This article contains everything you need to know about Swiss screw machines and their use.
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A Swiss screw machine is a highly efficient lathe that is capable of performing several cutting processes in a single machine cycle using multiple tools. They are unique in their ability to produce precision parts with excellent tolerances in high volume. Although Swiss screw machines are classified as lathes, they function in a manner that is like and unlike a lathe. The process for a traditional lathe involves moving a workpiece to the cutting tool as the workpiece rotates against the tool.
With Swiss screw machines, the workpiece and cutting tools move and reposition to shape the workpiece, a more efficient and time saving process. In addition to moving along the X, Y, and Z axes, a Swiss screw machine is capable of cutting along two or more additional axes. The cutting tool’s movements make it possible for Swiss screw machines to complete the production of precision parts without the need for additional finishing or secondary processing.
During the first industrial revolution, Swiss watch makers developed screw machines to produce small, intricate, precision screws in large quantities. In the over 150 years since their introduction, Swiss screw machines have become an essential and vital part of the production of a variety of precision parts. Their accuracy and efficiency have revolutionized manufacturing and improved the quality of parts and products.
The popularity of Swiss screw machines is due to their ability to produce highly complex parts with exceptionally close tolerances. CNC Swiss screw machines further enhance efficiency by having improved tooling that reduces cost. The first Swiss screw machines were known as automatic lathes since they completed the same processes as traditional lathes. Over the years, particularly since the Second World War, Swiss screw machines have rapidly improved and transformed into today’s CNC Swiss screw machines.
With advancements and improvements, Swiss screw machines have been repurposed for the manufacture of a wide assortment of parts and components. Using a rotating lathe, Swiss screw machines remove material from a workpiece. A disc cam is used to change rotary motion into linear motion or linear motion into rotary motion, depending on the machine’s programming, to position the spindles of the machine.
The two types of Swiss screw machines are automatic and CNC. Automatic machines have a disc cam that rotates tools to the workpiece bay. A collet holds the workpiece in place. The disc cam moves the tools in a radial motion and alters the position of the headstock to account for the longitudinal discrepancies of the workpiece. Automatic Swiss screw machines have very close spindle collets that prevent deflection and debris from interfering with the cutting process.
CNC Swiss screw machines operate on the same principles as an automatic Swiss screw machine but have codes entered into their CNC controller to direct the positioning of the workpiece. They have more sets of tools, which allows them to perform several operations on the same workpiece in a shorter amount of time.
Although automatic Swiss screw machines can perform several operations, they lack the precision, accuracy, and swiftness of the CNC version. CNC Swiss screw machines can rotate a part up to 10,000 RPM at an accuracy level of 0.00508 mm (0.0002 inch) to 0.0127 mm (0.0005 inch).
Automatic Swiss screw machines were a revolutionary development in the manufacturing industry and changed the concepts regarding the production of intricate parts and components. The structure of modern automatic Swiss screw machines includes an automatic lathe with a sliding headstock and guide bushing. The sliding headstock includes a collet that has clamps to hold the workpiece.
The sliding headstock makes it possible to rotate the workpiece being held by the collet and allows it to move axially on the Z axis. A chucking collet in the sliding headstock holds the workpiece as it moves through the guide bushing toward the cutting tools. Since the workpiece moves to meet the cutting tools, it experiences less lateral force, which allows for extremely accurate cuts.
The collet holds the workpiece as it is machined by the cutting tools. It is a cylindrical sleeve that forms a collar around the workpiece and has a hole down the center that forms a tube shape where the bar stock is positioned. Swiss machine collets have three moveable sections on one end that are tightened to hold the bar stock.
Guide bushings can be rotary or fixed and are the component of a Swiss screw machine that differentiates it from traditional lathes. A rotary guide bushing rotates the bar stock and pushes the workpiece into the cutting tool. As the headstock moves axially rotating the bar stock, the guide bushing rigidly supports the turning bar stock close to the tools. This allows for the production of high quality parts with exceptional accuracy and excellent finishes. Rotary guide bushings rotate with the bar stock while fixed guide bushings remain stationary as the bar stock spins.
The disc cam of a Swiss screw machine rotates the tools of the machine to the correct position. The guide bushing and collet hold the workpiece as the disc cam moves the cutting tools against the workpiece and changes the orientation of the headstock to adjust for longitudinal variances.
