Introduction: What is Custom CNC Turning and What Relevance Does it Pose?
Custom CNC turning is a method of manufacturing parts by material removal. It involves a type of machine tool called a lathe, which is controlled by a computer program. The lathe gratifies the creation of circular parts from a square stock by rotation and cutting of material. This operation is called chip-removal since it removes material to then create the final component.
The primary advantage is incredible accuracy and delivering of highly configurable pieces. It applies to one of the pieces as well as to thousands of the same ones. This is what makes it prevalent in various fields.
The system is highly applicable in engineering, product design, and research activities. The engineers can produce prototypes for the given project using cutting technologies. This article explains the entire process of CNC turning; the mechanism, the materials to use, design guidelines, the costs, and how to choose the proper service provider. In case, you are interested, we at Mekalite boast the highest levels of the quality of these technologies.
The Main Steps: The Mechanism of Custom CNC Turning
Comprehending how it all functions allows you to design better components. Circular cutting is a very easy technique to control and thus it is very efficient for making round details.
The Lathe at Work: Material Stock that is Ready to Go Work
The route which is taken by the rod in order to become a finished part involves definite steps. Here is a description of the operation of custom CNC turning:
- A rod or a block of material is gripped firmly in a clamp, which is called a chuck. The chuck spins the material at high speed.
- A sharp cutting tool is located at a section of the machine called a turret where it incubates.
- A computer program specifies the exact coordinates for the given cutting tool.
- The tool speculates in the central axis and executes the mumbling of the earmarked site. It shapes the part by the cutting of material and thus it creates round profiles, cone shapes, screw threads, and other features.
CNC Turning vs. CNC Milling: The Core Contradictory
The CNC turning and the CNC milling are often mistaken for each other. These processes are both programmable but differ in their operations.
- Токарная обработка с ЧПУ: The workpiece rotates, while the cutting tool usually keeps in a steady position. The tool will go across the two designated routes for cutting. This is the most appropriate method for cylindrical parts like shafts, pins, and rings.
- Фрезерование с ЧПУ: The tool is turning, while the workpiece is not. The tool is capable of moving in multiple directions to cut which is more appropriate for surfaces with flat areas or complex geometries such as brackets and enclosures.
The Performance of the Multi-Axis and Live Tooling
New machines have made custom CNC turning even more capable. Many advanced Токарные услуги с ЧПУ at present utilize live tooling machines. It refers to the ability of a machine to apply rotating tools, like drills or end mills, on the part while it remains in the lathe.
These machines boast of the ability to shift in multiple directions. The machine is then capable of drilling, milling, and tapping holes at once. This results in a more complex and faster job, which is of superior accuracy.
Picking the Material for Your Custom Turned Parts
The material you choose not only affects the overall shape, cost, and weight of the part but also the performance of the entire machine. It is pivotal to make the right choice during the design stage. We have a wide variety of metals and plastics to customers whenever necessary.
Metals: The Backbone of CNC Turning Work
This is a secret that many people do not know: Metals, being the most popular material from custom CNC turning, they provide the required toughness and durability.
| Material Category | Примеры | Основные свойства | Общие приложения |
|---|---|---|---|
| Алюминий | 6061, 7075 | Lightweight, strong, resists rust | Aerospace parts, electronic cases, bike frames |
| Сталь | Stainless 303/304, Alloy 4140 | Very strong, durable, wear-resistant | Shafts, bolts, gears, fasteners |
| Латунь | C360 | Easy to machine, low friction, resists rust | Plumbing fittings, electrical connectors |
| Титан | Grade 2, Grade 5 | Very high strength-to-weight, resists rust | Medical implants, high-performance aerospace parts |
Plastics: For Niche Uses Only
Some plastics have characteristics that are the complete opposite of metals. They are lighter in weight and provide a very strong chemical barrier but are only used in certain applications:
| Material Category | Примеры | Основные свойства | Общие приложения |
|---|---|---|---|
| Delrin (POM) | – | Stiff, low friction, holds its shape well | Bearings, gears, rollers, food-safe parts |
| Нейлон | – | Tough, flexible, good wear resistance | Insulators, wear pads, flexible clips |
| PEEK | – | Resists high heat and harsh chemicals | Medical devices, aerospace parts in tough spots |
Designing for Manufacturability (DFM): Optimize Your CNC Turning Product Design
Creating a design is one thing. But, coming up with a design that can actually be produced well at low cost is something else. It is known as Design for Manufacturability (DFM). Simple DFM strategies for custom CNC turning can save both time and money.
Keep Tolerances Close
A tolerance is the acceptable area of space for change in a dimension. When tolerances are very tight then one must dedicate more time, find special tools, and make extra checks. All these factors affect the cost. Common tolerances such as +/- 0.125mm will work with most characteristics. Just apply tighter tolerances to critical features which really demand them such as surfaces fitting another part.
Watch Your Wall Thickness
Very thin-walled parts can become a problem sometimes. In such cases, the stress from the cutting tool can cause the walls to bend, vibrate, or even break. These defective parts will be of no use, or in other words, they will not do the intended work. So, as a rule of thumb, try to maintain wall thickness above 1mm for metal parts and slightly higher for plastics.
Design Smart Internal Features
Drilling deep, narrow holes is difficult. The cutting tool can get clogged with chips. It’s also hard to get cooling fluid inside. This increases the risk of the tool breaking. It also makes the process slow and expensive. A good rule is to keep the depth of a hole to less than four times its diameter.
