Mastering CNC Turning and Milling Combined: Processes, Benefits and Applications

 

 

 

Words such as milling machines and lathes are often heard in CNC machining work, but they work in different ways and belong to different machine tools. The CNC machining industry has been in a state of separation of turning and milling for a long time, until the turning and milling compound machine tool. This situation ended only when it appeared. This article mainly talks about the related knowledge about CNC turning and milling compound machining, welcome to discuss together.
 

 

 

 

What is turning and milling compound machining?

 

 

 

CNC turning and milling compound machining is the use of the combination of milling cutter rotation and workpiece rotation to cut parts, so that the shape accuracy, position accuracy, and processing surface of the workpiece can meet the requirements of use. This processing method is called turning combined processing, turning and milling. Compound machining does not simply integrate the two machining processes of turning and milling on a machine tool, but uses the synthetic motion of turning and milling to complete the machining of each surface. Nowadays, the field of CNC machining has been greatly developed. Produced-a new type of theoretical cutting technology.

 

 

 

 

 

 

 

The CNC Turning and Milling Compound Process

 

 

 

The CNC turning and milling combined process generally follows these steps:

 

 

Workpiece Setup: The workpiece is securely mounted on the machine, ensuring proper alignment and stability.

 

Tool Selection and Setup: The appropriate cutting tools are selected and installed in the machine's tool holders. Tool offsets and parameters are set based on the machining requirements.

 

CNC Programming: A CNC program is created or loaded into the machine's control system. The program includes instructions for both turning and milling operations, specifying tool paths, speeds, feeds, and other parameters.

 

Turning Operations: The machine performs turning operations by rotating the workpiece while the cutting tool removes material to create cylindrical shapes, such as diameters, shoulders, and tapers.

 

Transition to Milling: Once the turning operations are complete, the machine transitions to milling operations. This may involve changing tools, repositioning the workpiece, or activating additional axes of movement.

 

Milling Operations: The machine performs milling operations, such as creating slots, holes, pockets, and complex contours. The cutting tools move along programmed paths to remove material and achieve the desired features.

 

Finishing and Inspection: After all the required turning and milling operations are completed, the machined part is inspected for dimensional accuracy, surface finish, and other quality criteria. Finishing processes, such as deburring or polishing, may be applied if necessary.

 

Finalizing the Part: Once the part meets the specified requirements, it is ready for any additional treatments, assembly, or packaging.

 

 

 

 

 

 

 

The Advantages of CNC Turning and Milling Combined

 

 

 

 

CNC turning and milling combined, or mill-turn machines, provide several advantages over performing these operations separately. Here are some key benefits:

 

 

Improved Efficiency: By combining turning and milling operations, mill-turn machines eliminate the need for workpiece transfers between different machines, resulting in reduced setup times and increased overall efficiency.

 

Enhanced Precision: The integration of turning and milling allows for precise and accurate machining of complex parts, ensuring tight tolerances and improved part quality.

 

Reduced Lead Time: Mill-turn machines enable simultaneous turning and milling operations, reducing the total machining time and allowing for faster production cycles.

 

Optimized Workflow: With a single machine capable of performing multiple operations, workflow management becomes more streamlined, reducing production bottlenecks and improving overall productivity.

 

Greater Design Flexibility: Mill-turn machines offer the flexibility to create intricate geometries and features that may be challenging or time-consuming to produce using separate machines.

 

Improved Part Consistency: Combining turning and milling in a single setup minimizes the chances of errors or inconsistencies that may occur during workpiece transfers, resulting in more consistent and reliable parts.

 

Improved Surface Finish: Mill-turn machines allow for smoother surface finishes and finer details compared to traditional machining methods. The combination of turning and milling enables the creation of complex geometries and intricate features with high precision and excellent surface quality.

 

Cost-effectiveness: Although mill-turn machines may have a higher upfront investment, their cost-effectiveness becomes evident in the long run. By consolidating multiple machining processes into a single machine, manufacturers can achieve cost savings in terms of equipment, labor, floor space, and maintenance.