The spindle holds one or more cutting tools. The number of tools a Swiss screw machine has depends on its design. Machines with more than one spindle are capable of performing multiple operations in a single machine cycle, which leads to faster completion of parts.
Spindles can operate at high torque at low speed for milling or at low torque and high speed for drilling with small diameter tools. They come with jaws to hold the cutting tools and can reach velocities of 10,000 RPM. The spindle is powered by a motor, the type of which varies according to the Swiss screw machine manufacturer.
Computer Numerical Control (CNC) Swiss screw machines operate using the same tools, parts, and mechanisms as those that are used by automatic Swiss screw machines. Unlike automatic Swiss screw machines, CNC Swiss screw machines are programmed using a set of codes that determine the path and cutting of multiple tools.
The loading of bar stock for a CNC Swiss screw machine is similar to that for an automatic Swiss screw machine, which is by hand or robotics. CNC Swiss screw machines depart from automatic Swiss screw machines in their capabilities and accuracy. They can have a greater number of axes for their approach to the workpiece and operate at a high speed.
The design for a part is created with Computer Aided Design (CAD) software or computer aided manufacturing (CAM) software, which makes it possible to create 2D and 3D renderings of products and parts. Although the CNC machine and CAD software contain commands, the codes used by a CNC machine are different from those generated by design software and have to be converted for CNC Swiss screw machine use.
Instructions from design software are changed to a set of codes that are known as G codes and M codes, miscellaneous codes. G codes are geometric codes and are the predominant set of codes used by CNC Swiss screw machines. They are similar to the programming language of computers in that they consist of a long list of instructions each of which is preceded by the letter G.
The controller for a CNC Swiss screw machine converts the G codes into a list of instructions regarding the axis, spindle, and tools of the machine. The accuracy and efficiency of G code programming allows CNC Swiss screw machines to make errorless precision cuts. Included in each G code is a positioning for the tool to be used and the axes where the tooling will be located on the workpiece, such as G03 X11 Y10 Z-1.
The instructions from G codes of CNC Swiss screw machines tells the spindle where to move the cutting tool and how to cut. The beginning and ending of the cutting or tooling process is determined by M codes, which are included in each set of G codes.
The G code, G00, determines the starting point for the cutting process. The cutting code is G01, programmed as G01 X0 Y20 F200. The last section of the programming code, F200, indicates the feed rate of the cutting process, which remains the same throughout. The initiation or turning ON of the spindle is programmed as M03, which indicates the spindle is ON and turning in a clockwise direction. M code M05 instructs the spindle to stop. The M03 code is placed at the beginning of the list of commands while M code M05 is at the end. M code M30 indicates that the program is completed and stopped.
The spindle collet on an automatic Swiss screw machine is capable of having a single spindle, which is not the case with CNC Swiss screw machines. Using multi spindles, CNC Swiss screw machines perform cuts, slotting, and drilling in one machining process. Each spindle has a cutting tool designed to create a feature on the workpiece. Multi-spindle machines can have as many as six spindles.
Both types of Swiss screw machines have been developed to meet the demand for more efficient manufacturing methods. The machining process begins with the feeding of bar stock through a feeding system. The different designs of bar feeding systems are designed to meet the requirements of volume and part complexity.
The key feature in a bar stock loading system is its ability to prevent harmful vibrations that are caused by the bar stock rotating. Vibrations can damage the spindle, cutting tool, and affect the precision of cuts, which degrades the surface finish. The two types of bar feed systems are hydrostatic and hydrodynamic.
The workpiece is held in place by a collet that extends into the enclosure of the machine and can be supported by tailstock.
From the collet, the bar stock passes into the headstock where it is tightly clamped.
The guide aspect of the tooling process is the guide bushing, which holds the bar stock in place prior to its entrance into the tooling area. The positioning by the guide bushing is unique to Swiss screw machines in that it prevents a buildup of debris due to its placement in relation to the spindle.
The movement of the headstock is another differentiating feature of Swiss screw machines since it is not fixed in place but moves back and forth on the Z axis.
The bar stock is moved in the correct positions for cutting as the tools make contact with the bar. The cutting feed is determined by the information programmed into the machine.
