Introduction

A computer that reads machine code instructions in order to control a machine tool is known as a Computer Numerical Controller. Computer Numerically Controlled, (CNC), Machine tools are used for machining raw material stocks into finished shapes by running a sequence of such instructions. CNC Lathes are the most widely known use of this particular modern technology. They spin a piece of material so that it can be cut, sanded, drilled or polished, with the result being a completed three-dimensional item. In essence, CNC lathes are basically the same as an old-fashioned turret lathe, but running under computer control.

History

Electric motors started to become generally available in the early 20th century, and this inevitably led to many conventional lathes being converted to electric power. This was the first phase in automating the milling or turning process, It continued rapidly through the 20th century as producers and industrialists increasingly sought to improve efficiency and reduce production costs.

Constituent Parts / Components

Today’s CNC lathes combine a computer with a lathe machine and a controller to convert each digital program instruction into the desired action at the cutting tip. Specialized software is first used to create the required design that needs to be replicated physically on metal, wood, etc. The piece of raw material is then fixed into the machine’s chuck and spun at the required speed so that the programmed action can be carried out. The computer then controls the cutting action of the lathe as required in order to produce the finished product. The latest lathes can have up to four spindles to perform multiple jobs simultaneously, which reduces production time and improves productivity accordingly.

CNC lathes are usually fitted with three jaw hydraulic chucks. Work holding is accomplished with hard jaws or bored soft jaws. Lathes may also have a collet chuck. This allows for variable size and precision holding without the need for soft jaw boring. When equipping a lathe with a collet chuck, it may be necessary to modify or change the draw bar connecting the actuator to the chuck.

Tool pieces are usually made of hard alloys such as titanium carbide and tungsten carbide, and may vary depending on the material that needs to be processed. They are used until the sharpness reduces below a predefined level. After this level is reached they are either resharpened, or replaced with a new bit.

A skilled operator is still required for a CNC lathe, despite all the advances in computer technology. This is still a much quicker, more productive and more cost effective solution than traditional lathes could achieve. A developer is also required to compile the program commands needed to instruct the equipment in the first place.

Programming a CNC lathe firstly requires a blueprint of the item to be created. The blueprint is then analysed and converted into the programming required to control the lathe. Every move is programmed in extremely fine detail so that the required engineering tolerances can be achieved. A lot of skill and quality review is required at this stage to ensure no problems occur once the program is running in the live environment.

Practical Applications of CNC Lathes

CNC lathes were primarily designed for cutting hard materials spinning at high speed. They are also frequently used for boring precise holes into such hard materials. Modern lathes are also often used on other materials such as plastic and wood. CNC Lathes are widely used for making cylindrical engineering parts such as pistons, gearboxes, etc which require a very high level of precision. Manual lathes are still used by smaller scale craftsmen, where mass production is not an issue, and where the craftsman’s skill is a key part of the production process.

Advantages / Benefits

CNC Lathes have rapidly replaced the older manual lathes due to their ease of programming and operation. They ensure consistency in quality control and design tolerances, and provide a more rapid turn-round time for complex one-off parts. They are very much leading edge technology in engineering circles and embody the latest processes and design principles. Three further benefits are reduced production time, reduced inventory and reduced set up times. With the continuing rise in demand for engineered parts, CNC lathes ultimately give higher production volumes, with greater precision and fewer errors.

Summary

CNC lathes bring real benefits to the general population and are a perfect example of man’s technological achievements being put to practical use. Goods today can be produced faster, more accurately and at a cheaper cost than previously due to their extensive use.

Bio:
Phil Marston is the editor of www.lathes-cnc.com. Please feel free to contact him for more info.

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Without the advancement of metal fabrication many things we take for granted could not be made today. One of the most useful forms is the one used to bend pipes to create such things as water lines, natural gas pipes and oil pipelines.

Interesting Fact #1:

Before the invention of steel pipe bending for oil pipelines, oil was transported from oil wells to railway stations by horse in converted wooden whiskey barrels. It is because of these wooden whiskey barrels that we still measure oil by the barrel today.

In the beginning pipelines used to transport oil were made from wrought iron, such as the very first pipeline that stretched only 6 miles long. This first wrought iron pipeline connected an oil field in Titusville PA to a railway station in Oil Creek. After its success pipelines became more popular and eventually were built out of metal and steel.

Oil is one of the most important materials that utilize pipelines, but it isn’t the only one. Beside fuel, such as oil and natural gas, pipelines also carry water, sewage and many other things. There are three main types of pipelines, which are ones for gathering, ones for transportation and those for distribution.

