In contemporary manufacturing, a CNC lathe machine's ability to work with a range of materials certainly proves its worth. Whether you work with automotive parts, new energy motors, or intricate components in varied industries, understanding the materials a CNC lathe machine is capable of processing will help with production planning and avoiding expensive errors. The variety of materials possible to work with is wider than most people realize, spanning from common metals and special alloys to non-metals. To better understand the types of materials suited for CNC lathe machines, let's examine some of the most common materials and how to work with them for optimum results.
The most for CNC lathe machines are metals due to the strength and versatility. The most common metals to process are steel, aluminum, and copper, and each is suitable to for specific jobs due to the unique characteristics of each.
Steel is known for its durability. Among the different types of steel such as: carbon steel and alloy steel, carbon steel is the most used. It is tough and cheap, which is ideal for normal components like: gears, shafts and even the brake drums of commercial vehicles. CNC lathe machines work superbly on carbon steel, achieving empty spaces in the shapes to be made that are close in distance to tolerance of 0.01mm. Other forms of alloy steel, which contain elements such as: chromium or nickel, are stronger. They are meant for components such as: hydraulics that are subjected to extreme pressure and wear. CNC lathe machines do not cut alloy steel randomly, they pick which type of cut is appropriate for the type of steel to guarantee it is not harmed.
CNC lathe machines work great with aluminum too, especially for applications in the new energy sector. Aluminum’s lightweight properties make it perfect for motor shells and other components for new energy vehicles. Because it’s essential for energy efficiency, helping to boost ranged vehicles. Aluminum also tends to be softer than most nonferrous alloys, which allows higher spindle speeds and thus, shorter cycle times. For example, the CNC lathe machine used to make shells for aluminum motors can form the outer casing and drill the required holes at the same time, eliminating the need for secondary operations. Its for these reasons that manufacturers keep CNC lathe machines for aluminum components.
Just like CNC machining, the CNC lathe machines work well with copper and copper alloys (brass and bronze). This is especially handy for the electrical and thermal connectors, and heat exchangers made of copper. Decorative parts and certain types of valves can be made out of brass which is an alloy of copper and zinc. Its good surface finish is an added bonus. The fact that these components are malleable is an added perk since they can withstand the cutting process without cracking. Moreover, the accuracy of the CNC lathe machine is of great importance as copper components must be in tight tolerances with other parts within the electrical system.
In addition to focusing on metals, CNC lathe machines can process various non-metal materials. This is valuable for industries that focus on non-metal components that are lighter and more corrosion resistant. The main non-metal materials are plastics, wood, and graphite.
Among many useful non-metal materials, plastics are widely used because they are light, cheap, and available in various types. Some of the plastics that can be processed with CNC lathe machines are ABS, PP, and nylon. ABS is used for components such as plastic gears and small device housings because of its toughness and impact resistance. PP is used for flexible and chemical resistant pipes and containers. CNC lathe machines need to be more careful with the speed when working with plastics. This is because the heat generated from fast cutting may melt or warp the plastic. However, with the right settings, CNC lathe machines can create precise and smooth plastic parts that meet the desired design specifications. As an example, CNC lathe machines are used in making plastic fittings for new energy equipment to ensure a tight seal.
You might think wood would be an odd material for a CNC turning lathe, but it's ideal for making custom or ornamental pieces. Oak and maple are some of the best types of hardwood because they are stable and smooth. CNC lathes can produce wood pieces such as custom tool handles, handrails, or even wooden legs for tables. CNC lathes are very precise so the pieces are all uniform, which is critical for mass production. Instead of woodturning, a CNC lathe can produce identical wooden pieces quicker because it doesn't get tired.
Graphite is handles well on CNC lathe machines, especially in the photovoltaic (solar energy) industry. Photovoltaic grade graphite is used to make guide tubes, which inner walls need to be smooth to control the silicon melt and maintain the thermal field. These tubes are 300-500mm in diameter and 400-600mm in length—dimensions which CNC lathe machines can handle with ease. They are designed to make slow and steady cuts to prevent the brittle graphite from breaking, resulting in a tube with the exact smoothness required for solar equipment. Therefore, most manufacturers in the photovoltaic sector use CNC lathe machines for graphite components.
For high-end manufacturing and aerospace where the industry standard is still considered conventional, the materials required are more specialized. This is because these industries need to use grade materials which can withstand compromised conditions. Although more careful setup is required, for these extreme tough materials, advanced CNC lathe machines are more than capable.
Titanium alloys are super strong and lightweight and resistant to corrosion. This is ideal for aerospace parts like aircraft fasteners and engine components. The only problem with titanium is that it is very hard and cutting it can be a challenge. For titanium aerospace parts, CNC lathes must have specific carbide cutting tools and run at slower speeds so that neither the tool nor the titanium overheats. Even with those adjustments, the CNC lathe can make precise parts to the rigid requirements of aerospace. An example of this is the production of aircraft titanium bolts. The CNC lathe achieves a tolerance of 0.005mm, required for the bolts.
In addition to those mentioned, CNC lathe machines are also utilized for custom processing of high temperature alloys such as Inconel, Hastelloy, or other special alloys all having excellent high temperature strength properties in excess of 1000°C. These alloys are utilized in the manufacturing of components for jet engines or power plants. The chief difficulty in processing such alloys lies in the fact that they are very hard, generate excessive heat during cutting, and rapidly dull cutting tools. The CNC lathe machine is equipped with heat exchangers and uses tools of ultra hard materials such as cubic boron nitride (CBN). Some CNC lathe machine operators provide custom engineered CNC lathe machine systems for machining these alloys. Such custom engineering is directed at all components of the systems to provide for smooth machining of the alloys. This sort of custom engineering permits the manufacturers to Magnesium the high temperature alloys and not compromise on the quality of machining.
Understanding the materials that can be processed on a CNC lathe machine is half the battle. You also need to set the right parameters, and get the appropriate cutting tools for the selected material. Some actionable steps may yield the desired results.
Your chosen cutting tool must match the material being cut. For carbide cutting tools (which are tough and suitable for cutting most metals, which include Steel and Aluminum, and other alloys), work effectively on metals. For cutting nonmetals (which include plastic and wood), use high sped steel (HSS) cutting tools, which are sharper and less likely to damage the material being cut. For tough alloys (which includes titanium), choose CBN or diamond coated tools, that can cut and are resistant to abrasion. Picking the wrong tool will damage the workpiece and slowly destroy the CNC lathe machine.
Lastly, the CNC’s speed and feed settings must also be primed for the material being cut. CNC lathe feed rate refers to the speed and force that tool applies to the material while cutting and speed also refers to the rate at which the material is spinning. Lower cutting speeds only work on softer metals like aluminum where higher speeds are more efficient (smooth finish) and productive (faster incut), while higher speeds work on harder metals like titanium. For aluminum work, the CNC lathe machine speed is 2000 RPM and for titanium work, it is 500 RPM.
The next step is preparing the materials before use. For metals like steel and copper, this includes cleaning off dirt, rust, and other impurities. Impurities can damage CNC lathe machine tools and result in cutting irregularities. For non-metals like graphite, the machine works better when the material is already sized. This minimizes cutting time and increases efficiency. Heat treatment might be required for certain materials, such as alloy steel, to make cutting easier. These steps help guarantee that the CNC lathe machine operates efficiently and produces quality components.
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