Once the process is completed, the part is safely removed without damaging its surface. With CNC Swiss screw machines, robots or automated devices are used. The accuracy and efficiency of Swiss screw machines removes the need for any secondary process such as deburring, polishing, or smoothing of surfaces. The completed part is ready for the application for which it was designed.
The unique nature of Swiss screw machines necessitates the use of cutting tools that are capable of making precise cuts with exceptional tolerances. The tools are crafted and designed for use with Swiss screw machines and have the necessary durability and strength. There is a wide assortment of Swiss screw machines cutting tools that vary from milling and threading tools to boring and forming ones.
Swiss screw machine drilling involves using a rotating cutting tool to produce round holes in the workpiece. A drill bit is secured to the spindle and programmed with drill speed, feed rate, and the position of the spindle such that holes of the correct depth and diameters are cut.
Boring is a process used to increase the diameter of a hole that does not have the correct diameter. The process enlarges the size of a smaller hole. The tool used for the boring process is referred to as a boring bar and is a single point tool that is attached to the spindle. It operates at hundreds of RPM and cuts off small chips as it removes material. The two common types of boring bars are line and back.
The milling process uses a series of cutting tools mounted on the spindle to create complex geometries and features. It is ideal for making angled shapes, slots, channels, chamfers, holes, curves, and smooth flat surfaces. Swiss screw machines remove large amounts of material accurately, quickly, and with exceptional precision to create high quality configurations with smooth surfaces.
Parting or cutoff tools are made of high speed steel (HSS) that is able to cut materials quickly and smoothly. HSS is a form of tool steel that is designed for use with cutting tools such as power saws and drill bits. Parting or parting off is the last part of the Swiss screw machine process and comes in various forms depending on the requirements of the part design.
The process of threading refers to cutting threads into the workpiece for making screws or bolts with the pattern of ridges and troughs in a screw being external threads and ones on the inside of a bolt being internal threads. The two versions of threading are single point and thread whirling.
With single point threading, a solitary cutting head attached to the spindle moves linearly and horizontally against the workpiece. The programmed speed of the cutter and its rotational speed determine the depth of the threads and how close together they are.
Thread whirling is like thread milling with the cutters mounted on the inside of a cutting ring or holder. It is an exceptionally fast and accurate method for making long threaded screws and bolts. Thread whirling allows for higher feed rates and increased production speeds. The rings for thread whirling come in several configurations with up to twelve cutting inserts.
An internal threading tool or tap is used to cut internal threads, a process that is referred to as thrilling, which is drilling and threading. For cutting internal threads, a single point or multiple point milling and tapping tool is mounted on the spindle. Unlike the external threading tool with the cutting blades on the inside of a ring, an internal threading tool resembles a mill with several blades on the outside of the ring.
A turning tool is a single point tool that is used for rough or fine cutting. The difference between the two turning tools is the result of their cutting process with rough turning tools removing large amounts of material while fine turning tools are used for finishing and removing small amounts of material.
A facing tool is used to plane the surface of the workpiece at right angles to the axis of its rotation. It removes material from the end of the workpiece, which is referred to as its face. The purpose of a facing tool is to produce a smooth even flat surface.
The process of machining a workpiece can produce sharp edges that need to be sloped and smoothed. The chamfering tool, mounted on the spindle, is used to eliminate sharp edges. Some of the chamfering processes include beveling, spotting, and countersinking. The key to the use of a chamfering tool with Swiss screw machines is programming the tool for the precise depth of the cut and the desired shape.
Knurling creates a pattern on the surface of the workpiece. It is a finishing process that places horizontal, vertical, or crossing lines on the surface of a workpiece to give the surface a texture. In many cases, knurling produces a diamond pattern that is a rough finish that makes gripping a tool easier. Unlike other Swiss screw machine processes, knurling does not involve cutting or material removal.
The use of Swiss screw machines is an efficient way for producing custom parts for unique and unusual applications. Their ability to manufacture nonstandard parts with unusual features and multiple elements that do not exist anywhere in the world makes them the perfect choice for producing custom components.
The manufacture of custom parts is essential to the medical field for the creation of instruments, orthopedic screws, and spine implants. The designs for weaponry and advanced technology for aerospace and defense requires the designing and manufacturing of unique components with exceptionally high tolerances.
