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Guide to Various Types of Lathe Cutting Tools for CNC Lathe Machines
Lathe cutting tools have become essential equipment in various industries, serving crucial roles in production processes. These tools are mounted on a lathe and are used to produce turned parts. They move along the lathe’s axis, their path determines the workpiece’s final shape.
There are different lathe cutting tools, including non-CNC and CNC options. Each has unique features and designs that dictate the types of lathe cutting operations it can perform and its respective applications. Therefore, selecting the right cutting tool requires a thorough understanding of its characteristics.
What is a Lathe Machine?
The lathe machine, often referred to as the “Mother of all Machines,” is a versatile tool with origins dating back to the 13th century in Egypt. It is primarily used for shaping materials such as metal and wood. The machine operates on a holding and rotating mechanism.
Stationary cutting tools are mounted on the lathe, which remove material from the rotating workpiece. This process leaves behind a shaped piece that conforms to the intended product design.
Various Types of CNC Lathe Machines
CNC lathes can be categorized by the number of movement axes:
2-axis: Performs outer and inner diameter machining, facing, drilling, and tapping.
3-axis: Adds live tools for milling and boring.
4-axis: Features a second tool carrier or turret.
5-axis and 6-axis: Include additional Y and possibly B-axes.
Specialized lathes with more than 6 axes are referred to as Multi-Spindle Machines, offering advanced features.
Lathe types include:
Speed lathes: Best for lighter tasks, commonly used in woodworking.
CNC lathes: Offer precision and automation.
Engine lathes: Versatile for general purposes.
Turret lathes: Efficient for high-volume production with rapid tool changes and complex designs.
Classification of Lathe-Cutting Tools
Lathe cutting tools are available in various shapes, dimensions, and forms, which can make it challenging to identify them. However, all lathe cutting tools can be classified into specific categories, which we will explain in this section. Understanding the classification of lathe cutting tools will make it easier to recognize each type of lathe cutting or turning tool used in the factory.
Classification 1. Lathe-Cutting Tools Based on Operation
It’s essential to understand what we can achieve with lathe-cutting tools in CNC lathe-cutting tool factories to recognize them. We categorize some of the lathe tools based on their operations, which include turning, thread-cutting, chamfering, forming, facing, boring, grooving, and knurling.
Building on our understanding of what a lathe machine is, it’s important to examine how lathe cutting tools are typically classified. This classification focuses on the specific machining or cutting operations for which they are designed.
Turning tools
Lathe turning tools are used to remove material from a rotating workpiece along its length, resulting in a part with a reduced diameter. There are two types of turning tools used in the CNC turning process: rough turning tools and finish turning tools.
Rough turning tools are designed to remove excess material from the workpiece. They have a specific ground-cutting angle that allows them to withstand maximum pressure during machining.
In contrast, finish turning tools are intended to remove only small amounts of material, resulting in a final part with a smooth and accurate finish.
Facing tools
A lathe facing tool is designed similarly to a conventional face milling tool, featuring a side cutting edge. This tool is used in facing operations, which involve removing layers of material from a workpiece to create either a smooth or rough surface, depending on parameters such as speed. There are two types of facing tools: right-hand and left-hand.
A right-hand facing tool operates on the right side of the workpiece, while a left-hand facing tool works on the left side. In either case, these facing tools are effective for producing a flat surface on a part.
Boring tools
Boring tools are single-point cutting tools designed to refine or enlarge an existing opening in a workpiece. They can create conical or cylindrical shapes or improve an existing feature’s finish. The main components of a boring tool include a boring bit (or tip), an arbor, and a boring bar (shank) that fits into a tool holder.
Knurling tools
Knurling tools are a type of cutting tool that consist of two or more metal rolling wheels featuring embossed patterns. There are various types of knurling tools, with two common varieties being straight knurling tools, which create straight patterns, and diagonal knurling tools, which produce diagonal or diamond-shaped patterns.
These tools are used to create a raised pattern on the surface of a workpiece, enhancing grip and improving aesthetics.
