This article will provide you with everything you need to know about Swiss screw machining and its uses.
You will learn:
What is Swiss Screw Machining?
The Swiss Screw Machining Process
Types of Swiss Screw Machining
How Swiss Screw Machining is Used
And much more …
Chapter 1: What is Swiss Screw Machining?
Swiss screw machining is a process for producing high precision parts in high volume using an automatic lathe that is programmed to perform every aspect of the cutting process. The method used for Swiss screw machining is unlike other forms of screw machining in that the part and tool move together, which makes it possible for Swiss screw machining to produce exceptionally tight tolerances and complex and intricate parts.
The process for Swiss screw machining is subtractive manufacturing that removes material from a workpiece or headstock using Z axis motion as the bar is supported by a guide bushing in front of the turning tools. This design makes it possible for operators to turn and shape long diameters with exceptional precision.
The concept for Swiss screw machining was developed during the first industrial revolution in Switzerland to assist watchmakers in the production of parts for the watch industry. Prior to the development of Swiss screw machining, the operation of a lathe was tedious and time consuming involving the turning of handles and pushing levers in the hope of achieving accurate machining.
Chapter 2: The Swiss Screw Machining Process
Swiss screw machining involves the use of a lathe that has multiple tool holders arranged about its spindle with a tailstock coaxial attached to it. The popularity of the process is due to how rapidly it can produce small high precision parts with repeatability and without flaws or errors.
Although there are different types of Swiss screw machining, all types follow the same basic principles that make the machining process efficient and productive. The key features of the various types are securing the bar stock or workpiece and the machine having the ability to move the tool and workpiece together.
Regardless of the intricacies of the parts produced by Swiss screw machining, the process itself is not that difficult to understand or that complicated. As with all forms of machining, Swiss screw machining requires careful planning and preparation to ensure the quality and tolerances of the produced parts.
Holding the Workpiece
The workpiece is tightly held such that it does not experience vibrations or wobble while being rotated. Several factors can happen if the workpiece is not securely set, which can affect the spindle, cutting tools, and the precision of the cuts.
The two forms of bar feeders are hydrodynamic and hydrostatic, which vary in how the workpiece is held as it enters the Swiss screw machining process.
Hydrodynamic Bar Feed System – With a hydrodynamic bar feeding system, a tube surrounded by pressurized oil supports the workpiece and pushes it through the feeder. The oil filled tube produces less noise and vibrations, which protects the machining process and integrity of the workpiece. Hydrodynamic bar feeding systems require that workpieces be fed one bar at a time and the changing of feed tubes when the diameter of the workpiece changes. The manual aspect of the feeding process lowers its cost and makes it more economical.
Hydrostatic Bar Feed System – Hydrostatic bar feed systems have the workpiece rest on a series of guide channels or bushings that clamp around the workpiece. Hydraulic fluid is pumped into each of the bushings that surround the workpiece with an oil film for support. A servo motor pushes the workpiece into the machining process. Workpieces can be 4 ft to 24 ft long and come in a variety of diameters without having to change the channels or bushings.
Modern bar feeders are a major step away from the original bar feeding method that was completed by hand with the lathe operator holding the workpiece in place during the cutting and shaping process.
Chucking Collet
The chucking collet uses mechanical force to hold the workpiece in place and is a standard work holding system for Swiss screw machines. It consists of a three jaw power chuck, a hydraulic cylinder, and drawtube. The hydraulic cylinder is connected to the rear end of the spindle with the chuck mounted on the front end of the spindle, the working side. The drawtube passes through the spindle bore to connect the hydraulic cylinder and the chuck. The axial motion of the hydraulic piston causes the collet chuck’s jaws to open and close. The drawtube moves with the piston driving a wedge-shaped plunger in the chuck body as the piston slides back and forth to convert axial motion to radial motion to open and close the collet chuck’s jaws with the force of the jaws regulated by a pressure valve.
Guide Bushing
Guide bushings are one of the most notable aspects of Swiss screw machining due to their rigidity. They are the part of Swiss screw machining that differentiates Swiss screw machining from traditional lathes. They support the workpiece throughout the machining process to prevent deflection when cutting force is applied. Guide bushings allow the cutting tool to make one deep pass instead of several shallower passes with exceptional precision, which reduces tool wear.
The accuracy of the guide bushing is indicated by its coaxiality, which is the tolerance of how close one cylinder is to another cylinder. In order to maintain micron tolerances, guide bushings for Swiss screw machining have a micron tolerance of 0.0002 in (0.00508 mm).