Custom parts are precision engineered from CAD/CAM renderings for making prototypes using Swiss screw machines. All Swiss screw machine companies provide design and engineering services capable of producing any part, regardless of its unusual design.
The original purpose for Swiss screw machines was the mass production of tiny screws for watches since producing them by hand was not sufficient to meet demand. Since the introduction of the machines during the first industrial revolution, the use of Swiss screw machines has expanded to the manufacture of a wide range of parts and components.
The popularity of Swiss screw machines is based on their ability to perform multiple machining processes in a single cycle, which is unlike traditional lathes that perform one process at a time.
A bushing or plain bearing is a hollow cylinder that reduces friction by sliding between two parts. They distribute high or heavy load bearing and act as shock absorbers to decrease noise and wear.
Screws are one of the products produced by Swiss screw machines that are in high demand. The process for producing screws includes a set of processes that are performed in a machine cycle and include taps, cutting tools, and forming tools. Swiss screw machines produce all forms of screws from micro screws for small items like watches, cellphones, and handheld devices up to larger screws for automobiles and airplanes.
Although the original purpose of Swiss screw machines was the production of screws, the first Swiss screw machine screws were for watches and timepieces. The production of screws has expanded far beyond the original purpose of the equipment into any form of screw using various metals and plastics.
There are an endless number of types of screws that include wood screws, metal screws, MDF screws, and machine screws. Each of the types comes in a variety of sizes with custom designed screws for specialized applications.
Bolts are similar to screws but are larger and stronger. They are used with a washer and nut to join pieces together. Washers are added to bolts to help spread the load and reduce wear and tear.
Pins are cylindrical fasteners that are used to join two components by sliding through a hole drilled in the components. They are made of a variety of materials depending on the required shape, size, and design of an application. Pins are used to secure parts where shearing forces push the pin in opposite directions.
Spacers are used to fill in gaps between surfaces and provide additional strength for machine connections. They are made of a wide variety of materials and come in an assortment of sizes, types, and shapes. Spacers, like bushings, reduce friction and vibrations by maintaining the space between components. Although spacers have a similar shape as washers, they are longer, more precise, and create space to add clearance.
Gears are an essential machine part that are found in engines and motors. They require the highest level of tolerance such that they mesh appropriately. Swiss screw machines produce the highest quality gears for a wide variety of engines from ones for automobiles to ones for airplanes and spaceships.
The few parts listed above are a small sampling of the types of components that are produced using CNC Swiss screw machines and automatic screw machines. In many cases, manufacturers have to develop custom designs of components to meet the needs of new designs and applications.
There are very few restrictions on the types of materials that can be fabricated using Swiss screw machines with the main concern being the ability of the material to withstand the stress created by the process. Manufacturers work with their clients to choose the correct material for the application where a component will be used and its cost. Rigidity, hardness, resistance to temperature and chemicals, heat treatability, and surface finish are all considerations when selecting materials.
Aluminum is a common and cost effective metal used by Swiss screw machines. It is lightweight, strong, has excellent conductivity, corrosion resistance, and can endure detailed machining. Aluminum is widely used for electrical components and in the automobile and aerospace industries.
As with aluminum, steel is widely used for its durability and strength. The variations in steel are determined by the percentage of various alloys to produce it. It is a highly durable metal that is resistant to wear and can be used in a variety of applications. The main attraction of steel for Swiss screw machine use is its exceptional tensile strength, which varies in accordance with its alloys. High carbon content steel has exceptional strength but is difficult to machine.
High carbon steel has a very high carbon content, which makes it hard and durable. It can be machined but becomes more difficult to machine as its carbon content rises. Carbon steel is used to produce components due to its resistance to damage, dimensional stability, and maintains its properties when exposed to variations in temperature.
Like aluminum, brass is a cost effective solution for the production of precision parts. It is easy to machine, produces an excellent finish, and maintains a high tolerance and threads. The properties of brass make it the first choice for the production of detailed complex parts. Since brass is antimicrobial, it is a popular choice for the production of medical implants and instruments. The low friction coefficient of brass makes it ideal for the manufacture of gears and bearings.