Chamfering tools
The cutting tools on these lathes are suitable for chamfering, which is the process of creating a slanted edge. Turning tools can also be used for chamfering, but they need to be set at the correct angle to the workpiece. Additionally, their effectiveness decreases when the inclination angle is steep.
Grooving tools
Grooving tools create grooves on workpieces with cylindrical surfaces. Depending on the type of lathe machine, these tools come in various shapes, with the most common being V-shaped and square-cut cutting tools.
Grooving tools feature a narrow cutting edge, making them ideal for creating slots, grooves, or parting lines on a workpiece at a specific depth. Additionally, they efficiently evacuate chips from the cutting zone.
Thread Cutting tools
Thread cutting tools are used to create spiral thread patterns on cylindrical parts. Typically, the angle of their corners depends on the desired thread angle. Furthermore, the cross-section of the tool affects the pitch of the thread.
Form tools
A form-cutting lathe tool is a commonly used tool for fabricating or welding materials. As the name suggests, form tools are utilized to shape workpieces into the desired designs or forms. Other common applications of form tools include turning, presswork, and stamping.
Form tools play a crucial role in CNC precision machining and are particularly popular for contour machining of concave or convex shapes. They are essential for creating parts that require high precision and accuracy, such as gears.
Taper Turning Tools
Taper turning tools are specialized for machining tapered surfaces, enabling the reduction or enlargement of a workpiece’s diameter. They effectively produce tapered shafts whose diameters vary along the length and are essential in industries like aerospace, automotive, and manufacturing for crafting components.
A notable feature of these tools is their adjustable angled cutting edge, which allows operators to customize the angle relative to the lathe’s axis. This flexibility enables precise shaping of various materials and sizes, making taper turning tools invaluable in precision engineering and custom part production.
Classification 2: CNC Lathe Tools Based on Materials
There are various materials that can be used to create tools for a lathe, each possessing distinct characteristics. Consequently, the properties of each lathe cutting tool are determined by the inherent mechanical properties of the material used. Below are some common types of lathe cutting tools categorized by the material they are made from.
High-speed steel
Lathe cutting tools made from high-speed steel (HSS) are known for their strength, hardness, and wear resistance. This material includes elements such as carbon, tungsten, chromium, and vanadium, allowing it to perform effectively at temperatures around 588 °C.
Due to their versatility, HSS tools are cost-effective and widely used in moderate-speed lathing operations, such as rough and semi-finish machining. However, they are not suited for high-speed machining and often require frequent tool changes.
Carbide
Carbide lathe cutting tools consist of a steel body or removable blades with edges that are brazed with carbide. This carbide tipping allows them to produce excellent surface finishes and prevents wear during steady machining.
In terms of longevity, carbide cutting tools for lathes can last approximately 99 times longer than high-speed steel tools. This durability is due to their ability to maintain a sharp and hard cutting edge, regardless of the machining temperature or speed.
These tools are further categorized into carbide-tipped tools and cemented carbide inserts.
Carbide-tipped tools are typically fixed or whole units, which means you need to replace the entire cutter or blade once it becomes dull. In contrast, cemented carbide inserts can be rotated when one side wears down, thereby preserving their size and maintaining a quality finish for a longer period.
Diamond
Diamond tools for lathe machines are renowned for being the hardest material available and offer outstanding performance in precision machining. Their primary advantage is exceptional wear resistance, which allows them to maintain sharpness and precision over extended periods, even at high cutting speeds. These tools are perfect for machining highly abrasive materials, such as composites, aluminum alloys, and ceramics, ensuring smooth finishes and precise dimensions.
They are particularly valued in industries that require ultra-fine finishes, such as aerospace and electronics. Their durability results in fewer tool changes and reduced downtime, making as cost-effective choice despite their higher initial price.
Ceramic
Ceramic lathe-cutting tools are popular due to their chemical stability and their ability to achieve both rough and fine finishes. They also have excellent heat resistance and are highly durable.
Similar to CBN (cubic boron nitride), ceramic lathe tools can cut harder materials at high cutting speeds and feed rates without the need for coolants. A common type of ceramic lathe tool is the ceramic insert turning tool, which is typically screwed into a tool holder. Like cemented carbide inserts, the sides of these tools can be rotated to maintain their finishing quality for a longer period.
