“Precision turning delivers highly accurate components by shaping materials with exact measurements. It’s a key process for producing intricate parts with fine details.”
CNC turning is a precise and complex process of creating parts and components on a lathe using computer-controlled instructions. This process comprises conventional lathe operations and computer numerical control (CNC), which has its roots in Egyptian civilization. In today’s precision turning, a CNC lathe is a machine tool that rotates the raw material called the stock at high speed on multiple axes.
In CNC turning, the workpiece remains in a state of high revolution, and a single-point cutting or dull tool provides the required shape. CNC precision turning is a crucial process in the manufacturing industry today since it can create complex shapes and narrow tolerances of ±0.001 inches (±0.025 mm) or better.
What Is CNC Precision Turning?
CNC precision turning
CNC turning is a precision machining operation that removes the material from the rotated workpiece on its axis. In CNC milling, the tool is fixed, and the workpiece is moved around it, and in CNC turning, the workpiece rotates around a fixed tool or traces a specific path on the workpiece. This method is particularly suitable for making rounded parts, such as cylindrical ones, with high accuracy. This makes this method better than CNC milling for some shapes.
In CNC turning, tools are installed on a turret that moves them to the required position according to a computer program and gradually transforms the material into the final 3D product. This setup enables the manufacturer to produce high-quality prototypes or final parts.
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Steps in the CNC Turning Process
CNC turning process
CNC turning operations are a high-accuracy process in which a cutting tool rotates and machines the workpiece. The following is a step-by-step process for making CNC precision turned parts.
- Selecting the Cutting Tool
The first step involves selecting the right cutting tool required to cut the material type and the design to be made. This selection is important since it contributes to attaining the finished part with the right properties.
- Installing the Cutting Tool
The cutting tool is then inserted into the holder to ensure it is well secured. Machining is a very delicate process, so installation is needed.
- Loading the Workpiece
The workpiece is placed in the machine’s chuck or any other holding tool used in the process. Therefore, it has to be well-centred to get the right results on the fabric as intended.
- Setting Up the Machine
The operation of the machine is controlled by feeding values into the CNC system, such as spindle speed, feed rate, and depth of cut. These parameters must be set well so the turning process can proceed without hindrance.
- Starting the Turning Process
When all these settings have been made, the machine is switched on, and the cutting tool begins to cut out the rotating material. It slides across the workpiece and cuts the workpiece in layers in its path to offer the required shape and size.
- Inspecting the Final Part
Once the process is complete, the workpiece is rotated in the opposite direction, the chuck is opened, and the part is examined to ensure it meets the required standards. This is a great step to ensure that the part has been produced to the expected standard of a finished part.
Comparison between CNC Milling and Precision Turning
In CNC mills, the cutting tools are rotated on the workpiece while the workpiece remains stationary, and they are made to rotate at high speeds. The spindle holds the milling cutter or cutting tool that rotates quickly and removes material. Depending on the requirements, the cutting tool may have 2-150 cutting edges or more.
On the other hand, a CNC lathe machining has a gripping tool (a chuck) that holds onto the cylindrical bar stock. A spindle rotates the gripping tool and material at a programmed speed rate, and a cutting tool is stationary to shave the workpiece.
Milling operations are suitable for flat surfaces on rectangular blocks of material. The cutting tool used in the procedure is intermittent; CNC milling uses a multi-point cutting tool called the milling cutter. In CNC turning, there is only one cutting tool point. Some CNC lathes have outer diameter limitations, and tooling and spindles are available as options.
Many CNC lathes produce round shapes but can also work on hexagonal bar stocks. Most CNC turning centers have only one spindle, which enables them to process a workpiece from one side. Other turning centers have a central spindle and a sub-spindle for auxiliary use. This allows both spindles to operate on a workpiece, creating space for extra features if necessary.
Technical Differences Between Conventional Lathes and Turning Centers
Lathes and turning centers are two different classes of machining tools. They are similar in their characteristics and attributes but not identical. Further, functional differences distinguish them.
