Our CNC Mill-Turning Services

Transform your complex part production with our CNC Mill-Turning services—the ultimate multi-tasking machining solution that combines milling and turning in one setup. Using advanced mill-turning centers, we craft high-precision components (tolerances down to ±0.001mm) from metals, Verbundwerkstoffe, and exotic materials—eliminating repositioning errors, cutting lead times, and delivering consistent results for aerospace, medizinisch, und Automobilindustrie. Whether you need cylindrical parts with intricate milled features or custom components requiring both turning and milling, our single-setup approach boosts efficiency without compromising quality.​

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What Is CNC Mill-Turning?

CNC-Mühle—also called multi-tasking machining—is an advanced manufacturing Technologie that integrates both turning and milling operations into a single mill-turning center. Im Gegensatz zur herkömmlichen Bearbeitung (which requires separate lathes for turning and mills for milling, plus manual part repositioning), it lets you complete complex parts in one setup—reducing errors, Zeit sparen, und Verbesserung der Konsistenz.

Der Prozessübersicht revolves around a hybrid machine: A mill-turning center combines a rotating spindle (for turning cylindrical features) with multi-axis tool turrets (for milling flat surfaces, Bohrlöcher, or adding slots). The part is held in a chuck or collet, rotated by the spindle (drehen), while tools move along linear (X, Y, Z) and rotational (A, C) axes to add milled features—all under CNC control.​

To explain “Wie es funktioniert” simply: Imagine a machine that can first turn a metal bar into a shaft (cylindrical turning), then immediately mill a slot on its side, drill cross-holes, and add threads—all without moving the part to another machine. Zum Beispiel, a medical bone screw (which needs a turned cylindrical body, milled flat drive, and threaded end) can be fully machined in one run. This seamless combination of turning and milling is what makes CNC-Mühle ideal for parts with both rotational and prismatic features.

Our CNC Mill-Turning Capabilities

We offer comprehensive mill-turning capabilities tailored to complex part requirements, mit einem Fokus auf Präzisionsniveaus, tolerance achievements, and multi-tasking flexibility. Below is a detailed breakdown of our key capacities:​

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Ob du brauchst 100 titanium aerospace shafts (with milled keyways) oder 50,000 brass electronics connectors (with turned bodies and milled slots), our mill-turning capabilities scale to match your project’s complexity.

The CNC Mill-Turning Process (Schritt für Schritt)

Unser Schritt-für-Schritt-Prozess is optimized to leverage the multi-tasking power of mill-turning centers, ensuring efficiency and precision from design to finish:​

1. Design and CAD Modeling: We start by reviewing your CAD model (or creating one from sketches) to identify all features—turned diameters, milled slots, Löcher, usw. Our engineers optimize the design for mill-turning—e.g., ensuring milled features are accessible without spindle interference and turning diameters are compatible with chuck size. Für komplexe Teile, we use 3D simulation to test tool paths.​

2. Cam -Programmierung: The CAD model is imported into CAM software (Mastercam Mill-Turn, Gibbscam) to generate integrated Werkzeugpfade for both turning and milling. We sequence operations logically: first turning (to create the cylindrical base), then milling/drilling (to add prismatic features), and finally finishing (polishing/threading). We also program C-axis rotation (for angular milling) and live tooling activation.​

3. Setup and Calibration: The raw material (bar stock or blank) is loaded into the machine’s chuck/collet. We calibrate the spindle (for turning speed) and tool turret (for milling accuracy) using laser measuring tools. Cutting tools are loaded into the turret, Und coolant systems are activated—directed to both turning and milling zones. A test part is run to verify tolerances and tool alignment.​

4. Turning Execution: The spindle rotates the part, and turning tools move along the Z (Länge) and X (Durchmesser) axes to shape cylindrical features—OD (Außendurchmesser), AUSWEIS (inner diameter), Verjüngung, oder Chamfers. For long parts, a tailstock provides additional support to prevent deflection.​