 

In conclusion, CNC turning and milling combined, or mill-turn machining, offers numerous advantages for manufacturers seeking efficient and precise production of complex parts. The integration of turning and milling operations within a single machine setup results in reduced setup time, improved accuracy, enhanced efficiency, and greater design flexibility. By utilizing mill-turn machines, manufacturers can optimize their workflow, achieve faster production cycles, and deliver high-quality parts to meet the demands of various industries.

 

 

At VMT, we specialize in CNC turning and milling combined services, leveraging advanced mill-turn machines and skilled operators to deliver superior precision and quality. Contact us today to discuss your machining requirements and experience the benefits of our state-of-the-art mill-turn capabilities.

 

 

 

 

 

 

 

The Disadvantages of CNC Turning and Milling Compound

 

 

 

While CNC turning and milling combined offers numerous benefits, it's important to consider a few potential drawbacks:

 

 

 

Machine Complexity: Mill-turn machines are typically more complex than standalone CNC turning or milling machines. Their intricate design and integration of multiple functions require specialized knowledge and training to operate and maintain effectively.

 

Higher Equipment Cost: Mill-turn machines tend to have a higher upfront cost compared to individual turning or milling machines. The advanced technology and added features contribute to the increased investment required for these versatile machines.

 

Limited Workpiece Size:A Mill-turn machines may have limitations in terms of the maximum workpiece size they can accommodate. Larger or bulkier parts may not fit within the machine's spindle or work envelope, necessitating alternative machining methods for such components.

 

Increased Programming Complexity: Programming mill-turn machines can be more complex and time-consuming compared to programming single-purpose machines. The integration of turning and milling operations requires careful consideration of tool paths, tool changes, and synchronization between the two processes.

 

Reduced Spindle Utilization: In certain cases, the simultaneous use of turning and milling operations may result in reduced spindle utilization. Depending on the part geometry and machining requirements, there may be instances where one process is idle while the other is active, affecting overall productivity.

 

Maintenance and Repair: Due to the combination of multiple functions and components, mill-turn machines may require more frequent maintenance and repairs. The intricate mechanisms and increased complexity can lead to additional maintenance challenges and potentially longer machine downtime.

 

It's important to note that these drawbacks can vary depending on the specific machine, manufacturer, and application. Despite these considerations, many manufacturers find that the benefits of CNC turning and milling combined outweigh the drawbacks, especially when it comes to producing complex and high-precision parts.

 

 

At VMT, we have extensive experience in CNC turning and milling combined, and our team of experts can help you navigate the potential challenges while maximizing the advantages of this advanced machining process. Contact us today to discuss your project requirements and leverage our expertise to achieve efficient and precise manufacturing results.

 

 

 

 

 

 

What Materials can be used for CNC Mill-Turn Compound Machining?

 

 

 

CNC turning and milling combined, or mill-turn machining, is a versatile process that can accommodate a wide range of materials. Here are some common materials that can be used in CNC turning and milling combined:

 

 

 

Metals: Mill-turn machines are well-suited for machining various metals, including:

 

 

Steel: Carbon steel, stainless steel, tool steel, alloy steel, etc.

Aluminum: Aluminum alloys, such as 6061, 7075, and cast aluminum.

Brass: Common brass alloys, such as C360, C464, and C687.

Copper: Pure copper and copper alloys like bronze and brass.

Titanium: Titanium and its alloys, known for their high strength-to-weight ratio.

Nickel-based alloys: Inconel, Hastelloy, Monel, and other heat-resistant alloys.

Precious metals: Gold, silver, and platinum alloys.

 

 

 

Plastics: Mill-turn machines can effectively machine various plastics, including:

 

 

Acrylic (PMMA): Transparent and lightweight material used in displays and signs.

Nylon: Known for its toughness, low friction, and excellent wear resistance.

Polycarbonate (PC): Impact-resistant material commonly used in automotive and electronic applications.