Traditional lathes, whether manual or CNC lathe turning, typically operate on two axes: X and Z. These machines can only perform simple operations such as turning, facing, threading, knurling, drilling with the help of tail stock, boring, reaming, and taper turning. They use one spindle and are recommended for use where there is only along-the-axis movement and simple cutting operations.
Nevertheless, turning centers are a more advanced category of machine tools than conventional lathes. They can have three, four, or even five axes, making them more accurate. These multi-axis machines can do operations that the conventional lathes cannot. Turning centers are equipped with cutting tool turrets through which tool change can be effected automatically, and many of them are fitted with live tools for milling and drilling.
Other features include sub-spindles that allow for simultaneous machining and thus reduce the number of operations on other machines. They are equipped with fully enclosed housing for safety and cooling, a chip removal system, and a high-speed coolant system for efficient working conditions. The whole idea of this type of setup is that more complex components can be addressed at once, thus improving efficiency and quality.
CNC Turning vs. Swiss Turning
Here’s a comparison between Swiss Turning vs CNC Turning.
CNC Turning
In CNC turning, the workpiece does not move while it is being turned at high speeds, while the cutting tool moves in the X and Z directions. It is beneficial for producing cylindrical parts with small tolerance dimensions and smooth surfaces. CNC turning is versatile; it accepts various materials and sizes and is suitable for making parts with slots, threads, and tapers. The method can be applied to other materials, including metals, plastics, and composites, thus making it versatile for different industries. CNC turning is the most efficient process of manufacturing round and cylindrical parts with various cross-sections, such as shafts, bushings, and other parts.
Swiss Turning
Swiss turning setup
Swiss or Swiss-type turning helps manufacture small-sized precision parts with close tolerance. In contrast to conventional CNC turning, the workpiece in Swiss turning can also move along the Z-axis during the machining. The workpiece is guided through a guide bushing, thus reducing deflection, making this method suitable for long and slender workpieces. Swiss machines can perform several operations, such as turning, milling, and drilling, in one cycle, which speeds up the process. Components made through Swiss turning may only need minimal finishing, thus reducing the overall process time.
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Benefits of Precision CNC Turning
CNC turning is among the most commonly used techniques in manufacturing due to its efficiency, high accuracy, and relatively low cost. Here are the key benefits of this method:
Superior Precision and Accuracy
CNC turning is ideal for producing cylindrical products that are highly accurate in size, will interconnect, and perform to the best of their capabilities.
Consistent Repeatability
This makes it possible to manufacture several units of similar parts within a short period with minimal or no compromise on the quality of the parts, which is crucial in industries that call for part standardization.
Wide-Ranging Versatility
CNC turning can handle various parts, complex shapes, and different material types. Due to this flexibility, it’s widely applicable across many industries.
Enhanced Efficiency
CNC turning can be done at high speeds because sophisticated cutting tools and automatic lathes allow for the simultaneous processing of many pieces.
Automation and Productivity
CNC lathes are programmable and can be left to operate independently, requiring minimal intervention. This automation enhances efficiency and reduces the amount of money spent on human resources.
Cost-Effective Production
CNC turning is also cheap since the technology offers high precision and reproducibility; hence, little material is wasted, and little workforce is required.
Complex Part Manufacturing
CNC turning can generate intricate contours that may be challenging to develop using other machining methods, and it does so with precision.
Ideal for High-Volume Production
This method is best suited for production processes since it allows for producing many similar parts at once, which is helpful for ongoing processes.
Standard Cutting Tools Used in CNC Turning
CNC precision turning requires proper cutting tools to produce quality and accurate parts. Cutting tools are chosen depending on the type of material to be machined and the geometry of the final product. Here is the list of standard cutting tools used in CNC turning, the materials with which they are compatible, the shapes that they often produce, and the conditions in which they are most helpful.
- Carbide Inserts: for straight, curved, and tapered shapes.
- Diamond-Tipped Tools: For sharp corners and fine details
- High-Speed Steel (HSS) Tools: For straight, Curved, and Tapered Shapes requiring exact dimensions.