Simplify and Standardize Threads
Threads are common features on turned parts. When possible, always use standard thread sizes. Use UNC/UNF in the US or common metric sizes elsewhere. Designing a custom thread requires a special, expensive tool. Using standard sizes means we can use tools we already have. This is much cheaper and faster.
Avoid Sharp Internal Corners
Cutting tools are round. So they cannot create a perfect, sharp 90-degree internal corner. They always leave a small curve, or radius. Designing a part that requires a sharp internal corner means it will need a second, special process to finish. This adds cost. It is always better to design your part with a small radius in all internal corners.
What is the Cost of Custom CNC Turning?
The price of custom turned parts is dynamic and can be affected by numerous factors. Understanding the key drivers of the cost can help you make informed design decisions and thus, help you manage the budget more effectively. Below are the main factors that have a significant impact on the final cost.
- Material Cost & Availability: The price of raw material is the largest part of the total cost. General metals such as Aluminum 6061 or mild steel usually are budget-friendly. Costs to purchase and machine high-performance materials, like titanium and PEEK, are greatly increased.
- Machining Time & Complexity: It is a well-known fact that the longer a part takes to produce, the higher its cost. Complicated parts with numerous small features or a hard to understand design need more machine time. Simplicity will always be a faster and cheaper way to go.
- Setup Time: Before we can make even one part, a skilled machinist has to prepare the CNC machine. This involves loading the material, setting up the tools, and programming the machine. This setup cost is the same whether we make one part or one thousand parts.
- Tolerances & Surface Finish: Tighter tolerances and very smooth surface finishes need more careful work. They many times mean slower cutting speeds, extra passes with the tool, or secondary finishing steps like grinding or polishing. Each of these add to the total cost.
- Quantity: This is often the highest factor. Due to the fixed setup cost, the price for a single prototype is significantly high. When a larger quantity is ordered, that setup cost is divided by all the parts. This is why the per-part price decreases a lot.
From CAD to Component: Your Step-by-Step Guide to Getting Parts Made
Getting your custom design made into a real part is straightforward. Here’s how we guide our clients through each step to ensure a successful outcome for their custom CNC turning project.
Step 1: Finalize Your Design and Technical Drawing
The process starts with your design. You will need a 3D CAD file. The best formats are STEP (.stp) or IGS (.igs). You should also have a 2D technical drawing in PDF format. This drawing should clearly show all the important dimensions, tolerances, materials, and any special finishes you need.
Step 2: Choose Your Manufacturing Partner
Look for a partner with experience in your industry and a strong quality system, like ISO 9001 certification. Make sure they have the right machines for your job. Some shops specialize in certain areas, like the large part manufacturing and reverse engineering mentioned by Galaxy Precision. Others focus on small, complex parts.
Step 3: Request a Quote (RFQ)
To get an accurate quote, send your manufacturing partner your 3D CAD file and your 2D drawing. Also, be sure to specify the quantity you need and the material. The more information you provide, the better the quote will be. When you’re ready, you can request a quote for our Токарные работы с ЧПУ.
Step 4: DFM Review and Order Confirmation
A quality manufacturer will do more than just provide you with a good price. They will also provide a review of every design for manufacturability (DFM). If we could propose to make your part more efficient or cheaper, we will. After being certain that the design is set, an order can be confirmed.
Step 5: Production and Quality Assurance
Quality assurance and checks are of utmost importance in this phase. The part does not have to pass the quality check only at the very end. We do tests all through the manufacturing period to be sure that every feature is correct. For instance, projects like joint open-die forging with CNC turning calls for special quality control measures to perfect the integrity of the final part.
Step 6: Finishing and Delivery
Some metal parts will require post-processing operations such as surface treatment. For example, the aluminum parts might go through anodizing or the steel ones through heat treatment for making the product harder. For some very small and complex parts, special processes like our Токарные работы с ЧПУ в Швейцарии can be used for maximum precision. In the end, the completed parts are carefully checked one more time, packed, and shipped quickly to your location.
Frequently Asked Questions (FAQ) about Custom CNC Turning
What is the typical lead time for custom CNC turned parts?
Lead times depend on a few things: part complexity, quantity, and material availability. Simple prototypes in a common material can often be made in just a few days. Larger production runs or parts made from special materials may take several weeks. Always check the timeline with your service provider when you get a quote.
What file formats do I need to provide for a quote?
A 3D CAD model format is the best file type that should be provided, an example is a STEP (.stp or .step) file. This will create the most precise quote. A 2D PDF also helps a lot as it has technical specifications with critical dimensions, classifying tolerances of the material type, and listing any required surface finishes.
Can you make a single prototype part?
Yes, custom CNC turning is perfect for making single, one-off prototypes. It is a great way to test a design before committing to a large production run. Just know that the cost for a single part will be higher than the per-part cost in a larger batch because of the setup fees.
What is the difference between CNC turning and Swiss turning?
Both are types of CNC turning, but Swiss turning is a special version. In a Swiss machine, the raw material moves back and forth through a guide bushing while it spins. This provides extra support. It makes it the best choice for machining parts with small diameters, precise tolerances, and complex shapes. Swiss turning can be more efficient than CNC turning in certain scenarios because it can perform multiple operations in a single machine setup.