Polyethylene (PE): Versatile plastic with good chemical resistance and low friction.

Polypropylene (PP): Lightweight and chemical-resistant material.

PEEK: High-performance thermoplastic with excellent mechanical properties.

PVC: Rigid plastic used in construction, electrical insulation, and piping.

 

 

It's important to note that different materials may require specific cutting tools, machining parameters, and techniques to achieve optimal results. When selecting materials for CNC turning and milling combined, consider factors such as material properties, machinability, part requirements, and application needs.

 

At VMT, we have extensive experience in machining a wide range of materials using CNC turning and milling combined. Our expertise allows us to recommend the most suitable materials for your project and deliver high-quality machined parts to meet your specific requirements. Contact us today to discuss your material needs and machining goals.

 

 

 

 

 

 

What is the difference between CNC Turning and Milling Compound and CNC Milling?

 

 

 

 

CNC turning and milling combined, or mill-turn machining, and CNC milling are both machining processes that utilize computer numerical control (CNC) technology. While they share similarities, there are key differences between the two:

 

 

CNC Turning and Milling Combined :

 

 

CNC Mill-turn machining combines both turning and milling operations in a single machine setup. This integration allows for the simultaneous or sequential execution of turning and milling processes on a workpiece.

 

 

 

 

 

 

 

CNC Mill-turn machines typically have multiple axes of movement, including rotational axes for turning and linear axes for milling. This enables the production of complex parts with a wide range of geometries and features.

The turning operations involve rotating the workpiece while a cutting tool removes material to create cylindrical shapes, such as diameters, shoulders, and tapers.

The milling operations involve rotating cutting tools that move along programmed paths to remove material and create various features such as slots, holes, pockets, and complex contours.

Mill-turn machining offers advantages such as reduced setup time, improved accuracy, increased efficiency, and enhanced versatility for producing complex parts with multiple features.

 

 

 

CNC Milling:

 

 

CNC milling is a machining process that primarily focuses on milling operations, where rotating cutting tools remove material to create various features on a workpiece.

 

 

 

 

 

 

 

CNC milling machines typically have multiple linear axes that move the cutting tools in different directions, allowing for precise and controlled material removal.

Milling operations can create a wide range of features, including flat surfaces, slots, holes, threads, and complex three-dimensional shapes.

CNC milling machines are widely used in various industries, including automotive, aerospace, electronics, and manufacturing, to produce parts with high precision and intricate geometries.

 

The process requires a CNC program that specifies the tool paths, speeds, feeds, and other parameters necessary for the milling operations.

 

 

In summary, CNC turning and milling combined integrates both turning and milling operations into a single machine setup, while CNC milling focuses solely on milling operations. Mill-turn machining offers the advantage of performing both turning and milling processes simultaneously or sequentially, allowing for the production of complex parts with multiple features. CNC milling, on the other hand, is specifically dedicated to milling operations and is widely used for creating a variety of features on workpieces.

 

 

 

 

 

 

 

What Types of Parts are CNC Turning and Milling Composites Generally used for?

 

 

 

 

CNC turning and milling combined, or mill-turn machining, is commonly used for machining various types of parts that require complex geometries, multiple features, and high precision. Here are some examples of the types of parts that are well-suited for CNC turning and milling combined:

 

 

 

Shafts and Spindles: Mill-turn machining is ideal for producing shafts and spindles that require precise diameters, lengths, and surface finishes. The combination of turning and milling operations allows for the creation of features like threads, keyways, and grooves.

 

 

 

Rotational Components: Parts that require rotational symmetry, such as pulleys, gears, and flywheels, can be efficiently machined using mill-turn machines. The integration of turning and milling processes enables the production of accurate teeth profiles, complex contours, and precise dimensions.

 

Complex Housings and Enclosures: Mill-turn machining is well-suited for manufacturing complex housings and enclosures, such as those found in electronic devices, automotive components, and machinery. The integration of turning and milling operations allows for the creation of intricate shapes, pockets, holes, and threads.