5. Milling Execution: After turning, the spindle stops rotating (or indexes to a fixed angle via C-axis), and the tool turret moves along X/Y/Z (and A/B if needed) to mill flat surfaces, Slots, Taschen, or drill holes. Live tooling (rotating tools in the turret) enables drilling and tapping without repositioning.​

Post-Machining Inspection: Parts undergo rigorous Qualitätskontrolle—we measure turning dimensions (diameter/length) with micrometers, milling features (slot depth/hole position) mit CMMs, and check surface finish with profilometers. Parts requiring finishing move to Enttäuschung oder Polieren.

Materials We Work With

CNC-Mühle excels with a wide range of materials, though tool selection and parameters vary based on material hardness and machinability. Below is a breakdown of our supported materials, key properties, und ideale Verwendungen:​

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We test all materials to optimize spindle speeds, Futterraten, and tool selection—ensuring consistent precision across every part.

Oberflächenbehandlung & OPTIONEN

After mill-turning, Wir bieten eine Reihe von einer Reihe von Oberflächenbehandlung Und finishing options to enhance part durability, Funktionalität, und Ästhetik. Our most popular services include:​

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Zum Beispiel, we use anodizing for aluminum automotive trim (Kratzer zu widerstehen) and electroplating for brass electronics connectors (to improve conductivity).

Toleranzen & Qualitätssicherung

Toleranzen for CNC Mill-Turning focus on both turning (diameter/length) und Fräsen (feature position/size) precision—critical for parts where fitment depends on multiple features. Unser quality control processes ensure strict adherence to standards:​

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Unser quality control processes enthalten:​

• Vorabbau: Inspecting raw materials for defects (Z.B., cracks in titanium, unevenness in composites) and verifying dimensions.​

• In-Prozess: Real-time monitoring of spindle speed, Futterrate, and tool wear via CNC software; touch probe checks (for critical features like hole position).​

Nach dem Maschinieren: 100% Inspektion auf kritische Teile (medical/aerospace); statistical sampling (5–10 %) für hochvolumige Bestellungen. We also document every step (Bearbeitungsparameter, Inspektionsergebnisse) for compliance.

Key Advantages of CNC Mill-Turning

Compared to traditional separate turning/milling or single-process machining, CNC-Mühle offers transformative benefits:​

1. Ein -Setup -Bearbeitung: Completes all operations (drehen, Mahlen, Bohren, Fäden) in one setup—eliminating part repositioning errors (common in traditional machining) and reducing tolerance stack-up.​

2. Hohe Präzision: Achieves tolerances as tight as ±0.001mm—critical for parts like medical implants (where fit directly impacts patient safety) or aerospace sensors (where precision affects performance).​

3. Consistency and Repeatability: CNC programming ensures every part is identical—even for high-volume orders (Z.B., 200,000 brass connectors). No variation from manual repositioning.​

4. Komplexe Geometrien: Handles parts with both rotational (umgedreht) and prismatic (gemahlen) features—e.g., a shaft with milled slots, a screw with a hex drive, or a valve with cross-holes.​
5. Reduzierte Setup -Zeit: One setup instead of 2–3 (Traditionelle Bearbeitung) cuts setup time by 60–80%—speeding up production for prototypes and high-volume runs.

6. Increased Efficiency: High-speed machining (bis zu 20,000 RPM for milling) and automated tool changers reduce per-part cycle time by 30–50% compared to traditional methods. Zum Beispiel, a brass connector that takes 5 minutes to make with separate turning/milling takes just 2 minutes with CNC mill-turning.​

7. Vielseitigkeit: Handles almost all materials (Metalle, Nichtmetalle, exotics) and part types—from tiny medical screws (0.5mm Durchmesser) to large aerospace shafts (150mm Durchmesser). It also supports low-volume prototypes and high-volume production (200,000+ Einheiten/Monat).​

