Grooving tools are used with a CNC lathe to cut channels or paths into holes or the surface of a workpiece. This grooving process is fully automated, reducing manual input and operator errors.
Part manufacturers in many industries use grooving tools to create holes and form different sized parts. However, it is important to fully understand the tools before using them. Therefore, this article describes the grooving tools available, how to use them with a CNC lathe, and what factors you should consider before choosing the right tool.
What is grooving?
Grooving (also known as grooving) is a machining operation performed on a CNC lathe. This process creates boundary holes (a groove) in a material, design, or workpiece.
The grooving process is crucial in part manufacturing because the tool creates long, narrow paths on the cylindrical surface of the part. These paths, in turn, guarantee a precise fit when joining the pieces.
Furthermore, the different types of grooving tools used in manufacturing parts are made of materials with different hardness and textures and have different shapes and widths, which in turn determine the shape of the path or groove.
Types of channel tools
There are different types of channel tools with shapes, sizes, and features that make them easier to use. Below are the most commonly used types in parts manufacturing.
Axial grooving tools
Designers use this plunge turning tool to machine the surface of a material. During the face grooving process, it is important to position the tip of the tool just above the centerline of the workpiece. The tool radius must match the radius of the cut in the workpiece. Furthermore, it is important to remove the chips to avoid breaking the insert.
OD Grooving Tools
The groove in the outer diameter occurs on the outer surface of the material or workpiece. Additionally, an OD groove produces best results when the tool tip is placed slightly below the center line. Just like milling tools, this type of grooving tool comes in different shapes, designs, and mechanical properties. Furthermore, they have cooling holes that increase wear resistance.
Inside Diameter Grooving Tools
Operators use bore-hole drilling tools on the inner surface of the material or workpiece. To obtain accurate and consistent results, it is best to keep the top of the tool above the center line. It also helps prevent the insert from breaking.
Most bore grooving tools are made from hard materials such as high-speed steel, carbide, diamond, and more.
How do you cut grooves on a CNC lathe?
Grooving on a CNC lathe involves several steps. Below are the steps to be followed during the grooving process:
1. Clamp the workpiece
Fixing the part is crucial to the final quality of the grooving process. Because every movement, no matter how small, can lead to errors in the final part. Below are some steps you should follow:
- Place the part in the lathe chuck;
- Fix the material in the mandrel and tighten the screws at the end;
- Mark the position of the groove.
2. Load the tool devices
Based on desired groove type
- Select the plunge turning tool and load it into the tool turret.
- Calibrate the tool.
The tools are operated automatically according to the written program.
3. Set up your CNC lathe
This is the first step to perform a channel operation. Furthermore
Turn on the machine and move all axes to position 0.
Set the lathe to the appropriate speed. This step is very important because each groove requires a different speed.
4. Enter and run the program
In this step the program is loaded and executed. The grooving tool remains stationary while the part rotates axially. To remove material accurately, follow these steps:
- Fix the tool correctly in the center and position the grooving tool to start working.
- Carefully place the grooving tool close to the part until the cut begins;
- Wait for the process to complete.
5. Clean
After successful piercing
- Turn off the machine and remove the part;
- Clean the machine and grooving tool.
Note: It is important to check the depth of the groove before starting the cut and use cutting oils to avoid deformation.
Various grooving operations on a CNC lathe
Based on the slot position, there are three basic types of slot cutting on a CNC lathe.
External drilling
In this type of grooving process, the tool is moved radially along the side of the material. During the grooving process, the tool removes unwanted material along the intersection points.
Part manufacturers use external channels to produce mainly wide channels. However, this process is time-consuming and has a greater impact on lathe machining time than smaller grooving. Therefore, coolant and a tool with very high precision are required.
There are three types of external channel
-Incision groove milling
This type of external grooving is the best method for creating grooving in a part. This involves making a single shallow cut into a workpiece. Because surface finish is critical, it is important to use an insert with an accurate profile and chamfer for mass production.
