Nowadays manufacturers need to deliver parts fast & precisely. Turn mill machining helps with that by combining two major operations in one setup and cutting production time by up to 50%. In this blog post we’ll cover the turn mill machining process, different machine types used, main advantages, basic uses and the limitations of this machining.
What is Turn Mill Machining?
Turn mill machining lets you perform turning and milling on one machine. Both operations happen without moving the part to another machine. In a traditional workflow, you turn round parts on a lathe and mill on a separate mill. But turn mill machines can do both of these steps in one setup. This means shorter cycle times and more accuracy and you can make complicated parts with fewer setups.
Also See: How CNC Milling differs from CNC Turning?
Turn Mill Machining Procedure
1. Workpiece Setup
Start by mounting the workpiece on the main spindle or chuck. Make sure it’s aligned as right setup is key for precise parts.
2. Turning Operation
Next you shape the outer diameter or create axial holes through turning. This is the basic shape of the part.
3. Milling Operation
After turning, rotating tools handle side milling, drilling, tapping or contouring. These add details to your part.
4. Simultaneous Machining
When parts are complex you can turn and mill together or one after the other. This shortens cycle times and improves the quality of the finished part.
5. Final Finishing and Part Removal
At the end you check the parts for quality and dimensions. Once you are satisfied you can remove them from the machine.
Software and Automation
Modern software is key to advance turn mill machining. CAD/CAM integration lets you design parts and automatically generate toolpaths. CNC programming then manages multiple axes at once so turning and milling work together smoothly. Automation like this cuts programming time and increases accuracy.
For example at Richconn we use advanced CAM systems that support 5 axis simultaneous machining and collision avoidance. This means efficient and safe production of even the most complex parts.
Also See: What is CAM?
Machine Types Used in Turn Mill Machining
There are several types of turn mill machines available, each suited for specific tasks and part sizes. These are:
Horizontal Mill‐Turn Centers
Horizontal Centers are good for bar-fed operations and machine small to medium parts well. The spindle is horizontal in this type which allow gravity to push chips away from the workpiece. This type of turn mill is great for high volume production.
Vertical Mill-Turn Centers
Vertical Mill-Turn Centers are good for large, heavy or odd shaped parts. Gravity holds the workpiece in place so you need less clamping pressure. They also take up less floor space which make them helpful in smaller shops.
Swiss-Type Turn Mill Centers
Swiss‐type turn mill centers are for small, high precision parts like medical devices or watches. They have strong spindles and can hold 60 or more tools. These features are great for short run & detailed work.
Also See: What is Swiss CNC Machining
Multi-Tasking Machines
MTMs have multiple turrets, live tooling and sub-spindles. Some can even do 5 axis machining. You can make very complex parts in one operation with these machines.
Key features
When selecting a turn-mill machine, look at the number of axes (3, 4 or 5+), live tooling, tool magazine size and the control system (FANUC or Siemens). These factors determine how flexible, fast and user friendly the machine will be.
Benefits of Turn Mill Machining
Turn-mill machining has many advantages. These advantages make it a popular choice for many manufacturers.
Increased Efficiency
You can do multiple operations in one setup with turn mill machines which make handling time drops by up to 50%. Moreover, cycle times are shorter so you can make more parts in less time.
Lower Production Costs
Fewer setups and less manual work is required so production costs can drop 20 to 30%. Tooling costs also decrease because you need fewer machines and operators. If you work with experienced suppliers like RICHCONN you can save even more. Their optimized workflows and bulk production helps lower per-part cost for your projects.
Improved Precision
In this process, parts stay in the same machine throughout the process. This reduces errors. As a result you get better concentricity and tighter tolerances often down to ±0.005″ or better.
Flexibility
Turn mill machining works for both small and large production runs. Quick changeovers allow you to switch between part types easily to support both prototyping and large production needs.
Smaller Footprint
One turn‐mill machine can replace several traditional machines. This frees up floor space and simplifies your workflow.
Uses of Turn Mill Machining
Turn-mill machining serves many industries by combining turning and milling in one machine. This lets you make parts which are complicated, precise as well as reliable.
