Turning and milling combined machining is a modern manufacturing technique that integrates the capabilities of both turning and milling processes. In this method, a rotating cutting tool is used to machine a workpiece that is also rotating. This hybrid approach combines the advantages of both technologies, offering greater flexibility, efficiency, and precision in complex machining operations. With the growing adoption of multi-task machine tools in recent years, this method has gained significant popularity in the industry.
For many years, even though CNC machine tools have become widely accepted, 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 like a clamping cutter or drill bit into a CNC lathe, the number of setups and workpiece relocations can be significantly reduced. This not only improves processing efficiency but also enhances overall productivity. The synergy between these operations has led to the evolution of the rotary power head on conventional CNC lathes, paving the way for advanced turning and milling complex machining.
Modern multi-tasking machines now feature a B-axis, allowing the tool to rotate and move freely. These machines are equipped with advanced control systems and state-of-the-art CAM software, enabling them to complete major machining tasks in a single setup. This reduces cycle times, minimizes errors, and improves surface finish quality.
There are two main types of turning and milling combined machining: one where the tool axis is parallel to the workpiece, and another where the tool axis is perpendicular to the workpiece. The contour type is similar to helical interpolation milling, allowing for the machining of inner and outer contours. The face type, on the other hand, is limited to external surfaces. Although it may appear similar to traditional turning, this process is fundamentally different. In turn-milling, the cutting speed is determined by the rotation of the milling cutter, rather than the workpiece. Additionally, the workpiece's rotational speed is primarily influenced by the feed rate.
The advantages of turning and milling combined machining are numerous:
- It allows for the machining of non-continuous surfaces, such as grooves and root clearing, without causing impact loads that could damage the tool or degrade surface quality.
- When working with long-chip materials, the use of a milling cutter produces short chips, making chip control easier and improving the overall machining process.
- For eccentric components like crankshafts or offset journals, the low rotational speed of the workpiece in turn-milling helps avoid unbalanced forces that could negatively affect the machining process.
- Heavy workpieces that are difficult to spin at high speeds during traditional turning benefit from this method, as the cutting speed is controlled by the tool rather than the spindle.
Isca’s indexable face milling cutters are specifically designed for turn-milling applications and deliver excellent performance. However, successful implementation requires careful consideration of the tool position, blade shape, and machining path. The tool position affects shape accuracy, while the blade shape influences surface quality. A wiper blade is often used to achieve the final desired shape. Proper selection of tools and cutting parameters must be verified through trial cutting to ensure optimal results.
In conclusion, the introduction of turn-milling combined machining has revolutionized modern manufacturing by addressing several traditional machining challenges. With the right machine tools and cutting tools, this method offers increased productivity and represents a key direction for future machining technology.
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