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, compositi, and exotic materials—eliminating repositioning errors, cutting lead times, and delivering consistent results for aerospace, medico, e industrie automobilistiche. 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?

Fresatura CNC—also called multi-tasking machining—is an advanced manufacturing tecnologia that integrates both turning and milling operations into a single mill-turning center. A differenza della lavorazione tradizionale (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, risparmiando tempo, e migliorare la coerenza.

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

To explain “Come funziona” 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. Per esempio, 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 Fresatura CNC 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, con un focus su livelli di precisione, tolerance achievements, and multi-tasking flexibility. Below is a detailed breakdown of our key capacities:​

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Se hai bisogno 100 titanium aerospace shafts (with milled keyways) O 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 (Passo-passo)

Nostro processo passo-passo 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, buchi, ecc. 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. Per parti complesse, we use 3D simulation to test tool paths.​

2. Programmazione di cam: The CAD model is imported into CAM software (Mastercam Mill-Turn, Gibbam) to generate integrated Percorsi degli utensili 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, E 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 (lunghezza) and X (diametro) axes to shape cylindrical features—OD (diametro esterno), ID (inner diameter), TOPERS, o Champhers. 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, slot, tasche, or drill holes. Live tooling (rotating tools in the turret) enables drilling and tapping without repositioning.​

Post-Machining Inspection: Parts undergo rigorous controllo di qualità—we measure turning dimensions (diameter/length) with micrometers, milling features (slot depth/hole position) con CMM, and check surface finish with profilometers. Parts requiring finishing move to sfacciato O lucidare.

Materials We Work With

Fresatura CNC 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, e usi ideali:​

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

Trattamento superficiale & Opzioni di finitura

After mill-turning, Offriamo una gamma di Trattamento superficiale E finishing options to enhance part durability, funzionalità, ed estetica. Our most popular services include:​

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Per esempio, we use anodizing for aluminum automotive trim (per resistere ai graffi) and electroplating for brass electronics connectors (to improve conductivity).

Tolleranze & Garanzia di qualità

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

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Nostro quality control processes includere:​

• Pre-machining: Inspecting raw materials for defects (PER ESEMPIO., cracks in titanium, unevenness in composites) and verifying dimensions.​

• Nel processo: Real-time monitoring of spindle speed, velocità di alimentazione, and tool wear via CNC software; touch probe checks (for critical features like hole position).​

Post-lavorazione: 100% Ispezione per parti critiche (medical/aerospace); statistical sampling (5–10%) Per ordini ad alto volume. We also document every step (Parametri di lavorazione, Risultati di ispezione) for compliance.

Key Advantages of CNC Mill-Turning

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

1. Single Setup Machining: Completes all operations (rotazione, fresatura, perforazione, filo) in one setup—eliminating part repositioning errors (common in traditional machining) and reducing tolerance stack-up.​

2. Alta precisione: 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 (PER ESEMPIO., 200,000 brass connectors). No variation from manual repositioning.​

4. Geometrie complesse: Handles parts with both rotational (girato) and prismatic (fresato) features—e.g., a shaft with milled slots, a screw with a hex drive, or a valve with cross-holes.​
5. Tempo di configurazione ridotto: One setup instead of 2–3 (Macchina tradizionale) cuts setup time by 60–80%—speeding up production for prototypes and high-volume runs.

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

7. Versatilità: Handles almost all materials (metalli, non-metals, exotics) and part types—from tiny medical screws (0.5diametro mm) to large aerospace shafts (150diametro mm). It also supports low-volume prototypes and high-volume production (200,000+ unità/mese).​

8. Costo-efficacia: 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. Tolleranze strette: 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 (PER ESEMPIO., lucidare, filo) in one setup reduce tool marks and improve surface roughness (Ra down to 0.02μm)—eliminating the need for secondary finishing in many cases.

Applicazioni del settore

Fresatura CNC is indispensable across industries that require complex, high-precision parts with both rotational and prismatic features. Ecco le sue applicazioni più comuni:​

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Per esempio, in the energy industry, our CNC-mill-turned wind turbine gear shafts (acciaio, ±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 tecniche di lavorazione and optimized processes tailored to complex parts:​

9.1 Core Mill-Turning Techniques​

• Live Tooling Machining:​

The cornerstone of CNC mill-turning—live tooling (rotating tools in the turret) enables milling, perforazione, and tapping while the part is held in the chuck. Per esempio, 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. Usiamo:​

• Radial Live Tools: For features perpendicular to the part’s axis (PER ESEMPIO., cross-holes, slot).​

• Axial Live Tools: For features parallel to the part’s axis (PER ESEMPIO., end-face holes, Discussioni).​