As with several aspects of Swiss screw machining, there are several different types of guide bushings with rotary, fixed, and precision being the most common.
Rotary Guide Bushing – Rotary guide bushings are used with larger workpieces and rotate with the workpiece.
Fixed Guide Bushings – Fixed guide bushings are used for tight tolerances and remain stationary as the workpiece spins.
High Precision Guide Bushings – High precision guide bushings are used for small parts and when it is necessary to meet the demands of difficult tolerances.
Headstock Movement
With Swiss screw machining, the headstock moves to make it possible for the workpiece to be positioned along the Z axis. The bar stock passes through the chucking collet that clamps onto the bar stock. The sliding headstock moves to allow the cutting tool to shape the bar stock. As the collet holds the workpiece, the headstock rotates the workpiece to position it for the cutting tool. The headstock moves the workpiece to the cutting tool to avoid lateral force and to provide exceptionally accurate cuts.
As the headstock moves and rotates the bar stock, the cutting tools cut the bar stock close to the guide bushing, about 0.0394 in to 0.118 in (1 mm to 3 mm) from the guide bushing. The uniqueness of the sliding headstock makes it possible to expose the portion of the workpiece to be cut while the tool remains stationary.
Spindle
The cutting tools for Swiss screw machining are carried on one or more spindles, which perform most of the cutting operations. They carry a variety of tools including holders for fixed single point tools and several other tools. The tools on the spindle can move along the X, Y, and Z axes to provide precision cuts and complete single or multiple cuts as the workpiece is rotated by the headstock. The cuts performed by the tools on the spindle include turning, drilling, milling, threading, and cross drilling. With the help of the guide bushing, each of the various cuts performed by the tools has the highest tolerance with exceptionally high precision.
The spindle is mounted on the bed of a Swiss screw machine between the headstock and feed base. The primary spindle performs most of the cutting processes while the secondary spindle completes operations like drilling and picks up, completes, and ejects finished parts. The spindle serves as a support for the workpiece, positioner, and drive for the tools.
There are several different forms of spindles each of which performs the positioning of tools in a unique way. Three common and broad forms of spindles are direct drive, belt drive, and integrated, which differ in their configuration and drive mechanism. Each of the three are used for Swiss screw machining.
Belt Driven Spindle – Belt driven spindles are versatile and make it possible to adjust pulley ratios. With the addition of a gear box, they are able to achieve higher torque. Belt driven spindles can reach speeds of 8000 rpm. They have a high noise level and the potential for belt slippage.
Direct Drive Spindle – The design of direct drive spindles eliminates the possibility of belt slippage and are used for light materials. They can reach speeds of 12000 rpm.
Integrated Spindle – Integrated spindles are known as built in motor spindles and have the motor and rotor integrated. They have reduced noise and exceptional accuracy.
Traditional CNC Machining Compared to CNC Swiss Screw Machining
The key difference between traditional machining and CNC Swiss screw machining is the headstock. With traditional machining, the headstock is fixed and immovable with the workpiece clamped at both ends. The headstock for Swiss screw machining moves making it possible to reposition the workpiece along the Z axis.
Traditional CNC machining uses two, three, or four axes when shaping a workpiece. The verticality of CNC Swiss screw machining makes it possible for a workpiece to be shaped along five or more axes, which is the reason that CNC Swiss screw machining is able to produce exceptionally complex and intricate parts. An essential factor is the ability of CNC Swiss screw machining to complete multiple operations in a single cycle removing the need for several setups and the changing of tools.
Chapter 3: Types of Swiss Screw Machining
The many varieties of screw machines have been used for over one hundred years to manufacture a wide assortment of metal parts. Swiss screw machining is used to produce bolts, pins, screws, and several types of fasteners. The precision, accuracy, and exceptional tolerances of parts produced by Swiss screw machining has led to their popularity and use. While the name Swiss screw machining implies that the only thing the process can produce is screws, the name originated from the initial purpose of the process but has expanded into an endless number of applications and uses.
A more accurate description of Swiss screw machining is that it is a machining process that is used to shape metal parts and components by firmly holding bar stock or a workpiece in place as it is shaped from the middle or either end. Swiss screw machining is a seamless production process capable of producing high volumes of precision parts with exceptional repeatability.
The two general types of Swiss screw machining are automated and computer numerically controlled (CNC), which differ in their design and capabilities. Both types of Swiss screw machining methods perform the production process with accuracy and efficiency. How they complete their machining functions are distinctive and unique.