-Multiple slots
This involves making several deep grooves in a workpiece. For a perfect final part, it is necessary to increase the material processing advance to around 30-50%. Additionally, the materials left for final cuts must be narrower than the width of the inserts.
– Ramps
Ramping is an external grooving method that involves sequential axial and radial movement to create a groove in a material. Axial movement is similar to end milling. For excellent chip control, it is important to reduce axial cutting action and notch wear.
Internal drilling
Internal grooving involves moving a grooving tool along the internal parts of a material.
It is important to accurately apply high-flow refrigerant. This increases the material removal rate and controls chip formation. Additionally, to achieve optimal chip evacuation, start the internal grooving process from the back of the hole to the front.
Axial channel
In this process, the CNC lathe is moved along the surface of the material. Coping tools are used for this. To achieve high stability, use a facing tool with the smallest depth of cut. Also use high-precision coolant facing tools. This results in better chip control and removal.
Considerations when selecting a channel tool
When selecting a tool for grooving, certain factors must be understood and considered. Below are some very important factors to consider:
1. Types of grooves
As mentioned earlier, there are three main types of channels based on common channel tools. Most channel tools available are designed specifically for different types of channels. For example, axial grooving tools are used for axial grooving. These tools can move accurately in an axial pattern when placed slightly above the center line.
2. Part material
Some material properties such as stiffness, tensile strength, heat resistance, etc. play a big role in selecting a grooving tool. When choosing a channel tool, you should pay attention to the above factors. The harder the material, the more robust the grooving tool. For example, tools made from carbide or steel are ideal for very hard parts.
3. The desired format
The shape of the groove is an important factor to consider. This is because different types of channel tools create a unique format. However, manufacturers often use more than one tool for a single part.
How can channel processing be improved?
For many types of channels, performance depends on the efficiency of the machine and the process itself. However, below are some ways to increase grooving efficiency:
1. Testing and measurement procedures
Part manufacturers and engineers use different measurement tools depending on the level of accuracy. They typically use steel rulers and calipers for grooves that require very low precision. On the other hand, use calipers, limit gauges and micrometers for those who require a high level of precision.
2. Feed and cutting speed
Feed rate and cutting speed play a crucial role in machining time and surface finish of the part. Therefore, it is important to use the correct feed and cutting speeds. To improve grooving, you can start with a low feed rate and work up to a higher feed rate to improve chip breaking and evacuation. Additionally, you should work at the recommended cutting speed to extend tool life.
3. Selection of channel tools
There are many different types of channel tools. The tool used directly affects the appearance of the final part. It is recommended to use high-speed steel CNC cutting tools. This helps prevent wear during machining. Additionally, a groove turning tool with the same width as the groove is ideal for grooves with smaller widths and low turning points.
4. Using cutting fluid
Cutting fluids such as oils, pastes and aerosols help reduce the temperature of the part's cutting surface during the grooving process. Additionally, they help lubricate the workpiece to aid in the cutting process, which in turn facilitates chip evacuation.
Concluding
Grooving tools are multifunctional devices that manufacturers use to create grooves and shape parts. The slot machining process is important in manufacturing because the slot guides another part that moves against the main part.
Common questions
What is the difference between a groove and a groove?
A slot is a long, straight hole with a full radius at its edges. Furthermore, it is often cut perpendicular to the axial points of the cylinder. A groove, on the other hand, resembles a cylindrical groove. It is usually cut into the outer or inner diameter of a cylinder.
What kind of material is best for making grooving tools?
Since the workpiece is generally made of hard materials, grooving tools must be able to achieve strength and texture. The recommended material is diamond due to its high hardness and thermal conductivity. However, it is expensive. Parts manufacturers use relatively cheaper alternatives such as carbide and steel.
Is it necessary to coat drilling tools?
Drilling tools are mainly made of metal. For this reason, manufacturers often coat them. However, no coating is required for drilling tools. The coating prevents corrosion and ensures longer tool life.