8. Kosteneffizienz: While mill-turning centers have higher upfront costs, reduced labor (one operator runs 2–3 machines), fewer setups, and lower scrap rates (due to fewer errors) cut long-term costs by 25–40%.​

9. Enge Toleranzen: The single-setup approach eliminates tolerance stack-up (errors from repositioning), enabling tighter tolerances (± 0,001 mm) than traditional machining (which often struggles with ±0.005mm for multi-feature parts).​

10. High-Quality Surface Finish: Integrated finishing operations (Z.B., Polieren, Fäden) in one setup reduce tool marks and improve surface roughness (Ra down to 0.02μm)—eliminating the need for secondary finishing in many cases.

Branchenanwendungen

CNC-Mühle is indispensable across industries that require complex, high-precision parts with both rotational and prismatic features. Hier sind die häufigsten Anwendungen:​

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Zum Beispiel, in the energy industry, our CNC-mill-turned wind turbine gear shafts (Stahl, ±0.002mm tolerance) reduce friction and extend turbine life by 20% compared to traditionally machined shafts. In medical devices, our titanium orthopedic screws (with milled drive slots and turned threads) ensure a perfect fit for patients—reducing surgical complications.

Advanced Manufacturing Techniques in CNC Mill-Turning

To maximize the performance of CNC mill-turning, we leverage specialized Bearbeitungstechniken and optimized processes tailored to complex parts:​

9.1 Core Mill-Turning Techniques​

• Live Tooling Machining:​

The cornerstone of CNC mill-turning—Live -Werkzeug (rotating tools in the turret) enables milling, Bohren, and tapping while the part is held in the chuck. Zum Beispiel, after turning a shaft’s outer diameter, we use a live drill to add cross-holes and a live tap to create threads—all without repositioning. Wir verwenden:​

• Radial Live Tools: For features perpendicular to the part’s axis (Z.B., cross-holes, Slots).​

• Axial Live Tools: For features parallel to the part’s axis (Z.B., end-face holes, Themen).​

• C-Axis Indexing/Rotation:​

The C-axis (rotational axis of the spindle) lets us position the part at precise angles (indexing) or rotate it continuously (for circular milling). Zum Beispiel:​

• Indexing: Rotating the part 90° to mill a slot on its side, then 180° for another slot—ensuring perfect symmetry.​

• Continuous Rotation: Rotating the part while milling to create helical features (Z.B., spiral grooves on a turbine shaft).​

• Y-Axis Machining:​

The Y-axis (linear axis perpendicular to both X and Z) enables off-center milling—critical for parts with features not aligned to the spindle axis (Z.B., an eccentric slot on a camshaft). It eliminates the need for specialized fixtures to offset the part.​

• Bar Feeding & Unattended Operation:​

Für hochvolumige Produktion (Z.B., 200,000 brass connectors), Wir verwenden automatic bar feeders (3–6 meter capacity) to load raw material into the machine. This enables unattended operation for 8–12 hours, reducing labor costs and increasing efficiency.​

9.2 Supporting Technologies​

• Werkzeugpfadoptimierung:​

CAM software generates integrated Werkzeugpfade that minimize tool travel and prioritize operations by material removal:​

1. Rough turning (removes most material quickly).​

2. Rough milling (shapes prismatic features).​

3. Finish turning (refines cylindrical surfaces).​

4. Finish milling (polishes slots/holes).​

5. Sekundäre Operationen (Fäden, Enttäuschung).​

For hard materials like titanium, Wir verwenden trochoidal milling (circular tool paths) to reduce cutting force and extend tool life.​

• Cutting Tool Selection:​

We match tools to material and operation:​

• Drehwerkzeuge: Carbide inserts (TiAlN-coated for heat resistance) für Metalle; diamond tools for plastics.​

• Mahlwerkzeuge: Solid carbide end mills (Für Präzision) für Metalle; Hochgeschwindigkeitsstahl (HSS) Ende Mills (kostengünstig) for plastics.​