Cubic Boron Nitride
Cubic Boron Nitride is known for its exceptional hardness. It is highly durable, abrasion-resistant, and suitable for rough machining and intermittent cutting, especially when working with cast iron.
Classification 3: CNC Lathe Tools Based on Feed Direction
Lathe turning tools can be classified based on the feed direction during machining.
Left-Hand Tools
A left-hand lathe cutter removes material from the workpiece as it moves from left to right. These cutters are not common, which makes them more expensive. Additionally, they cut away from the chuck, causing the chips to form towards the chuck. However, they are preferable for tasks like back turning and creating sharp shoulders on the back of the workpiece. They are also the best option for short workpieces that cannot be securely held by the sub-spindle chuck.
Right-Hand Tools
These tools are designed to remove materials while transporting them from right to left. Their design resembles that of a human hand. The right thumb indicates the feed direction, and the main cutting edge is positioned on the left side of the tool.
Center Lathe-cutting Tools
These tools are referred to as round nose tools. They typically feature equal angles of 45 degrees on both the left and right sides of the main cutting edges. Rake angles may be present or absent. An example of their use is in chamfering tools, which are employed to create smooth surfaces.
Classification 4: CNC Lathe Tools Based on Structure
Lathe tools can be classified into three main types based on their structure.
Single Body Tools
They are crafted from a single piece of material, designed to have specific shapes, dimensions, and geometries. Consequently, they are the most common tools used on lathe machines due to their speed and strength.
Welding Lathe Cutting Tools
Welding is an essential process in the fabrication of cutting tools for CNC lathes, as it involves joining different materials together. This technique enables creating custom geometries, modifying existing tools for new applications, and replacing cutting inserts. The result is a cost-effective and versatile solution, particularly valuable in situations that require adapting tools for new or complex parts. Welded cutting tools are especially common in environments where frequent modifications are necessary.
Clamp Lathe Cutting Tools
These cutting tools share a similar material composition with welding tools. However, unlike welding tools, the clamp lathe tool is constructed by attaching a cutting tool insert to a handlebar. Clamp lathe cutting tools are designed to be both dexterous and replaceable. As a result, their properties, such as strength and durability, depend on the type of inserts used.
Tips to Consider When Choosing a Lathe Tool
Consider the following tips when selecting a lathe tool for successful machining operations:
Workpiece Properties and Material
For efficient machining, the cutting tool’s material must be stronger, durable, and harder than that of the workpiece. If this requirement is not met, the tool may chip or break. For example, when machining hard materials like titanium, it is essential to use tools made from tougher substances, such as diamond, which are more effective than high-speed steel options.
Surface Finishes
The necessary surface finish will influence characteristics such as the sharpness and rake angle of the lathe tool. For instance, it is advisable to use metal lathe tools in high rake angles and sharp cutting edges to attain a smooth surface finish.
Tolerances
Achieving a tight tolerance is possible by utilizing small, dimensionally stable materials such as carbide.
Desired Shape
When selecting a lathe cutting tool, consider the tool and part shape. For example, during facing operations, if you want to create a cube shape on a material, a rectangular facing tool can be used.
Consider the Operation Speeds, Feed Rates, and Cut Depths
It is essential to consider cutting speeds, feed rates, and depth of cuts, as these factors will influence the strength and classification of the lathe tool. For instance, single-body tools, whether coated or made from carbide and diamond, perform well at high cutting speeds and feed rates due to their high tensile strength, hardness, and durability. Additionally, a greater depth of cut requires the tool to be sufficiently long to ensure effective chip evacuation.
Machine Tool Capabilities and Limitations
The capability of a lathe machine can significantly impact production cycle times and the effective use of turning tools. For instance, rigid equipment designed for large-scale operations requires lathe cutters made from durable materials like carbide, which can withstand higher cutting forces and challenging operating conditions. Additionally, machines equipped with multiple tool-holding devices can facilitate the use of various lathe tools, reducing production cycle time.