 

Valve Bodies and Fittings: Mill-turn machines are commonly used for machining valve bodies, fittings, and connectors. The combination of turning and milling operations enables the production of precise threads, bores, and sealing surfaces, ensuring proper functionality and performance.

 

Medical Implants: Mill-turn machining is widely employed in the production of medical implants, such as orthopedic implants, dental components, and prosthetic devices. The integration of turning and milling processes allows for the creation of intricate shapes, precise features, and smooth surface finishes.

 

Aerospace Components: Mill-turn machines play a crucial role in the aerospace industry, where complex components with tight tolerances are required. Parts like turbine discs, engine components, and structural elements can be efficiently machined using the combination of turning and milling operations.

 

Automotive Parts: Mill-turn machining is commonly used for manufacturing automotive components like axles, driveshafts, transmission parts, and engine components. The integration of turning and milling processes enables the production of accurate dimensions, precise features, and complex contours.

 

Tooling and Prototypes: Mill-turn machines are valuable for producing tooling components, such as molds, dies, and inserts. Additionally, they are often utilized for creating prototypes that require a combination of turning and milling operations to accurately represent the final part design.

 

 

 

These are just a few examples of the types of parts that can be effectively machined using CNC turning and milling combined. The versatility and flexibility of mill-turn machines make them suitable for various industries and applications where complex, high-precision parts are required.

 

 

 

 

 

 

 

CNC Turning and Milling Compound Machining Accuracy

 

 

 

CNC turning and milling combined, or mill-turn machining, can achieve high levels of machining accuracy, depending on several factors such as machine capability, tooling quality, programming, and part design. Mill-turn machines are capable of producing parts with tight tolerances and excellent precision.

 

 

The integration of turning and milling operations within a single machine setup offers several advantages that contribute to the overall accuracy:

 

 

Reduced Setup Time: Mill-turn machines eliminate the need for multiple setups and workpiece transfers between machines, reducing the potential for alignment errors and improving overall accuracy.

 

Enhanced Rigidity: Mill-turn machines are often designed with robust structures and precise positioning systems to ensure stability during machining. This rigidity minimizes vibration and deflection, resulting in improved accuracy.

 

In-process Measurement and Compensation: Some advanced mill-turn machines incorporate in-process measurement systems that can detect any deviations from the desired dimensions. This allows for real-time adjustments and compensation, ensuring greater accuracy throughout the machining process.

 

Multi-Axis Capability: Mill-turn machines typically have multiple axes of movement, allowing for complex machining operations. The ability to perform simultaneous or sequential turning and milling operations enables precise control over part geometry, resulting in high accuracy.

 

It is important to note that the accuracy achieved in CNC turning and milling combined can be comparable to that of CNC milling or turning processes alone. The choice between the two methods depends on factors such as part complexity, required features, and production efficiency.

 

In some cases, CNC milling may be preferred for parts that primarily require milling operations, while CNC turning may be more suitable for parts with predominantly rotational features. However, when a part requires a combination of turning and milling operations, mill-turn machining offers advantages in terms of accuracy, efficiency, and reduced setup time.

 

Ultimately, the accuracy achieved in CNC turning and milling combined is highly dependent on the machine, tooling, programming, and operator expertise. With proper setup, calibration, and optimization, mill-turn machines can deliver high levels of machining accuracy, meeting the precision requirements of various industries and applications.

 

When comparing the accuracy of CNC turning and milling combined to CNC milling or turning processes alone, it's important to consider the specific requirements of the part and the capabilities of the machine being used. Both processes can achieve high levels of accuracy, but their suitability depends on the specific application.

 

CNC milling, for instance, is well-known for its ability to create complex 3D shapes, intricate contours, and precise features with tight tolerances. It excels in situations where the primary focus is on milling operations, such as creating intricate molds or aerospace components with complex geometries.