• 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). Per esempio:​

• 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 (PER ESEMPIO., 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 (PER ESEMPIO., an eccentric slot on a camshaft). It eliminates the need for specialized fixtures to offset the part.​

• Bar Feeding & Unattended Operation:​

Per la produzione ad alto volume (PER ESEMPIO., 200,000 brass connectors), Usiamo 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​

• Ottimizzazione del percorso degli strumenti:​

CAM software generates integrated Percorsi degli utensili 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. Operazioni secondarie (filo, sfacciato).​

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

• Cutting Tool Selection:​

We match tools to material and operation:​

• Strumenti di svolta: Carbide inserts (TiAlN-coated for heat resistance) per i metalli; diamond tools for plastics.​

• Strumenti di macinazione: Solid carbide end mills (per precisione) per i metalli; acciaio ad alta velocità (HSS) mulini finali (economico) for plastics.​

• Drills/Taps: Cobalt drills for hard metals (titanio, inconel); HSS taps for soft metals (ottone, alluminio).​

• Sistemi di refrigerante:​

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.​

• Design del dispositivo:​

Custom fixtures enhance stability and precision:​

• Collets: Per parti di piccolo diametro (≤20mm) 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.

Casi studio: CNC Mill-Turning Success Stories

Nostro CNC Mill-Turning services have solved complex part challenges for clients across aerospace and medical industries. Di seguito sono riportati due progetti di successo showcasing our expertise:​

Caso di studio 1: Aerospace Turbine Shaft Manufacturer (Titanium Shafts)​

• Sfida: Il cliente aveva bisogno 500 titanium turbine shafts (80diametro mm, 600lunghezza mm) for jet engines—each requiring a turned outer diameter, 4 milled keyways (120° apart), 6 cross-holes (0.8diametro mm), and a threaded end. Tolerances were ±0.002mm (critical for engine balance), and the client’s previous supplier used separate turning/milling (3 setups), causando 10% of shafts to fail due to misaligned keyways. Lead time was 5 settimane, delaying engine production.​

• Soluzione: Abbiamo usato un 5 assi 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 (Rivestito con tialn) e refrigerante ad alta pressione (80 sbarra) to handle titanium’s low machinability. Our in-line touch probe checked keyway alignment mid-production, rejecting out-of-tolerance parts immediately.​

• Risultati:​

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

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

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

• Testimonianza del cliente: “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.​

Caso di studio 2: Medical Device Company (Titanium Orthopedic Screws)​

• Sfida: Il cliente aveva bisogno 10,000 titanium orthopedic screws monthly (5diametro mm, 30lunghezza mm)—each with a turned cylindrical body, milled hex drive (Per strumenti chirurgici), and threaded end. Tolerances were ±0.001mm (to ensure compatibility with bone plates), and the screws required a smooth surface finish (Ra ≤ 0,1μm) Per ridurre l'irritazione dei tessuti. The client’s previous supplier used separate turning/milling, conducendo a 8% of screws having mismatched hex drives and threads.​

• Soluzione: 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. Post-lavorazione, we inspected 100% of screws with a CMM and profilometer.​

• Risultati:​

• Tasso di difetto scende da 8% to 0.2%—only 20 screws failed per month (contro. 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.​

Testimonianza del cliente: “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: Il nostro team ha 22+ years of specialized experience—we master advanced techniques like live tooling, C-axis rotation, and Y-axis machining. I nostri ingegneri sono certificati in AS9100 (aerospaziale) e iso 13485 (medico) and can solve complex challenges (PER ESEMPIO., ±0.001mm tolerances in titanium, multi-feature small parts) that other providers struggle with.​

• Experience in Various Industries: Abbiamo servito 750+ clienti attraverso 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: Investiamo in all'avanguardia 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.​

• Ottimo servizio clienti: Il nostro team è disponibile 24/7 to support your project—from design consultation (optimizing parts for mill-turning) al follow-up post-consegna. 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). Per progetti urgenti (PER ESEMPIO., medical supply shortages), we assign a dedicated project manager.​

• Tempi di inversione rapidi: Our optimized processes deliver industry-leading lead times:​

• Prototipi (1–50 unità): 1–3 giorni

• Low-volume orders (50–1.000 unità): 3–7 giorni

• High-volume orders (1,000+ unità): 7–14 giorni

Per ordini di punta (PER ESEMPIO., aerospace emergency replacements), we can deliver parts in 48 ore (per piccoli lotti) by running machines 24/7.​

• Soluzioni economiche: 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: Siamo iso 9001, AS9100, e iso 13485 certified—our quality control processes garantire 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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