Automotive
Automotive production uses turn mill machines to make gear housings, shafts and pistons. These machines can form round & flat features which helps to speed up the manufacturing procedure. This is important for making large quantities of car parts.
Aerospace
Aerospace companies use turn mill centers to make turbine blades, engine casings and structural parts. Turn mill machines can work with hard materials like Inconel and titanium. They can also get tolerances in fractions of an mm which is important for aircraft & satellite safety and performance.
For example: RICHCONN recently delivered a batch of Inconel turbine blade mounts for a satellite project and every part met aerospace quality standards and dimensional needs.
Oil and Gas
Oil and gas industry uses turn mill machining to make downhole tools, valve bodies and couplings. Many of these parts have complicated internal shapes which traditional machining can’t produce.
Medical Devices
Turn mill technology is used in medical manufacturing for surgical tools, implants and prosthetics. These machines provide smooth surfaces and high accuracy which are important for patient safety & comfort.
At RICHCONN we have experience with medical grade machining. We follow strict quality protocols to assure every part meets ISO 13485 standards.
Defense and Electronics
Defense & electronics companies choose turn mill machines for connectors, housings and mounts. These parts need high precision and reliability which this technology delivers.
Limitations of Turn Mill Machining
Turn mill machining has many benefits but you should also be aware of some important challenges.
High Initial Cost
Turn mill machines come with a high price tag. Advanced versions with multi axis functions and live tooling can cost more than $200,000. For small shops or those producing low volumes, this large upfront cost can be a burden.
Maintenance Demands
Compared to standard lathes or mills, turn-mill machines have more moving parts and complicated systems. This naturally translates to higher maintenance needs and more frequent servicing which adds to your operating costs.
Operational Complexity
Running these machines requires skill. So you need experienced CNC programmers and operators to handle the advanced multi axis features. Finding and training the right people takes extra money and time.
Size Constraints
Turn mill machines have limits on shape & size of parts they can handle. Unusual or large shaped workpiece may not fit which restricts the type of projects these machines can handle.
Machine Downtime Risks
A failure in any part of the system can stop the entire machine. When this happens you may experience unexpected delays and a drop in productivity.
Best Practices to Produce Turn Mill Machined Parts
You can get better results from turn mill machining by following some proven practices. These steps will help you avoid costly mistakes, be more proficient as well as maintain quality.
Evaluate Production Needs
Start by evaluating your batch sizes, part complexity and tolerances. If you need to make high precision or intricate parts, choose machines with traits like sub spindles and automatic tool changers.
RICHCONN offers free design‐for‐manufacturability (DFM) reviews to help you choose the best turn mill strategy before production.
Operator Training
Make training a priority for your team. Experienced operators and programmers are necessary for running multi‐axis turn mill machines safely & efficiently.
Simulation Software
Run your tool paths through simulation software like Vericut or TopSolid before machining. This will improve cutting sequences and save you from costly collisions. It is particularly useful for multi-channel or 5 axis machines.
Weekly Maintenance
Clean the machine every week, lubricate all moving parts and check for leaks. These steps will keep accuracy high and prevent breakdowns.
Quality Assurance
Inspect finished parts and calibrate your measuring equipment regularly. If possible, add in-process metrology for real-time quality checks and consistent results.
At RICHCONN we use advanced CMM inspection and in-process measurement to assure every part meets your required needs.
To Sum Up
Turn mill machining offer accuracy & efficiency by combining multiple processes in one setup. It is particularly a go for machining method if you need complicated parts that need multi axis work and tight tolerances. Although it has high upfront machining cost, its long term benefits make its cost worth.
If you need any type of custom CNC machining services then Richconn is your best option. You can contact us any time.
Related Questions
How can I know if turn mill machining is the one for my production needs?
Use turn mill machining when you need complicated & high precision parts or want to reduce setups & production time.
What materials can turn‐mill machining work with?
Turn mill machining works well with metals like aluminum, titanium and steel. It can also machine plastics like POM & ABS very well.
Can turn mill machines make small and large parts?
Yes these machines can precisely make any type of parts no matter they are small or large.
Is CNC turn mill machining expensive?
Initial cost of turn mill machines is high. But they save you money in the long run for complex or high volume work.
