Lathes are ubiquitous in industrial facilities and are used for cutting, turning, and forming various components. The core functions include clamping the required material and rotating it through a spindle. They can be manual, semi-automatic, or fully CNC automated. What is the difference between CNC metal lathe and regular lathe?
Manual lathes require a trained operator to position the workpiece and select the cutting tool. Typically, these tools use high-speed steel (HSS) containing chromium, tungsten, vanadium, and carbon. These lathes are best suited for symmetrical parts quickly clamped into the spindle.
CNC metal lathes produce parts with extremely high dimensional accuracy. It can process different materials, including metal, wood, and glass. These machines were initially designed by American John T. Parsons in the 1940s and use computer numerical control. G-code (geometry code) and M-code (miscellaneous) programs control the movement and functions of CNC machines, directing feed rates, spindle speeds, and more.
CNC lathes, that is, lathes controlled by computer numbers, are highly efficient automated equipment that automatically processes workpieces according to pre-programmed CNC programs.
“CNC lathes are primarily utilized for cutting and processing the inner and outer cylindrical surfaces of shaft parts or disk parts and the inner and outer conical surfaces of various taper angles. They are also used for machining complex rotating inner and outer curved surfaces and creating cylindrical and conical threads. Additionally, they can perform grooving, drilling, reaming, and boring operations.”
The working principle of CNC metal lathe is to compile the processing route, process parameters, tool motion trajectory, displacement, cutting parameters, and auxiliary functions of parts into a processing program sheet according to the instruction code and program format specified by the CNC metal lathe, and then record the contents of this program sheet on the control medium, and then input it into the CNC device of the CNC lathe, to command the lathe to process parts.
An ordinary lathe is a horizontal lathe that can process various types of workpieces, such as shafts, disks, and rings in multiple processes.
The main components of an ordinary lathe are the spindle box, feed box, slide box, tool holder, tailstock, guide rod, lead screw, and bed. It is characterized by ample low-frequency torque, stable output, high-performance vector control, fast torque dynamic response, high steady-speed accuracy, rapid deceleration and parking speed, and strong anti-interference ability. It is often used to process the internal and external rotating surfaces, end faces, and various internal and external threads of workpieces. The corresponding tools and accessories can also be used for drilling, reaming, tapping, and knurling. The ordinary lathe is the most widely used, accounting for about 65% of the total lathes. Because its spindle is placed horizontally, it is called a horizontal lathe.
Operation and Control
· Manual vs. Automatic
With a regular lathe, all operations are performed manually, which involves manually moving the cutting tool and the workpiece. With a CNC lathe, these processes are controlled by computer software, which eliminates variability and the need to look after the machine constantly.
· Control Mechanisms
On a regular lathe, there are slides and levers for setting and controlling the tool via a handwheel. Ideally, this should require a lot of skill and experience because you shouldn’t forget that the measurements should be precise.
CNC lathes are operated by inputting commands into a computer control panel, from which the CNC coordinates the tool movement and operations. This makes large-scale and repetitive machining operations possible with limited human interference.
Precision and Accuracy
· Tolerances
A regular lathe requires a practitioner and further manual micromanagement if you need parts with tight tolerances. Coordination is difficult to maintain, and precision consistency in complex operations becomes difficult. However, with a CNC lathe, it is easy to achieve high precision and accuracy. Since the entire process is computer-controlled, there is little or no margin for error and no varying thicknesses.
· Repeatability
Performing the same operation multiple times on a regular lathe can be problematic due to human factors. However, on a CNC lathe, you have accuracy in your work because the cutting tool can return to the same point over and over again.
Once a program is set up, it can be repeated repeatedly to perfectly replicate the same part, allowing large production lines to be consistent.
Production Speed and Efficiency
· Mass Production
Mass production is also faster and more efficient when using a CNC lathe. It enables you to set up the machine once and then have it create many similar parts without any intervention from you.
These dependencies and automation help reduce the time required to produce a product to a minimum.
With a regular lathe, you must adjust specific settings, which is time-consuming and error-prone. Another difference with CNC lathes is that they can be produced in large quantities because they involve process automation.
CNC lathes offer many advantages over traditional machines. Five of the main benefits are outlined below.
1. No Highly Skilled Operators Required
In the past, using a lathe required two highly skilled operators to operate the lathe and control the material. It was a tough job. But now, with the introduction of computers and automation, lathe tasks are much more manageable. You only need one operator – one skilled enough to input the dimensions into the machine, adjust the feeds and speeds, and let the computer (and machine) do the rest.
2. Fully automated, making the job easier and faster
Thanks to modern CNC lathes, producing hundreds or even millions of similar dimensions is easier than ever. Today, machine control systems make it easier and faster for CNC lathes to produce perfect parts than ever before. Whether you need a simple part, a complex part with tight tolerances, or a unique, intricate shape, a CNC lathe can do it.
3. Versatile and can be used to make a wide range of products and parts
Unlike manual lathes, CNC lathes are versatile and can produce almost any type of product or part – from sturdy furniture and car parts to delicate lamps and pottery. Cylinders or spheres can be easily shaped using CNC lathes and can even be used to produce replacement parts for other machines.
4. 99.99% Accuracy
The likelihood of achieving optimal accuracy with CNC lathes is relatively high due to the less manual labor involved. This makes these machines a top choice for industries that require high precision – such as aerospace, healthcare, and hospitality. Additionally, CNC lathes can process almost all types of materials. That said, you can never eliminate all errors, manual or otherwise. That’s why we’ve left that 0.01% aside.
5. Cost-effectiveness
While CNC lathes are significantly more expensive than manual lathes, CNC models still offer a range of economic benefits, including:
Low installation costs: With CNC lathes, installation costs are a one-time expense.
Machining costs: With a CNC machine, you can produce 20 times more parts in a given time than with a manual lathe, thus recovering every investment.
Labor costs: CNC lathes require fewer operators to work, and they don’t need to be at the machine 24/7. This frees up your labor budget for other essential operations.
Material waste: Fewer human errors means less material waste.
CNC lathes are computerized, precise, timely, and suitable for complex and repetitive work. At the same time, regular lathes are cheaper and more appropriate for simple operations. Choose wisely according to your requirements.