Machining

Rough Turning is the first and fast-cutting stage done on a lathe for gears shape, which is a machining process to rapidly remove the bulk of material from a workpiece, bringing it close to its final shape which is like using a chainsaw to carve a block of wood down to its basic form. Rough turning is to using high depth of cut and high speed rates for maximum material removal. Its toolings need to be strong, durable interts with tough geometries that allows it to bear high sorces and shocks. The roughness after rough turning is not precision, dimensions are rough and will kept some fine turning allowance for fine machining on gears.

Fine Turning is a precision finish machining process on a lathe. It is in order to achieve the final dimensions of the finish gears, tight tolerances, and excellent surface finish specified on the engineering drawing which is like using fine sandpaper and a polishing cloth to achieve a smooth, precise final surface. Fine turning is using light depth of cut, low feed rate, and high cutting speeds for accuracy and surface quality on finish gears. Its toolings need to be sharp, wear-resistant inserts with polished rake faces or larger nose radii to produce a smooth finish. Fine turning could bring the gears into its final specifications with superior surface integrity (low Ra value).

CNC machining is a an automated manufacturing process controlled by pre-programmed computer software and code. Normally gears are designed in CAD software. CAM software translates the CAD model into G-Code, a machine language that dictates tools paths, speeds, feeds, and all movements. This profram is loaded into a CNC machine. The machine’s computer controller executes the program, automatically driving the cutting tools to shape the raw material into the finished gears. CNC is not an alternative to rough turning or fine turning. It is the primary modern platform for executing these operations with unmatched efficiency and consistency.