You need to know a number of variables for successful cylindrical machining. Materials, tools and machining parameters all play an important part. Consistent machining results come from knowing the whole process. In this blog post you will learn methods, tooling, quality control and industry uses to master cylindrical manufacturing.
What is Cylindrical Parts Machining?
In simple words it is a machining process that shapes & finishes round workpieces such as rods or shafts. First machines like lathes or cylindrical grinders rotate the part. Then grinding wheels or cutting tools remove material from it. This procedure can get smooth surface finishes and tolerances as tight as 0.001 mm.
Materials Used in Cylindrical Machining
Metals
You can machine many metals including aluminum, brass, stainless steel, copper and titanium. Aluminum alloys like 6061‐T6 are light & strong. Stainless steels like 316 and 304 are corrosion resistant.
Composites
Composites like glass fiber reinforced polymer (GFRP) and Carbon fiber reinforced polymer (CFRP) are commonly used. GFRP is durable and affordable while CFRP is light & strong.
Also See: A Complete Guide on Composite Material Machining
Plastics
Cylindrical machining works with plastics like polycarbonate (PC), ABS, nylon and POM (acetal). POM is good for precision parts while ABS is durable and easy to machine.
Main Procedures and Techniques
Turning
Turning is the foundation of cylindrical parts machining. The workpiece rotates at speeds up to 3,000 RPM. A single point cutting tool moves along its length and removes material. This creates accurate diameters and surfaces. CNC turning can get tolerances as close as ±0.01 mm. Moreover it is best for making pins, shafts and bushings.
Facing
Facing produces a flat, even ends on a cylindrical part. The cutting tool travels perpendicular to the axis and trims the part to its final length. This assures the face is square. You need this step to prepare parts for later machining or assembly. Each pass removes 0.2 mm or more of material.
Grooving and Parting
Grooving forms narrow channels on the inner or outer surface of a part. These channels mostly hold retaining rings or O-rings. Also known as cutoff, parting separates finished parts from raw stock by cutting through the workpiece. Both operations use special tools. Plus its setup is critical to prevent tool breakage.
Threading
Threading forms helical grooves on conical or cylindrical parts. These grooves allow parts to seal or fasten with other components. CNC mills or lathes can cut internal & external threads. You can use methods like thread turning, tapping or thread milling for this. The choice depends on precision required and part size.
Drilling and Boring
Drilling makes initial holes by using rotating drill bits on stationary workpieces. Boring uses single point cutting tools to improve accuracy and enlarge existing holes. Drilling is quick hole making while boring is for extraordinary surface finishes and tight tolerances. Both operations are used to complete the hole making process.
Also See: CNC Drilling vs CNC Boring_ Main Differences
Design for Manufacturability
When designing cylindrical parts you need to balance machining efficiency, function as well as cost. Pay attention to tolerances and surface finish and you’ll get high quality & reliable parts.
1. Tolerances
Choose tolerances which match your precision needs and what manufacturing can achieve. For metals ±0.005” is a standard tolerance. For plastics ±0.01” is mostly enough. Now if you specify tolerances tighter than ±0.001” then inspection costs and machining time will skyrocket. Only use these tighter tolerances for features which are critical like assembly interfaces.
Richconn’s engineering team offers free DFM analysis. This service helps you increase tolerance choices and can save up to 25% on machining costs in aerospace shaft projects.
2. Surface Finish
Choose a surface finish which suits your part’s needs. Most cylindrical parts use a finish between 1.6 and 3.2 μm Ra. If you need a smoother finish like 0.4 μm Ra you’ll need finer tools and slower speeds. This increases both cost and machining time. Also avoid ultra-smooth finishes unless your application really demands them.
Also See: A Complete Guide to Surface Finish
3. Feature Design
Try to avoid complicated internal features which need extra setups or special tools. Keep wall thickness above 0.02” to prevent distortion and help maintain rigidity. Design symmetrical specifications around the turning axis whenever you can. This makes manufacturing easier and can save you money.
If you work with an experienced manufacturer like RICHCONN early in your design process, you can address manufacturability issues more easily.
4. Material Removal
Design your parts to reduce material waste as much as possible. Removing too much material increases tool wear, cycle time and energy use. When you consider standard material sizes you can maximize material use and reduce offcuts from raw stock.
Richconn’s engineering team focuses on DFM (design‐for‐manufacturability) analysis. Their expertise will help you control material use and cost.