• Drills/Taps: Cobalt drills for hard metals (Titan, inconel); HSS taps for soft metals (Messing, Aluminium).​

• Kühlmittelsysteme:​

Directed coolant ensures optimal performance:​

• Flood Coolant: For metal machining—high-pressure (50–80 bar) coolant directed to the cutting zone reduces heat and flushes chips.​

• Mist Coolant: For plastics/exotics—atomized coolant prevents melting/warping without residue buildup.​

• Through-Spindle Coolant: For deep-hole drilling—coolant flows through the drill’s center to reach the cutting tip, improving chip evacuation.​

• Vorrichtungsdesign:​

Custom fixtures enhance stability and precision:​

• Collets: Für Teile kleiner Durchmesser (≤ 20 mm) to ensure concentricity (± 0,001 mm).​

• Chucks: For large-diameter parts (20–150 mm)—3-jaw chucks for round parts, 4-jaw chucks for irregular shapes.​

Tailstocks: For long parts (≥300mm) to prevent deflection during turning/milling.

Fallstudien: CNC Mill-Turning Success Stories

Unser CNC Mill-Turning services have solved complex part challenges for clients across aerospace and medical industries. Unten sind zwei Erfolgreiche Projekte showcasing our expertise:​

Fallstudie 1: Aerospace Turbine Shaft Manufacturer (Titanium Shafts)​

• Herausforderung: Der Kunde benötigte 500 titanium turbine shafts (80mm Durchmesser, 600MM Länge) for jet engines—each requiring a turned outer diameter, 4 milled keyways (120° apart), 6 cross-holes (0.8mm Durchmesser), and a threaded end. Tolerances were ±0.002mm (critical for engine balance), and the client’s previous supplier used separate turning/milling (3 Setups), Ursache 10% of shafts to fail due to misaligned keyways. Lead time was 5 Wochen, delaying engine production.​

• Lösung: Wir haben eine 5-Achse verwendet mill-turning center with live tooling and C-axis rotation. We machined each shaft in one setup: first turning the outer diameter and threading the end, then using C-axis indexing to mill the 4 keyways (120° apart) and radial live tools to drill the cross-holes. We used carbide turning inserts (Tialn beschichtet) und Hochdruckkühlmittel (80 Bar) to handle titanium’s low machinability. Our in-line touch probe checked keyway alignment mid-production, rejecting out-of-tolerance parts immediately.​

• Ergebnisse:​

• Misalignment rate dropped from 10% to 0.5%—only 3 shafts failed per batch (vs. 50 previously).​

• Lead time shortened from 5 Wochen zu 2 weeks—helping the client meet their engine launch deadline.​

• Production cost per shaft decreased by 35% (reduced labor from 3 setups to 1).​

• Client -Zeugnis: “The single-setup mill-turning eliminated our biggest pain—misaligned keyways. The shafts balance perfectly, and the fast delivery saved our production line. We’ve made them our exclusive supplier for turbine shafts.” — Raj P., Aerospace Engineering Director.​

• Before and After: Traditionally machined shafts had uneven keyway spacing; mill-turned shafts featured perfectly aligned keyways and cross-holes that met engine balance requirements.​

Fallstudie 2: Medical Device Company (Titanium Orthopedic Screws)​

• Herausforderung: Der Kunde benötigte 10,000 titanium orthopedic screws monthly (5mm Durchmesser, 30MM Länge)—each with a turned cylindrical body, milled hex drive (für chirurgische Werkzeuge), and threaded end. Tolerances were ±0.001mm (to ensure compatibility with bone plates), and the screws required a smooth surface finish (Ra ≤ 0,1μm) Gewebereizungen reduzieren. The client’s previous supplier used separate turning/milling, führt zu 8% of screws having mismatched hex drives and threads.​

