The main purpose of step turning is to create a shaft with multiple different diameters to fit up with the requirements of such components as bearings, gears, or pulleys. The change between the diameters must be a step that is perpendicular to the shaft axis to allow for the accurate location of mating parts.
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Step turning is commonly used in machine design applications. For example, a shaft that is driven by a gear motor may need multiple diameters to allow the fitment of bearings as well as pulleys, gears, or chain sprockets, depending on the application.
Step turning is different from other turning operations in the sense that it produces a shaft with step diameter changes along the length of the shaft. This is different from straight turning, during which a shaft is turned down to a single diameter, or taper turning which creates a shaft with a gradually changing diameter. It must, however, be noted that it is possible for step turning to simply be one of many turning operations on a shaft.
To learn more, see our article on Types of Turning.
No, turning and milling are two distinct processes. Turning refers to the process of shaping a cylindrical part on a lathe by spinning the workpiece while introducing a non-spinning tool into the side of the part to cut the desired cylindrical shape. Milling, on the other hand, is a process that shapes a part by placing a workpiece into a fixture on the bed of a milling machine and then introducing a spinning tool into the material to shape the part. A milling machine can produce non-cylindrical components.
The process of step turning begins with fixing a cylindrical piece of material, either a round bar or a hollow bar, into the chuck of the lathe. Next, the cutting tool is selected and mounted to the tool post. In general, a straight cutting tool can be used. The required rotating speed of the lathe is selected based on standard speed and feed recommendations, and the machine is started up.
The end of the workpiece must then be faced using a straight-cutting tool. Next, the outer diameter of the workpiece is cut using a standard, straight cutting tool. This process removes any mill scale while also discarding any deviations in the diameter of the part. This first cut can typically be a rough cut that is meant to remove a lot of material in one pass. Then a final finishing pass can be performed to reduce the diameter to match the diameter of the largest required diameter on the workpiece.
Starting at the end furthest away from the chuck, the cutting tool is then introduced into the rotating workpiece. Depending on the depth of the step, either a single cut or multiple cuts are performed to reduce the diameter. If the step requires a slight radius, which is typically the norm to reduce stress concentrations, then the straight-cutting tool can be moved axially along the shaft performing multiple cutting passes until the shaft matches the required diameter and reaches the corner of the step. Then, the tool can be backed out perpendicularly to the shaft axis to produce a straight perpendicular edge. The tool radius determines the corner step radius; for larger radii, a CNC machine would need to be used to create the radius.
Most metals and plastics are suitable for step turning. In general, step turning is performed on materials that are used for making shafts, such as stainless steel or low to medium-carbon steels. If a material can be cut on a lathe, then it can be used for step turning.
Step turning is a fundamental turning operation and can be performed on even the most rudimentary lathes. To successfully perform this operation, certain tools are required, as described below:
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The vernier caliper is used to measure the diameter of the shaft throughout the turning process. Digital vernier calipers can be used to speed up the process. After each turning pass, the diameter must be measured to determine how much material must still be removed to achieve the final diameter. Verniers are typically accurate to the second decimal place. For more precise measurements, a digital micrometer can be used, which can be accurate to the third decimal place. It must be noted that if step turning is performed on a CNC lathe, then vernier calipers are not required, apart from using them for a standard quality control check at the end of the process.
A parting tool has a rectangular shape with sharp corners. It is designed to cut perpendicularly into the shaft and is often used to separate the finished component from the stock material. It is a tool that can essentially perform a facing and a cutting operation in one. A parting tool can be used in step cutting by advancing the tool into the material until it has created a groove with the diameter of the step. Then, the turning tool can be used to remove the remaining material up to the groove. This is ideal if a sharp corner is required for assembly purposes.
A turning tool is the most common lathe tool and can take on many different shapes. A common example is shown in Figure 2 below:
CNC Machining: advantages and disadvantages. Half a century ago, machinists were always responsible for crafting every single piece to perfection. These skills are still needed, but when it comes to producing the same piece at high volume and high precision, computerized machines are vastly superior.
That&#;s where Computer Numerical Controlled (CNC) machining comes in.
CNC machining is a manufacturing method that uses pre-programmed computer software to control machining tools. This technology can be used to perform a range of complex processes, including grinding, routing, milling, punching, turning, and lathing. e
CNC machining revolutionized the industry in the s and is the dominant method of machining today. It is important to understand the various advantages and disadvantages of utilizing this technology in your manufacturing operations.
Overall, the advantages of CNC machining far outweigh the disadvantages. As with the advent of any new technology, we must anticipate shifts and adjustments to meet new challenges. This has never been more true in the manufacturing industry, as automation and 3D printing continue to advance.
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