Automatic Swiss Screw Machining
Swiss screw automatic machining is automated lathe machining with holders placed around the spindle with tailstock coaxial to it. It is a cam operated process that provides all of the benefits of Swiss screw machining. The automatic process is a rapid method for producing high precision components. Disc cams that change rotary motion into up and down or side to side motion are used to move the cutting tools and change headstock positioning to adjust for parallel differences in the workpiece. Spindle collets prevent debris and deflection and protect against the intrusion of any obstacles.
Automatic Swiss screw machining is based on the machine's ability to rapidly produce tiny parts in high volume with precision, speed, and exceptional quality. Automatic Swiss screw machining has all of the features of CNC Swiss screw machining but without the more advanced technological and computerized functions. The process is able to machine several metals such as brass, aluminum, nickel, bronze, and copper and various forms of plastics.
Computer Numerical Control (CNC) Swiss Screw Machining
While the original version of Swiss screw machining was automatic and precise, the advent of CNC machining in the 1940s took the precision, accuracy, and efficiency of Swiss screw machining and moved it to a whole new level. In essence, the marriage of CNC digitally controlled tools and Swiss screw machining created the perfect methodology for the manufacture of high tolerance parts.
Much like original Swiss screw machining, CNC Swiss screw machining relies on a set of commands entered by an analog or digital system that provides a set of instructions for the movement of the workpiece and multiple tools. The unique nature of CNC Swiss screw machining provides greater accuracy and higher tolerances. Multiple tools are able to complete several shaping processes in one cycle and quick succession. To finish certain processes, more than one spindle is used with each spindle having a different function and set of tools.
The higher precision of CNC Swiss screw machining is due to the tight hold on the workpiece provided by the collet, which allows for more precise machining. The initial steps for CNC Swiss screw machining begins as with all other forms of CNC machining, which is the creation of the various codes that guide the facets of the machine as it performs each of the machining tasks. The codes take advantage of the structure and design of CNC Swiss screw machining that rests with the guide bushing that allows for more aggressive cuts and specialized cutting cycles, all of which are completed in a single operation. CNC Swiss screw machining, with its multiple machining functions performed in one cycle, is referred to as synchronous optimization.
Chapter 4: Tools for Swiss Screw Machining
The unique nature of Swiss screw machining enables the process to use a wide variety of cutting tools capable of making precision cuts with exceptionally high tolerances. The essence of all forms of machining is the removal of material from a workpiece to create a component, part, or fastener. Although the process can be completed using a lathe, CNC machine, or other subtractive process, the unique method used by Swiss screw machines ensures that each cut is of the highest tolerance and precision.
The method of material removal used by Swiss screw machining requires that the tools used for the process be of the highest quality due to the precision and accuracy of the cuts. The main functions of the tools are designed for a long list of machining operations with a parting off tool used to separate the final part from the bar stock.
Grooving Tool
Grooving tools are used with bushing tools to make recesses for maintaining the rings and necks for conjoining materials for optimal performance. The tandem cutting of grooving tools with bushing tools cuts channels on the face of a workpiece or the existing bore of a workpiece, which is internal grooving.
Drilling Tool
Of the many Swiss screw machining functions, drilling is one of the most common. The drilling tool serves as a cutting and rotating mechanism to place precision cut round holes in a workpiece. The exceptional precision of Swiss screw machining places the holes in perfect alignment for other parts and screws, which are necessary for the assembly process. The wide use of drilling tools in Swiss screw machining requires the placement of several sizes of drill bits in the spindle with drill bits starting as small as micro drills of 0.1 mm (0.0039 in) and 3 mm (0.118 in). In the majority of cases, drilling tools for Swiss screw machining are made of tungsten carbide steel due to its strength and durability.
Chamfering Tool
The chamfering tool is designed to produce a smooth curved edge on a part and is referred to as a lark’s tongue. The process eases the sharp edges of metal for safety reasons and to prevent damage to other parts. Also known as a chamfer mill or chamfer cutter, a chamfering tool that has a head that is similar to the point of a drill is able to perform several functions aside from chamfering, which include beveling, deburring, spotting, and countersinking. The flexibility of chamfering tools makes them an essential part of Swiss screw machining.
Turning Tool
Turning tools serve two functions depending on the requirements of a workpiece. A rough turning tool removes large amounts of material in order to achieve a specific shape while a fine turning tool finishes the workpiece by removing small minute amounts of material with precision to reach part designs and tolerances.
