In precision manufacturing, high-quality CNC turn-mill parts are rarely just “turned.” Modern components like complex flanges and shafts require off-axis holes, milled keyways, and strict flatness tolerances that a standard lathe cannot achieve alone.
At Rapid Model, we specialize in Complex Rotational Parts. Whether it’s a batch of aluminum sealing flanges or a stainless steel drive shaft, the secret to quality lies in our “One-Setup” strategy.
1. The “One-Hit” Strategy: Perfect Phase Synchronization
Take a look at the stainless steel component. It features a central turned shaft, a milled keyway, and a specific pattern of tapped holes on the flange.
The Engineering Challenge:
The most critical tolerance here is Position. The keyway must be perfectly aligned (phased) with the bolt holes.
- The Old Way: Turn the shaft on a lathe -> Remove part -> Clamp on a mill -> Indicate center -> Cut keyway.
- Result: Accumulated error. The keyway might be off-center by 0.05mm, causing assembly failure.
- The Rapid Model Way (Turn-Mill):
We machine this part on a Turn-Mill Center. The machine turns the diameter, drills the bolt holes, and mills the keyway without ever unclamping the part.
Why it matters:
By eliminating the second setup, we guarantee:
- True Concentricity: The shaft axis and the hole pattern share the exact same center.
- Perfect Phasing: The angle between the keyway and the first hole is mathematically precise.
2. The “Rainbow” Finish: Engineering for Air-Tight Sealing
The Function:
These flanges are designed for an application requiring Air-Tight Sealing (vacuum or high-pressure fluid).
- The Requirement: A standard “turned” finish (spiral marks) can create a leak path for gas or fluid to escape.
- The Solution: We achieve this specific “Rainbow Finish” using a large-diameter Face Mill (Fly Cutter) running at high RPM with a slow feed rate.
How we control it:
Achieving this mirror-like finish on 500 parts requires more than just a sharp tool:
- Program Optimization: We calculate the exact chip load to prevent vibration (chatter).
- Machine Rigidity: Our machines are calibrated to ensure the spindle is perfectly perpendicular to the table, eliminating “step-over” marks.
- Result: A surface roughness (Ra) that meets strict sealing requirements, straight off the machine.
3. Material Versatility: 6061-T6 vs. Stainless 304
These photos represent the core materials we machine daily for automation and robotics industries:
- Aluminum 6061-T6 : Lightweight and easy to anodize. Ideal for high-speed robotic arms or electronic housings.
- Stainless Steel 304/316 : Tough and corrosion-resistant. Essential for drive shafts, outdoor machinery, or food-grade equipment.
Conclusion
A flange isn’t just a connector; it’s a precision interface. Whether you need the Geometric Truth of a Turn-Mill shaft or the Surface Integrity of a sealing flange, Rapid Model delivers.
Don’t risk your assembly with “close enough” parts.
Send us your STEP file today. We will optimize the machining strategy for maximum precision and sealing performance.