 

On the other hand, CNC turning is highly effective for producing cylindrical parts with rotational symmetry and features such as diameters, shoulders, and tapers. It is particularly suitable for components like shafts, spindles, and fittings.

 

CNC turning and milling combined, as the name suggests, offers the advantages of both processes in a single setup. This integration allows for the production of parts with both rotational and complex milled features. The accuracy achieved in mill-turn machining can be comparable to that of CNC milling or turning processes alone, provided that the machine is properly calibrated, the tooling is of high quality, and the programming is optimized.

 

The choice between CNC turning and milling combined or CNC milling or turning alone depends on various factors, including the complexity of the part, the required features, production efficiency, and cost considerations. Mill-turn machining can provide a more streamlined and efficient solution when a part requires a combination of turning and milling operations, eliminating the need for multiple machine setups and reducing overall production time.

 

 

In summary, both CNC turning and milling combined and CNC milling or turning processes alone can achieve high levels of accuracy. The suitability of each method depends on the specific requirements of the part and the capabilities of the machine. Mill-turn machining offers the advantage of integrating both turning and milling operations, providing a versatile and efficient solution for producing parts with a combination of rotational and milled features.

 

 

 

 

 

 

The Time and Cost of CNC Turning and Milling Compound

 

 

 

 

The time and cost associated with CNC turning and milling combined, or mill-turn machining, depend on several factors, including the complexity of the part, the machine capabilities, the programming requirements, and the desired quality and precision. Here are some key considerations:

 

 

 

Time:

 

 

Setup Time: Mill-turn machining can reduce setup time compared to separate turning and milling operations. Since both processes are integrated into a single machine setup, there is no need for workpiece transfers or additional setups, resulting in time savings.

 

Programming Time: The time required for programming mill-turn operations depends on the complexity of the part, the number of features, and the desired tool paths. Programming for mill-turn machining may require more time and expertise compared to programming for individual turning or milling operations.

 

Machining Time: The total machining time depends on the size of the part, the intricacy of the features, and the desired surface finish. Mill-turn machines can perform turning and milling operations simultaneously or sequentially, potentially reducing the overall machining time.

 

Tool Changes and Setup: Mill-turn machines typically have tool changers that allow for automatic tool changes during the machining process. This helps minimize downtime and reduces the time required for tool setup.

 

 

 

 

Cost:

 

 

Machine Cost: Mill-turn machines are generally more expensive than individual turning or milling machines due to their integrated capabilities. The cost of acquiring and maintaining a mill-turn machine should be considered when evaluating the overall project cost.

 

Tooling Cost: The cost of tooling for mill-turn machining may vary depending on the complexity of the part, the required tools, and the desired precision. Mill-turn operations often require specialized tooling, which can impact the overall cost.

 

Labor Cost: The expertise and experience of the operators and programmers involved in mill-turn machining may affect the labor cost. Skilled operators and programmers with knowledge of both turning and milling operations may be required, potentially impacting the labor cost.

 

Material Cost: The cost of the material being machined is a significant factor in the overall project cost. The choice of material can impact the machining time, tool wear, and tooling cost.

 

It's important to note that the time and cost considerations for mill-turn machining can vary depending on the specific project requirements, such as the quantity of parts, desired quality standards, and any additional post-processing or finishing requirements.

 

 

To accurately estimate the time and cost for a specific mill-turn machining project, it is advisable to consult with a reputable CNC machining service provider. They can assess the project requirements, evaluate the complexity of the part, and provide a comprehensive cost and time estimate based on their expertise and available resources.

 

 

 

 

 

 

Precautions and Skills of CNC Turning and Milling Compound

 

 

 

 

When working with CNC turning and milling combined, or mill-turn machining, there are several important considerations and techniques to keep in mind to ensure successful and efficient operations. Here are some key points:

 

 

Design for Mill-Turn: When designing parts for mill-turn machining, consider the capabilities and limitations of the machine. Optimize the part design to leverage the advantages of both turning and milling operations, such as incorporating rotational features and complex geometries that can be efficiently produced using the mill-turn process.