Cutting Parameters and Tooling
Tool Selection
Choose your cutting tools based on the workpiece material, part shape and the finish you want. Use carbide tools for hard metals. For softer materials use high speed steel. Always make sure the tool size and shape matches the operations like threading, turning or grooving. This will give you longer tool life and better accuracy.
Cutting Speeds and Feeds
Cutting speed has a big impact on tool wear and heat. The Speed for standard turning operation is usually set between 200 to 400 SFM. Also set your feed rates 0.005 to 0.020 inches per revolution because this range balances material removal with quality of surface finish. Higher speed can increase productivity but then you will have to monitor the process closely.
Coolant Use
Coolant plays a big role in reducing friction, managing heat and clearing chips from the cutting area. Most jobs work with water based coolants. For hard metals like carbide, oil based coolants are better. High pressure coolant systems i.e., up to 80 bar help control chips and surface finish.
Tool Wear Monitoring
You need to monitor tool wear to keep your machine safe and part quality high. Use vibration sensors, visual inspections or advanced systems which can track real‐time data. Automated monitoring can stop your machine in milliseconds if it detects a broken tool or too much wear.
Inspection and Quality Control
Measurement Tools
You need precise measurement tools to keep every cylindrical part within tight tolerances. Tools like bore gauges, micrometers, calipers and CNC measuring probes are mostly used for this purpose. And for high precision jobs advanced systems like roundness testers and 3D scanners are used which can measure features as small as 0.001 mm.
Dimensional Accuracy
You can verify dimensional accuracy with micrometers, calipers, coordinate measuring machines (CMM) and optical systems. Advanced options are 3D scanning and machine vision. These methods assure all tolerances and dimensions match the design so your parts remain fit and give performance as needed.
Surface Roughness Testing
To check surface roughness you can use non contact optical devices or contact profilometers. Profilometers scan the surface with a diamond tipped stylus and give Rz or Ra values. If you want a faster method which doesn’t damage sensitive parts, non contact options like 3D scanning or laser work well.
Also See: Surface Roughness Explained
Documentation
Documentation means you record every measurement, inspection as well as process change. This allows you to track, trend and prove compliance to quality standards. Moreover accurate records are needed for audits and to improve CNC machining procedures over time.
RICHCONN is ISO 9001 certified and provides full inspection reports for every cylindrical part. These reports include surface roughness and CMM data results.
Uses Across Industries
Automotive
Engine parts such as camshafts, crankshafts, cylinder heads and drive axles rely on cylindrical machining. CNC milling and turning keeps tolerances tight mostly within ±0.01 mm. This precision assures reliable operation in gearboxes, engines and even complex lighting systems.
Aerospace
Cylindrical machining produces engine shafts, turbine blades and actuator pins for aerospace use. These parts have to withstand intense forces and temperatures above 2000°F. This process also creates flight control parts and lightweight structural parts.
Electronics
In electronic, cylindrical machining is used to shape heat sinks, connectors and enclosures. Machined cylindrical parts have a main role in sensor housings and circuit board frames. These parts not only keep connections reliable but manage heat in industrial tools & consumer electronics too.
Medical
Bone screws, knee implants, hip and surgical tools are made with cylindrical machining. Tolerances can be as close as ±0.005 mm. This process also forms housings and shafts for diagnostic machines. It assures that every part meets strict standards for biocompatibility and safety.
Also See: Medical Implant Manufacturing
To Sum Up
Machining cylindrical parts need the right materials, precise procedures and strict quality checks. And accurate results depend on expertise in tooling, design as well as inspection.
For professional solutions and services in cylindrical parts machining, RICHCONN is your best option. You can contact us anytime.
Related Questions
What’s the difference between cylindrical grinding and turning?
Cylindrical grinding uses an abrasive wheel to get a smooth surface finish and fine precision. Whereas turning shapes rotating parts with a single point cutting tool. Grinding mostly follows turning as a finishing step to get higher accuracy.
Why is computer aided design (CAD) important in cylindrical machining?
CAD software builds exact 3D models of cylindrical parts. These digital models direct CNC machines so the physical part matches the original design.
How do you assure concentricity during cylindrical machining?
Concentricity is retained by stable machine setup and accurate clamping. Use a multi step approach and sharp tools such as turning first then grinding. This also improves final accuracy.
How does cylindrical machining work with additive manufacturing?
Cylindrical machining mostly finishes or refines parts made by additive manufacturing. By combining both methods in hybrid production, you can get higher precision, better quality and more complicated shapes.
What are the quality control steps for cylindrical machining?
Quality control includes measuring dimensions with precision instruments and surface roughness testing. Operators also check machining feeds, speeds and tool sharpness to meet all specifications.