• Lösung: We used a compact mill-turning center with live tooling and C-axis indexing. We loaded titanium bar stock into an automatic bar feeder (for unattended operation) and programmed the machine to: 1) turn the screw’s body and threads; 2) index the C-axis to 60° increments to mill the hex drive; 3) polish the surface with a fine-grit live tool. We used diamond-coated milling tools for the hex drive (to ensure sharp edges) and mist coolant to prevent titanium oxidation. Nach dem Maschinieren, we inspected 100% of screws with a CMM and profilometer.​

• Ergebnisse:​

• Die Defektrate fiel von gesunken 8% to 0.2%—only 20 screws failed per month (vs. 800 previously).​

• Surgeons reported a 40% reduction in screw insertion time (due to precise hex drive/thread alignment).​

• The client’s patient satisfaction score increased by 25% (thanks to the smooth surface finish).​

• Challenge Overcome: Separate turning/milling caused hex drives to be off-center relative to threads; CNC mill-turning’s single setup ensured perfect alignment.​

Client -Zeugnis: “These screws fit better than any we’ve used—no more struggling with misaligned hex drives. The smooth finish also means less post-surgery irritation for patients. We’ve doubled our order.” — Dr. Lisa M., Orthopedic Surgeon.

Why Choose Our CNC Mill-Turning Services?

With numerous CNC mill-turning providers, here’s what sets us apart as a trusted partner for complex part production:​

• Expertise in CNC Mill-Turning: Unser Team hat 22+ years of specialized experience—we master advanced techniques like live tooling, C-axis rotation, and Y-axis machining. Unsere Ingenieure sind in AS9100 zertifiziert (Luft- und Raumfahrt) und ISO 13485 (medizinisch) and can solve complex challenges (Z.B., ±0.001mm tolerances in titanium, multi-feature small parts) that other providers struggle with.​

• Experience in Various Industries: Wir haben gedient 750+ Kunden über 10 industries—from aerospace giants to medical startups. This cross-industry experience means we understand sector-specific requirements: FAA compliance for turbine shafts, FDA regulations for orthopedic screws, and ISO/TS 16949 for automotive parts.​

• High-Quality Equipment: Wir investieren in hochmoderne Art mill-turning centers—15 systems (5-axis and 3-axis) with live tooling, automatic bar feeders, and in-line inspection (laser micrometers, touch probes). All machines are calibrated weekly (using laser interferometers) to maintain ±0.001mm precision.​

• Hervorragender Kundenservice: Unser Team ist verfügbar 24/7 to support your project—from design consultation (optimizing parts for mill-turning) Nachfolger. We offer free CAD reviews (identifying features that can be consolidated into one setup) and free samples (so you can verify quality before placing large orders). Für dringende Projekte (Z.B., medical supply shortages), we assign a dedicated project manager.​

• Schnelle Turnaround -Zeiten: Our optimized processes deliver industry-leading lead times:​

• Prototypen (1–50 Einheiten): 1–3 Tage

• Low-volume orders (50–1.000 Einheiten): 3–7 Tage

• High-volume orders (1,000+ Einheiten): 7–14 Tage

Für Rush -Bestellungen (Z.B., aerospace emergency replacements), we can deliver parts in 48 Std. (für kleine Chargen) by running machines 24/7.​

• Kostengünstige Lösungen: We help you save money through:​

• Single-setup machining: Eliminates 2–3 setups, reducing labor costs by 40–50%.​

• Unattended operation: Automatic bar feeders let us run machines overnight, lowering per-part labor costs.​

• Volume discounts: 10% off orders over 10,000 units and 15% off orders over 50,000 units—ideal for automotive/electronics high-volume parts.​

Commitment to Quality: Wir sind ISO 9001, AS9100, und ISO 13485 certified—our quality control processes sicherstellen 99.9% of parts meet your specifications. We also offer full traceability (each part is labeled with a unique ID linked to machining logs and inspection data) for compliance.

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