 

Tooling Selection: Choose the appropriate cutting tools for the specific operations and materials involved. Consider factors such as tool life, cutting speed, feed rates, and surface finish requirements. Selecting high-quality tooling and regularly monitoring tool condition and wear can help maintain accuracy and productivity.

 

Machine Calibration: Ensure that the mill-turn machine is properly calibrated and aligned to achieve accurate positioning and movement. Regularly check and calibrate the machine's axes, tool turret, and spindle to maintain precision and minimize errors during machining.

 

Programming Considerations: Pay close attention to programming mill-turn operations. Utilize CAM software that supports mill-turn functionality and take advantage of simulation features to identify any potential collisions, errors, or inefficiencies before the machining process. Optimize tool paths and minimize unnecessary movements to improve efficiency and reduce cycle times.

 

Workholding Solutions: Select appropriate workholding solutions to secure the workpiece during machining. Consider factors such as stability, accessibility for tooling, and the ability to accommodate both turning and milling operations. Explore options like chuck jaws, collets, and custom fixtures that provide secure and accurate clamping.

 

Material Handling and Setup: Streamline material handling and setup procedures to minimize downtime. Efficiently load and unload workpieces, and optimize the machine setup for quick and accurate alignment. Consider using fixture location pins, reference edges, or automation systems to expedite the setup process.

 

In-Process Inspection: Implement in-process inspection techniques to ensure quality and accuracy throughout the machining process. Use measurement tools such as probes, gauges, or vision systems to verify critical dimensions, tolerances, and surface finishes during machining. Implement feedback systems to make real-time adjustments and maintain consistent quality.

 

Post-Processing and Finishing: Consider any additional post-processing or finishing requirements, such as deburring, polishing, or coating. Plan for these processes in the overall workflow to achieve the desired final part specifications.

 

Operator Training and Expertise: Ensure that the operators and programmers have the necessary training and expertise in mill-turn machining. Familiarity with both turning and milling operations, as well as the specific capabilities of the machine being used, can help optimize the process and address any challenges that may arise.

 

By paying attention to these considerations and utilizing appropriate techniques, you can maximize the benefits of CNC turning and milling combined. Continuous improvement, regular maintenance of the machine and tools, and staying updated with the latest advancements in mill-turn technology can further enhance productivity, accuracy, and overall success in mill-turn machining operations.

 

 

 

 

 

 

Summarize

 

 

 

CNC turning and milling combined offers a versatile and efficient solution for producing parts with both rotational and milled features. It combines the advantages of turning and milling operations in a single machine setup, reducing setup time and improving productivity. Mill-turn machining can achieve high levels of accuracy, depending on factors such as machine rigidity, tooling quality, programming, and part design.

 

When working with mill-turn machining, it is important to consider design optimization for mill-turn operations, select appropriate cutting tools, ensure machine calibration, and optimize programming for efficient tool paths. Proper workholding solutions, streamlined material handling, and efficient setup procedures help minimize downtime and maximize productivity. In-process inspection techniques and operator expertise play crucial roles in maintaining quality and accuracy throughout the machining process.

 

Understanding the time and cost implications of mill-turn machining is essential for project planning and evaluation. While mill-turn machines may have higher initial costs compared to individual turning or milling machines, the integration of multiple processes can result in time savings and improved overall efficiency.

 

By implementing the techniques, considerations, and best practices outlined in this guide, manufacturers can master CNC turning and milling combined, enhance their expertise, and achieve successful outcomes in mill-turn machining operations. Continual improvement, regular maintenance, and staying abreast of advancements in mill-turn technology contribute to maximizing productivity, accuracy, and overall success in this versatile machining method.

 

CNC turning and milling compound machining is currently one of the most popular processing techniques in the field of mechanical processing, and it is an advanced manufacturing technology. It effectively improves processing efficiency and has obvious effects in processing complex parts. Turning-milling compound has obvious advantages compared with traditional machining in terms of fixture or floor space.