Step 1: CAD to Code – The “Brain Transplant”
You provide: 3D model (STEP/IGES) + 2D drawing (critical dimensions/tolerances).
What happens:
- CAM software generates toolpaths(think Google Maps for cutting tools).
- G-code created– every spindle RPM, feed rate, depth of cut defined.
Undefined radii | Over-tolerancing (±0.001” everywhere) | No material callout
Step 2: Machine Setup – Where Time = Money
(60% of lead time happens here!)
| Task | Key Actions | Time Sink Alert |
| Workholding | Chuck selection + jaw customization | Up to 4 hrs |
| Tool Loading | Insert holders, drills, boring bars mounted | 1-2 hrs |
| Zero Point Set | Probe establishes X/Y/Z reference | 30 min |
| Dry Run | Verify no crashes | 15 min |
Step 3: Metal Meets Machine – The Cutting Symphony
Core Operations (Your “Turning Toolkit”):
| Operation | Purpose | Tool Used | Sound Check |
| Roughing | Bulk material removal | Carbide insert CNMG | Roar |
| Facing | Create flat end surface | CCMT insert | High-pitch |
| Turning | Reduce diameter (OD) | VNMG insert | Consistent hum |
| Boring | Enlarge holes (ID) | Boring bar + TCMT | Low vibration |
| Grooving | Cut channels/o-ring seats | Parting blade | Sharp screech |
| Threading | Internal/external threads | 60° threading insert | Rhythmic tap |
Step 4: Inspection – The “Trust but Verify” Rule
In-process: Laser micrometers check dimensions during cutting.
Final QA:
- CMM (Coordinate Measuring Machine) for ±0.0002” tolerances.
- Surface roughness tester (Ra/Rz values).
- Go/No-Go gauges for threads/holes.
Red Flag: Shops without ISO 9001 certification → risk of dimensional drift!
Step 5: Post-Processing – The Makeover
| Anodizing (Aluminum) → +2 days | Bead Blasting → +4 hrs |
| Plating (Steel) → +3 days | Laser Engraving → +1 hr |
| Heat Treat (Alloy) → +1 week | |
Step 6: Packaging – Surviving the Shipping Wars
Anti-rust: VCI paper for steel | Desiccant for humidity.
Anti-scratch: Foam slotting for delicate features.
3 Ways to Accelerate Your Turned Parts
Design for Turning (DFT):
- DO: Uniform wall thickness | Generous corner radii | Avoid deep skinny holes
- DON’T :Design thin webs behind heavy-cut surfaces → vibration!
Material Smart = Faster Chips:
“Turning 6061 aluminum? Run at 1,200 SFM. 304 stainless? Drop to 250 SFM or murder inserts.”
Speed Kings: 12L14 Steel, C360 Brass
Slowpokes: Inconel 718, Titanium 6AL-4V
Batch Wisely:
- Order 10+ identical parts→ amortize setup cost/time.
- Combine similar diameters→ fewer tool changes.