Turning and milling combined machining is a sophisticated manufacturing process that integrates the capabilities of both turning and milling operations. This technique utilizes a rotating cutting tool to machine a workpiece that is also rotating, enabling efficient and precise material removal. As multi-task machine tools become more prevalent, the advantages of this integrated approach are becoming increasingly evident.
For many years, even though CNC machine tools have been widely adopted, the development of metal-cutting machine tools has remained largely traditional. Each machine was typically designed for a specific function—such as turning, milling, or drilling. However, by integrating the functions of a rotating tool, such as a clamping cutter or drill bit, into a single CNC lathe, the number of workpiece setups and movements between machines can be significantly reduced. This not only enhances processing efficiency but also improves overall productivity. The synergy of these operations has driven the evolution of the rotary power head on traditional lathes, leading to the rise of advanced turning and milling complex machining systems.
Modern multi-tasking machines now feature B-axis capabilities, allowing the tool to rotate and move in multiple directions. These machines are supported by advanced control systems and state-of-the-art CAM software, which enable the completion of major machining tasks in a single setup. This integration reduces cycle times, minimizes errors, and increases precision, making it an attractive option for manufacturers looking to streamline their production processes.
There are two main types of milling machining: one where the tool axis is parallel to the workpiece, and another where the tool axis is perpendicular to the workpiece. In contour turning and milling combined machining, the process resembles helical interpolation milling, allowing for the machining of inner and outer contours of rotating parts. Face machining, on the other hand, is limited to the outer surfaces. While it may appear similar to traditional turning, the fundamental differences lie in the cutting speed and feed mechanisms. In turn-milling, the cutting speed is determined by the rotational speed of the milling cutter, whereas in conventional turning, it's based on the workpiece's rotation.
The benefits of turn-milling combined machining are numerous. For instance, when machining non-continuous surfaces—such as tanks or root clearance areas—intermittent cutting can cause impact loads in traditional turning, leading to poor surface quality and premature tool wear. In contrast, the use of a milling cutter allows for periodic load changes, reducing these negative effects. Additionally, when working with long-chip materials, chip control becomes a challenge in turning. Milling cutters, however, produce short chips, improving chip management and enhancing the machining process.
Another advantage is the ability to handle eccentric workpieces like crankshafts or shafts with eccentric journals. During traditional turning, the unbalanced forces caused by the eccentric mass can lead to vibrations and instability. Turn-milling, with its lower workpiece rotational speed, helps mitigate these issues. Similarly, heavy workpieces that are difficult to spin at high speeds during turning benefit from this method, as it avoids the limitations imposed by the spindle drive.
Isca’s indexable face milling cutters are well-suited for turn-milling applications, offering excellent performance and durability. However, successful implementation requires careful consideration of the tool position, blade shape, and machining path. The tool’s position affects shape accuracy, while the blade type influences surface finish. A wiper blade is often used to achieve the desired final geometry. Proper tool selection, along with optimized cutting parameters, must be verified through trial cutting to ensure optimal results.
In conclusion, the introduction of turn-milling combined machining offers a powerful solution to various machining challenges, significantly boosting productivity. With the right modern machine tools and cutting tools, this innovative approach represents a promising direction for the future of manufacturing.
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