Since copper is very soft, malleable, and ductile, it has to be strengthened with various alloys such as beryllium. It is easy to shape with some alloys having strength that is comparable to steel. Copper can be heat treated to enhance its hardness and improve its durability. The one characteristic of copper that makes it desirable for manufactured parts is its superior conductivity.
Titanium is widely used due to it being one of the strongest and most durable metals on earth. It has the highest strength to density ratio of any metal and rivals the strength of steel but is less dense than steel. Like aluminum, titanium has a natural resistance to rust and corrosion due to it forming an oxide layer. The drawback to titanium is its cost, which is much higher than iron, steel, and aluminum.
As with other forms of steel, stainless steel is used for Swiss screw machining due to its strength. Unlike other steels, stainless steel is alloyed with a percentage of chromium, which makes it resistant to corrosion. It comes in a wide assortment of grades each of which has properties that can be applied to a specific or special application. For components that have to endure constant stress, stainless steel is an ideal metal because of its durability.
The emphasis for the use of Swiss screw machines is the manufacture of metal components with high tolerances and precision. Although this was the original design of Swiss screw machines, they are also used to shape various plastics for home appliances and toys. In certain conditions, engineered plastics are a cost effective replacement for light metals such as aluminum. For certain applications, plastics have the same strength and durability of metals.
Precision parts and components are an essential part of several industries to ensure the performance of their products. The ability of Swiss screw machined parts to meet the tolerance of designs has been the driving force behind using the process for the manufacture of components. CAD/CAM intricate and complex renderings are produced in volume with exceptional tolerances and compliance to design parameters.
Over the last thirty years, there has been an ever growing trend to miniaturize the components of electronic devices. As the electronics industry has striven to make things smaller, they have required their products to be lightweight, compact, and easily accessible. Swiss screw machining perfectly matches this growing demand by being able to produce specialized miniature parts.
Medical component manufacturing is one of the main uses of Swiss screw machines due to its ability to produce complex, antimicrobial, and innovative parts. The production of medical components, especially for implants, have to meet the strict standards established by the Food and Drug Administration (FDA) and be able to produce unique geometric shapes.
Titanium and certain plastics are the primary materials used to manufacture medical implants and instruments. A major problem in the production of medical implants is the constant changes and adaptations engineered to meet medical conditions. These advancements and improvements have led Swiss machine manufacturers to produce equipment and tools capable of meeting the increasing innovations.
Many medical parts have exceptionally small diameters that are not able to be processed using other lathe methods. Swiss screw machines excel at working with diameters smaller than 32 mm (1.26 inch). Miniature parts are delicate, fragile and require reduced handling. Aside from their size, small parts have thin walls, intricate facets, and small attachments. Swiss screw machines are the ideal choice because of their ability to be programmed to the finest detail.
Thread whirling has become a major development in the production of precision bone screws, which do not have the need for female threads. They are attached directly into the bone and must be able to remain stable and tight.
Of the many industries that make use of Swiss screw machines, the aerospace industry has the greatest need for precision accuracy with repeatability. Parts and components are produced at tolerances of ±0.0001 to ensure safety and have the reliability demanded by aircraft engineers. It is the precision of Swiss screw machines that is the first choice in the production of aerospace components, such as fasteners, bushings, clamps, manifolds, hinges, shafts, and valve, engine and cockpit components.
Although not as strict, the food industry is required to comply with the same standards as the medical industry, which are overseen by the FDA. The established requirements necessitate the use of certain materials when producing components to ensure sanitary conditions for the production of food. Conveyor belts, stainless steel mixers, and motors are made with parts produced using Swiss screw machines, all of which have been approved by the FDA.
The key factor for the military sector is durability with the highest possible tolerances. Military gear undergoes a great deal of stress and must be able to perform in the harshest conditions. For safety and compliance with regulations, parts for military equipment have to meet the standards developed by military engineers to the smallest detail. Every aspect of military equipment is outlined in the documentation presented to manufacturers down to the thread size of screws to the diameter of bolts. The need for high quality, precision, and high tolerances necessitates the use of Swiss screw machines in the production of military hardware.