Components of a Lathe-Cutting Tool
While lathe machine tools come in various designs for different functions and applications, they all share certain common parts. Below are the components that are common to every type of lathe cutting tool.
Face
The face is the area where chips typically accumulate during machining. It is designed with a curve or spacing that facilitates the flow of chips, preventing them from clogging the cutting edge.
Shank
Different experts in lathe tooling may use various terms to refer to a shank. Some define a shank as the part of a lathe tool that connects to the holder, while others consider it to be the body of the cutting tool itself. Regardless of the terminology used, both definitions convey a similar meaning.
In essence, the shank is the section of a lathe tool that lacks any specific styling or face used for machining; it can be interpreted as its body or handle. Typically, shanks are secured in a tool holder through friction.
Cutting Edge
The cutting edge of a lathe tool is also referred to as the tool lips. Typically, this part is coated with materials such as diamond, carbide, graphite, or cubic boron nitride (CBN) through a brazing process. The cutting edge is essential for shaping or turning the workpiece material and for removing chips during machining.
As a general guideline, avoid overheating the cutting edge of lathe tools to extend their lifespan. After each use, be sure to inspect the edges and maintain them properly before the next use.
Lathe-Cutting Tool Angles
Lathe tool angles are specifically designed to enhance the efficiency of machining processes. There are three main types of angles: Rake Angles, relief Angles and Cutting-edge Angles.
Heel
The heel is the rounded section that connects the flanks to the base of the lathe-cutting tool. This shape significantly influences the overall geometry and performance of lathe-cutting tools.
Nose
The rounded part of the lathe-cutting tool is where the main cutting edge meets the auxiliary cutting edge. This area resembles a right-angled triangle, but the point of intersection is rounded to create a nose radius.
The nose radius enhances surface finishes and contributes to the longevity of the cutting tool.
Flank
This part interacts with the workpiece and defines the cutting edge. It can be major or minor and forms the cutting edge with the cutting tool’s side.
Advanced Technology in Lathe Cutting Tools
Advancements in technology have improved tool bit production and increased precision, efficiency, and versatility.
Unique Geometry for Tools
Tools now feature unique geometries that enhance machining efficiency in lathe machines. These tools incorporate advancements such as chip breakers, which improve chip evacuation and the surface finish. Additionally, their designs now include variable helix and pitch, significantly reducing vibration and enhancing stability during the lathing process.
High-Grade Materials
There is an increasing trend in the use of high-grade materials that possess enhanced properties such as thermal stability, hardness,toughness, and wear resistance, all aimed at improving performance. Common advanced materials include high-performance carbide grades and ceramics like silicon nitride and alumina. Additionally, coatings such as aluminum titanium nitride and titanium aluminum nitridehave become prevalent in lathe tool manufacturing due to their superior mechanical properties.
CAD Software and Simulation Tools
Using Computer-Aided Design (CAD) and simulation tools, manufacturers of lathe-cutting tools can create virtual prototypes and optimize their tool geometries. This approach allows them to predict the tools’ performance before they are produced.
Additionally, by employing Finite Element Analysis (FEA), manufacturers can simulate how turning tools behave under different machining conditions. This capability facilitates the development of stronger and more efficient cutting tools.
Additive Manufacturing Techniques
Additive manufacturing have become essential for producing complex, customized cutting tools for lathes. This innovation streamlines the creation of specialized tools with intricate designs tailored to specific machining needs.
Integrated with Sensor
Some tool bits for lathe machines are now equipped with sensors that allow manufacturers to monitor parameters such as vibration and temperature in real time. This capability enables the optimization of the tools, reduces tool wear, and enhances their overall performance.
Applications of Lathe Tools
Lathe tools are attached to a lathe machine, which helps in shaping parts of a rotating workpiece. This is done through different lathing operations, such as turning, grooving, and chamfering.
Conclusion
The blog describles the different materials ,forms, structures of lathe tools, helping you select the right tool for your needs. Are you looking for a reliable supplier for your lathe tool machining requirements? Choose Enze for high-quality experience. Contact us to receive fast quotes.
