Star CNC
Published

Re-Evaluating The Controlled Cycle Lathe

The gap between manual lathes as found in a toolroom and CNC turning centers as found in a production plant is very wide. Many applications call for something in between--a turning machine that not only lends itself to making a single part or a small batch of parts, but also lends itself to complex or difficult operations.

Share

The gap between manual lathes as found in a toolroom and CNC turning centers as found in a production plant is very wide. Many applications call for something in between—a turning machine that not only lends itself to making a single part or a small batch of parts, but also lends itself to complex or difficult operations. Lathe manufacturers have responded to this demand by developing a class of turning machines that is rather diverse and goes by a variety of names. These machines have been called semi-CNC, semi-automatic, teachable, hybrid and controlled cycle lathes. The common characteristic of these machines is that they can be operated in a mode involving some level of electronic assistance. Many also can be operated in a strictly manual mode with the operator simply working the handwheels.

The level of electronic assistance found on these machines varies widely. It ranges from a level one step above a simple digital readout that gives the operator prompts, to a level one step below full CNC in which automatic operation does not require standard G-code program input. Given this broad range of electronic modes, it is not surprising that no single term has emerged as an acceptable name for this category of machines.

One of the machine tool builders that is particularly active in this area is Weiler Machine Tools, a German builder with U.S. offices in Fort Mill, South Carolina. This 64-year old firm has a strong reputation in Europe as a builder of high precision toolroom lathes and CNC turning centers. About 10 years ago, the firm began introducing precision lathes with automatic cycles. Although these machines have been widely accepted in Europe, Weiler has found that these machines are not well understood in the U.S. market.

The company ascribes part of this resistance to the general confusion surrounding this category of machines and the unsatisfactory experience some users have had with lower quality imports. Another factor is the scarcity of skilled lathe operators in this country, causing many U.S. companies to conclude that only full CNC machines are the answer to this situation.

Weiler company officials would say that these companies are overlooking a better solution, the lathe with automatic cycles, which the company is now promoting under the term "controlled cycle" lathes. This name seems to be favored because it succinctly characterizes the high level of electronic assistance that it offers while preserving the flexibility that manual operation provides.

The threading routines that can be called up and executed on a Weiler controlled cycle lathe show how one of these machines can perform operations in a way that neither a manual nor a CNC machine could. Recutting a threaded workpiece provides the best example. Responding to prompts on the control interface, the operator selects a thread type, the start and stop points of the thread, and the diameter. The handwheel is used to locate the bottom of the existing thread, and then the operator presses the key to memorize this position. At this point, the operator has an option to start the cycle and let it run with limited handwheel input or choose to maintain complete control over both axes. The lathe will continue to run along the established lead, or the operator may manipulate the axis input using the two handwheels. The display continues to maintain the location, aiding the operator in decisions concerning changes in axis input. According to Weiler, this mode of operation reduces the time of manual rework by about 75 percent compared to unassisted operation, noting that it would be virtually impossible to perform this operation on a CNC machine.

The control features also allow contour routines to be "memorized" easily. The operator generates the contour profile by entering a series of simple profile elements and related dimensions, then lets the system automatically calculate points of intersection, radius blends, tapers and other math functions.

Shop managers who believe that CNC versus manual operation in turning is an either/or situation should take a closer look at the spectrum of machines that fill the gap. These managers may discover a class of turning equipment, such as the Weiler controlled cycle lathes, that transcends both manual and CNC machines. These lathes perform complicated turning operations impossible to do on any manual lathe and, compared to a full CNC machine, they offer considerable time saving through shorter programming and quicker tool setups.

Marubeni Citizen CNC
Star CNC
MWR120 Automated Twin Spindle Multitasking CNC
World Machine Tool Survey
MMS Made in the USA
VERISURF
IMTS+
TIMTOS
Paperless Parts
SolidCAM
JTEKT
Innovative Manufacturing for the Medical Industry

Related Content

Custom Motorcycle Parts Made Here: Video Tour of a Family-Owned CNC Machine Shop

Lee Wimmer invited us to tour his second-generation family-owned machine shop in Perkasie, PA. This video explores the production processes behind precision-machined parts for both Wimmer Custom Cycle and LS Wimmer Machine Co., and shows how ingenuity and determination are still at the heart of American manufacturing. Today, both companies are now managed by Wimmer’s three sons.

Read More
Sponsored

Quick-Change Tool Heads Reduce Setup on Swiss-Type Turning Centers

This new quick-change tooling system enables shops to get more production from their Swiss turning centers through reduced tool setup time and matches the performance of a solid tool.

Read More
Automation

Inside the Premium Machine Shop Making Fasteners

AMPG can’t help but take risks — its management doesn’t know how to run machines. But these risks have enabled it to become a runaway success in its market.

Read More
Turning Machines

DN Solutions Launches New Series of Turning Machines

The Puma DNT Series is equipped with a powerful spindle, a redesigned turret body and live tool drive that provide precise machining and productivity.

Read More

Read Next

Automation

IMTS 2024: Trends & Takeaways From the Modern Machine Shop Editorial Team

The Modern Machine Shop editorial team highlights their takeaways from IMTS 2024 in a video recap.

Read More
Workforce Development

Inside Machineosaurus: Unique Job Shop with Dinosaur-Named CNC Machines, Four-Day Workweek & High-Precision Machining

Take a tour of Machineosaurus, a Massachusetts machine shop where every CNC machine is named after a dinosaur! 

Read More
Sponsored

The Future of High Feed Milling in Modern Manufacturing

Achieve higher metal removal rates and enhanced predictability with ISCAR’s advanced high-feed milling tools — optimized for today’s competitive global market.

Read More
MWR120 Automated Twin Spindle Multitasking CNC