Threading Tool
The two forms of threading tools are single point threading tools where a single point cutting tool moves along the length of the workpiece cutting ridges and troughs for external threads and drill type threading tools that cut internal threads. A second version of threading tools is thread whirling, which has a series of cutting heads mounted in a ring or holder. As the workpiece rotates, the thread whirling tool rotates placing ridges in the workpiece.
Parting Tool
The parting tool is the final function in the Swiss screw machining process. Parting tools take different shapes, cutting mechanisms, designs, and methods with all forms having the same function, which is to remove the completed component from the bar stock. Due to the nature of the work that a parting tool performs, it is made of exceptionally sturdy and durable steel that is usually high strength steel.
Clamping Tool
One of the critical processes for all Swiss screw machining is indexing, which is the positioning of a cutting tool at the right angle and location to complete a process. Indexing enables Swiss screw machining to cut symmetrical and repeating patterns with precision and accuracy. Clamping makes it possible to index a tool from the back side of the tool holder without having to remove the tool or holder. It makes tool changes faster, increases the rate of production, and does not damage the cutting edge.
The few tools listed above is a small sampling of the many tools used for Swiss screw machining. Aside from the well known and widely used Swiss machining, there are several varieties of custom-made machining tools that are specifically designed for unique and specialized components. Additionally, as new products are developed and introduced, Swiss screw machining tools are produced to meet any new requirements and part configurations.
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Chapter 5: Types of Materials Used in Swiss Screw Machining
There are very few limitations to the types of materials that can be shaped and cut using the Swiss screw machining process. The range of materials includes various types of plastics, non-ferrous metals, and ferrous metals, each of which is handled with the greatest care and precision. One of the reasons for the wide use of Swiss screw machining is how it can be used for shaping so many forms of materials.
Aluminum
Aluminum is ideal for Swiss screw machining because of its strength to weight ratio, multiple alloys, and its properties. The ductility of aluminum enables it to be machined in a wide assortment of intricate and complex shapes. It is widely used for automotive and aircraft components and parts.
Brass
Brass, an alloy of copper, is a strong and inflexible metal that is used to produce components with very tight tolerances. It is widely used by Swiss screw machining due to its conductivity, resistance to corrosion, and cost. One of the characteristics of brass that makes it ideal for Swiss screw machining is its exceptional finish and appearance, which enhances components made from it.
Plastics
The choice of Swiss screw machining for the forming and shaping of plastics is an alternative for parts that cannot be successfully cast or molded or have very tight tolerances. Swiss screw machining is ideal for rapidly producing plastic prototypes and producing end use components. There are manufacturers that specialize in producing tight tolerance plastic parts from sheets of plastic that require precision processing.
Carbon Steel
The machining of carbon steel requires the use of equipment that is strong, durable, precise, and able to withstand the stress required to machine steel. The unique nature of Swiss screw machining makes it possible to machine steel without causing uncommon damage to tools. The movement of the workpiece in relation to the tools reduces the wear on the tools when shaping carbon steel. Shafts, screws, bolts, connectors, sockets, bushings, and brackets can be easily and efficiently produced using Swiss screw machining.
Nickel Alloys
As with aluminum, nickel alloys are used in Swiss screw machining for their resistance to corrosion. Components made from nickel alloys have exceptional stiffness and structural integrity. Nickel alloys are ideal for Swiss machining due to their surface finish, which makes it possible to use components in visible placement without detracting from the appearance of an assembly.
Stainless Steel
Stainless steel has all of the necessary qualities required by components that have to face hazardous conditions and hostile environments. It has the strength of steel with an oxide coating to protect the metal from corrosion. Additionally, there are a wide assortment of stainless-steel alloys that can be configured, shaped, and formed to meet the needs of any type of application. Stainless steel components produced by Swiss machining can undergo different treatments to further enhance their substantial properties.
Titanium
Titanium is used for Swiss screw machining due to its lightweight, corrosion resistance, and ductility. It can easily be cut, formed, milled, drilled, and fabricated into tiny minute dimensional parts without losing its strength, durability or structural integrity. Titanium has the same strength as steel but is less dense, which makes it ideal for the manufacture of strong components that require limited weight. As with several other metals, titanium comes in different grades that are chosen to specifically meet the needs of an application.