The automotive industry is one of the biggest users of the technology associated with Swiss screw machines. Over the years since the introduction of the first gas powered automobile, the automobile industry has developed several automated technologies to increase production speed and eliminate labor intensive machining. Swiss screw machines have easily adapted to the goals of the industry and provide it with the types of automation it requires.
There are several aspects of automotive production that rely on the use of Swiss screw machine parts. Dashboard panels are manufactured using the process as well as starter motors, cylinder heads, drive axles, and gearboxes. Swiss screw machines offer design engineers the flexibility to develop new custom designed parts that enhance the performance of automobiles.
A key feature that is often used by automobile designers is prototyping, which can be easily completed using Swiss screw machines. Prototypes can be headlights, engine parts, cylinder heads, and custom newly designed components. Swiss screw machines make it possible to produce a wide range of complex parts since CNC Swiss screw machines can have multiple cutting tools loaded onto the spindle.
The major industries listed above are a sampling of the many industries that rely on the precision, accuracy, high tolerances, and rapid production provided by Swiss screw machines. The manufacturers of Swiss screw machines are constantly striving to develop new tools, capabilities and programming to enhance the machining process.
During the beginning of the first industrial revolution, Swiss watch makers needed to improve their ability to produce the small parts that were a crucial part of the assembly of watches and timepieces. At the time, screws and other components were manufactured by hand and did not have the precision and accuracy required for the manufacture of quality timepieces.
With the development of the collet chuck and headstock, the original Swiss screw machine came into being. The machines became a necessity during the Second World War and had their use rapidly expanded during the decades after the war. Today, CNC Swiss screw machines dominate the market for precision produced parts and components.
Swiss screw machines have a shorter cycle time being able to produce thirty components in the same time an ordinary CNC machine produces one. Unlike other machining methods, when a part is finished by a Swiss screw machine, it does not need any secondary operations and can be packed to ship.
Since the workpiece is held close to the tooling operation, the applied cutting force produces exceptionally tight tolerances. The bar stock is supported through the tooling process to avoid deflection. The process makes it possible to produce distinctive features, make deeper cuts, and parts with thin walls.
Deflection is avoided due to the positioning of the workpiece between its support and the cutting tool. The close proximity results in less bending and the possibility of deflection on the cutting surface. The removal of deflection leads to tighter and higher tolerances.
The movement of the workpiece and tool allows for greater efficiency in the manufacture of a component. Slots, cross drilling, tapping, and back drilling are all completed in one cycle eliminating the need for secondary operations. A component produced by a Swiss screw machine is ready to use at the end of machining.
Of the many features of Swiss screw machines, precision is the most notable and one of the reasons they are so popular. Complicated, intricate, and complex parts are produced with the minutest details and exceptional precision due to the guide bushing that supports a part.
The rotational speed of a CNC Swiss screw machine can be up to 10,000 RPM to produce parts with a close tolerance of 0.005 mm (0.0002 inch). These factors make CNC Swiss screw machines the most accurate and reliable forms of machining.
An additional benefit of CNC swiss screw machine precision is the reduction of the amount of waste produced during the machining process due to the removal of potential human error. What scrap metal waste that is produced is collected and recycled.
The ability of Swiss screw machines to produce thousands of parts in a short amount of time significantly lowers manufacturing costs, which is one of the reasons that the auto industry, aerospace, and defense industry rely on the precision of Swiss screw machines.
The types of materials used by Swiss screw machines include soft metals, like aluminum and copper, and hard metals, such as carbon steel and titanium. In addition to machining metals, Swiss screw machines work well with plastics like thermosets and thermoplastics. Regardless of the type of material, complex and complicated parts are created with exceptional precision, accuracy, and efficiency.
Although the main focus of Swiss screw machines is the production of small intricate parts, the Swiss process is capable of producing large parts with less deflection, high tolerances, and smooth even surfaces. This flexibility makes it possible for manufacturers to meet the needs of all of its customers, regardless of the requirements.
One of the challenges of modern industry is the rapid development of innovations, improvements, and advancements. This aspect of today’s manufacturing requires manufacturers to quickly adjust to the ever changing needs of their clients. Swiss screw machines use new CAD/CAM renderings to produce the most unique and unusual parts efficiently with precision and accuracy.
Swiss screw machines can have their tools and programming adjusted to meet the needs of customized innovations for a wide array of parts and assemblies.
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