- Cermet Inserts: For straight, curved, and sharp shapes with high precision.
- Polycrystalline Diamond (PCD) Inserts: For straight, curved, and tapered shapes with sharp corners and fine details
CNC Precision Turned Parts
CNC precision turned parts are used in almost all industries, including automotive, aerospace, electronics, medical, and fluid control. These parts are usually characterized by their high accuracy, reliability, and conformity to specific standards.
CNC turned part examples
Commonly Produced CNC Precision Turned Parts include;
- Custom Connectors
- Valve elements
- Shafts and Pins
- Medical Implants
- Threaded Fasteners
- Optical Housings:
- Sensor Housings
- Bushings and Bearings:
- Nozzles and Fittings.
- Prototypes for R&D
Types of Precision Turning Operations
Several turning operations are used in the manufacturing industries to make machine parts. Some common types of operations include;
- Precision Threading: The threading process helps form spiral grooves on a workpiece with the help of a threading tool. The tool translates along the longitudinal axis of the workpiece, and threads are produced by passing the tool over the surface many times. Machine setting is crucial to achieve the right thread depth and location.
- Precision Boring: Boring increases the size of an already made hole or makes it more accurate with the help of a single-point cutting tool. It changes the size and shape of the hole and the surface finish and enhances the internal contours. Boring cannot initiate a hole but is useful when making fine-tuning.
- Precision Tapping: The tapping process involves cutting threads in a pre-bored hole with a tap. The tap, which has a diameter equal to the holes, is then inserted and twisted to make threads. This process is often done on a faceplate to make it stable.
- Precision Knurling: Knurling produces a pattern on the surface of the workpiece that is most often diamond-shaped. This operation enhances grip and surface finish using a knurling tool that indents and turns about the revolving workpiece.
Precision Turning: Application in Different Fields
CNC turning is one of the most influential production technologies in manufacturing precise and complex parts. Due to its capacity for providing close tolerances and intricate shapes, it is essential for many uses. Here’s how precision CNC turning serves different sectors:
Aerospace
In the aerospace industry, high-accuracy CNC turning is used to manufacture parts with complex geometries requiring high accuracy levels. It is applied to produce parts like shafts, probes, eccentric hollow shafts, and some landing gear parts. Every part should conform to specific standards to guarantee the dependability and safety of aircraft operations.
Automotive
The automotive industry stands to gain significantly from precision CNC turning since it delivers highly accurate parts critical to vehicles’ performance. Parts such as gears, camshafts, transmission elements, hydraulic valves, and the like are manufactured to very high standards. This technology assists in satisfying the industry’s demands for high-quality and long-lasting parts that will function as required under different circumstances.
Electronics
Precision CNC turning is vital to creating high-quality parts in the electronics industry. Common examples include earphone housing, computer panels, conductive pins, and brass precision turned components, which are sensitive to the touch. The high level of precision guarantees that electronic devices work correctly and fulfil performance criteria.
Medical
Precision CNC turning is essential in producing parts and accessories for medical and dental equipment in the healthcare sector. It is used to manufacture parts like packaging products, mechanical parts, equipment spares, and medical tools and dies. CNC turning is accurate, which is essential in producing these components with high accuracy to meet the required standards for medical applications.
Mechanical
High-accuracy turning is widely used in the mechanical industry to produce parts with particular technical demands. Better accuracy is used to achieve the best results and efficiency of mechanical systems, such as motor shafts, connector joints, and hydraulic fittings.
Prolean Tech – Leading The Way Precision Engineering
Prolean Tech stands among the top precision turning corp in the world. Precision turning requires both skill and modern technology. At Prolean Tech, we aim to acquire the best quality equipment, such as fully automated Computer Numerical Control (CNC) machines. These sophisticated instruments provide precision and uniformity that cannot be rivaled, enabling us to manufacture only the highest-quality parts.
We also incorporate the best software tools and design methodologies into our manufacturing processes to reduce cycle time and maximize efficiency. This commitment to innovation and quality has placed Prolean Tech at the forefront of precision CNC turning service providers worldwide.
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