer electronics.
* Stainless Steel (e.g., 304, 316): It does not rust and is easy to clean. They are suitable for making medical devices and food-grade equipment.
* Brass: It has low friction and is easy to machine. This is a common brass material used for electrical connectors, fittings, and bearings.
* Titanium: It is exceptionally strong, light, and safe to the body. Implants for orthopedic surgeries and aerospace fasteners are some examples.
Kunststoffe:
* Delrin (POM): This plastic is dense, strong, and has low friction. It is perfect for such parts as gears, bushings, and rollers.
* Nylon: This is a tough and wear-resistant material. They are usually found in insulators and wear pads.
Choosing the Right CNC Turning Service
The selection of the right partner for manufacturing is as important as the design. A solid partner is one who not only helps you to optimize the part for production but is also responsible for delivering high-quality products on time.
When selecting a CNC turning partner, try to focus on the following factors:
- Fähigkeiten: Has the shop adequate machines for the job? Check if they have live tooling, Y-axis, or Swiss turning in case your part possesses complex features.
- Erfahrung: Have they worked with your specific material? Background in your industrial sector is a benefit, be it medical, automotive, or aerospace.
- Quality Control: What steps do they take to ensure quality? Look out for associations such as ISO 9001. Inquire about their inspection technology and process.
- Kommunikation: A good partner is easy-going and wins on time. They should be responsive and give recommendations about your design. This makes it easier to manufacture.
Partnering with someone with suitable know-how is crucial. A dependable CNC-Drehservice will be with you in the process of design optimization. They will ensure superb product results. For further info on how we help with the project and the advanced capabilities we offer, please visit our main page to Mekalit.
Schlussfolgerung
CNC turning is a powerful and versatile manufacturing method. It is the swiftest and most cost-effective path for producing high-precision, round parts. With the understanding of the whole process, its major operations, and design principles, you will improve your products. CNC turning is the favorite technology through the years, from simple items like pins to complicated medical devices.
Frequently Asked Questions (FAQ)
What is the main advantage of CNC turning?
A remarkable feature of CNC turning is its possibility to create highly accurate and repeatable round components. It also offers excellent finishing. The process is extremely quick yet effective. This is a very good reason for both prototyping and large batch production of round parts to be very economical.
What is the difference between a CNC lathe and a CNC turning center?
The standard CNC Lathe mainly works on two axes. It is involved in processes like turning, facing, and drilling. A CNC turning center is more advanced. It often includes extra capabilities like live tooling for milling and sub-spindles. This allows more complex parts to be finished in a single setup.