1 – Transportation Pipelines: These are the pipelines that are the ones that probably first come to mind when you think or an oil pipeline. These pipelines consist of very long pipes with large diameters and are used to transport products such as crude or refined oil and natural gas long distances. Transportation pipelines can stretch between cities, countries and even continents.

2 – Gathering Pipelines: These type of pipelines are typically a group of smaller interconnected pipes that are used to gather crude oil or natural gas from a number of different areas or wells with the purpose of sending the material to nearby processing or treatment plants. The pipes used in gathering pipelines are smaller, both in length and diameter, than the large oil pipeline that most likely comes to mind. Gathering pipelines are also used in deep-water oil platforms.

3 – Distribution Pipelines: These are the pipelines that send the finished product, such as natural gas, directly to the consumer’s home. Pipelines that are located at shipping and storage areas that send the product to tankers and storage facilities are also considered distribution pipelines.

As you can see, all three types of pipelines are important, and the pipes in each one would require bending at many points along the way.

Over the years pipes have been made from a variety of materials, from wood, stone, glass, plastic, metal, steel, lead and copper. Oil pipelines are typically made from bending steel pipe while natural gas pipelines are made using carbon steel. When it comes to water pipes, the majority of them are made using copper, but older houses and buildings may still be using lead pipes.

Interesting Fact #2: The Romans were the first civilization to use lead pipes to transport water. Plumbum is the Latin word for lead and one who works with water pipes is still known today as a Plumber. (The next time a plumber comes to your house – may it be a long time from now – ask him if he knows where the word “plumber” comes from.)

In order to bend steel pipe for pipelines a significant amount of heat and pressure is required. This is why only a major metal fabrication plant can construct them. That’s right – don’t try this at home! As the demand for more pipelines increases metal fabrication plants will have to become more economical and develop systems that produce pipelines that are also more reliable.

Metal tubes are used in a number of things we take for granted each day, from anything that needs to be constructed, like buildings and bridges, to the transportation of fuel, water and even sewage. The one process that allows us to use metal or steel tubes in many different functions is the ability to bend them to the specific angles and shapes that we require.

You would be amazed at how flexible they are. In fact, check the underside of your car and you will see the results of bending metal tubes on a smaller scale than, say, a cross-country pipeline.

The 7 ways to bend steel tubes are:

1 – Press Bending – Press bending is the first bending process that is used on cold metal tubes. In this process a die that is in the shape of the bend that is required is pressed against the tube with extreme pressure forcing the tube to conform to the shape of the die. In this process the tube does not have any internal support so there will be a significant amount of deformation.

2 – Bending Springs – Typically bending springs are only used for smaller diameter tubes made from copper. In this process a strong flexible spring is inserted into the tube for added support during the bend. This will minimize the amount of distortion that occurs at the bend point.

3 – Rotary Draw Bending – Rotary draw bending machines are the most popular type of machines when it comes to bending metal tubes for such things as handrails, furniture frames and roll cages for vehicles.

4 – Sand Bending – In order to create a bend with the sand packing process the tube is completely filled with sand and the ends are sealed off. Next the tube is heated to 1,600 degrees Fahrenheit, placed on a slab and set with pins. The actual force to create the bend comes from a winch and the sand helps to minimize the distortion of the tube.

5 – Roll Bending – Roll benders are typically used in a series where the tube is passed under a number of these benders that apply pressure to the tube to gradually change the shape and form the required bend. There are two different types of roll benders, which are the pyramid style and the double pinch style.

6 – Mandrel Bending – With mandrel bending a steel rod is placed inside the metal tube to give the tube extra support, which will help minimize the distortion during the bending process. There are for types of mandrel bends and they are: Plug mandrel, Form mandrel, Ball mandrel without a cable and Ball mandrel with a cable.

7 – Heat-induction Bending – With heat-induction bending a small coil is placed around the area of the tube that requires the bend. This area is then heated up to 800 to 2,200 degrees Fahrenheit and while the tube is still hot pressure is applied to bend it into the desired shape.

These are just seven of the techniques for steel tube bending. Many more have been tried over the years; these remain. The seven types of metal tube bending process that were mentioned in this article are only the most common types of tube bending that are used today. Technology is always advancing and as the supply for materials like steel and metal tubes increases industry leaders will find more cost effective and environmental ways to produce the metal tubes that help carry the lifeblood of our society.

Here is another place where you can find out more on how to bend steel tubes.