Chapter 6: Components Produced by Swiss Screw Machining
When an assembly requires precision parts that are manufactured to the tightest tolerances, the first choice is always Swiss screw machining due to its ability to rapidly and effectively produce any part with precision and accuracy. A common characteristic of parts for modern manufacturing is the requirement for quality and accuracy such that products will last longer and be more durable. CNC Swiss screw machining can meet all of the paradigms and criteria necessary to fulfill the needs of modern products.
Plow Studs
Plow studs are a critical part of road plows and off-road vehicles. They are used to attach the blade of a plow to the bottom of the plow, attach bucket teeth to an excavator, hold wear resistant blocks in place, and to hold side cutters in place. There are several versions of plow studs, also known as plow bolts, with each type having a different configuration.
Gears
The use of Swiss screw machining for the production of gears is due to the complexity of gears that require precision cut ridges for their proper mating. There are an infinite number of gears made from an endless number of materials from simple plastics to heavy duty steels. Every machine, assembly, motor, or engine relies on gears to convert motion. Swiss screw machining is used to produce all forms of gears in a wide variety of sizes and configurations.
Banjo Bolt
A banjo bolt is a hollow bolt with a flanged head and holes in its sides. It is one half of a banjo fitting that is used to pass pressurized fluids. The holes in the sides of a banjo bolt allows fluids to transfer to other parts of the fitting. The hollow tube nut of a banjo bolt is made of steel or brass to be able to endure the constant movement of liquids.
Bushing
Bushings provide a cushion between metal parts to reduce noise, rough movements, and control vibrations. There are a wide variety of bushings designed to cover an innumerable number of conditions, applications and assemblies. Swiss screw machining is an ideal method for producing the many varieties of bushings regardless if they need holes in their sides, inner or outer threads, or the use of highly durable metals.
Screws and Bolts
Based on the original purpose of Swiss screw machining, the manufacture of screws and bolts is one of its expected functions. The features that make the use of Swiss machining for the manufacture of screws and bolts are how rapidly the screws and bolts are produced and their exceptional quality, which cannot be achieved by any other process. Every form of screw or bolt can be rapidly, efficiently, and accurately produced to meet the tightest tolerances.
Chapter 7: Benefits of Swiss Screw Machining
The rapid rise and wide use of Swiss screw machining is mainly based on the precision and accuracy of the process. Although these are key features of Swiss screw machining, they are not the only aspects of the process that make it ideal for the production of tight tolerance parts. Since the introduction of Swiss screw machining, many companies have found how the process improves the quality of their products and enhances the efficiency of the manufacturing process.
Precision
Whenever anyone speaks about Swiss screw machining, the first word that comes to mind is precision, which is an overlaying descriptor that gives the process a one-word definition. Over the years of its use, Swiss screw machining has amazed manufacturers with the high tolerance of the pieces being produced and the accuracy of the machining process that cannot be found in any other type of machining. Swiss screw machining is an innovation that was ahead of its time and fits perfectly into modern day production.
Designing
The flexibility and versatility of Swiss screw machining enables it to produce parts and components that are too complex or intricate for other processes. While various items can be produced using other methods, the time and cost involved increases the cost of the final product and labor costs. The speed at which Swiss machining can produce any type of product in large quantities lowers the cost of the parts and the final product.
Materials
Swiss screw machining can process a wide spectrum of plastics and metals to produce extremely precise products and parts. With seemingly little effort, CNC Swiss screw machining can be configured to produce one product and can be quickly reconfigured to produce a completely different product. This aspect of the process allows clients to select any type of material for multiple components to be swiftly manufactured.
Deflection
The unique process of Swiss screw machining places the bar stock or workpiece closer to the cutting and shaping tools. During normal machining, the workpiece will bend or deflect during the cutting process due to the orientation of the workpiece in relation to the cutting tool. The close proximity in Swiss machining lowers the amount of deflection, which increases the accuracy of the process.
Production Efficiency
The process of Swiss screw machining can operate for hours, once it has been configured and loaded. This aspect of the process limits the need for operator intervention. Operations for the completion of a component can be finished in a single pass without the need to change cutting tools or make adjustments, a factor that lowers production costs and increases efficiency.
Number of Cutting Tools
While a traditional CNC machine or lathe may be limited in its number of cutting tools, the multiple spindles of CNC Swiss screw machining makes it possible to load a large number of cutting tools that can work simultaneously to complete the shaping of a component. As with other aspects of Swiss machining, this factor enhances performance and increases productivity.
Control
Of the many features of Swiss screw machining, control is one of the most outstanding and the reason that the process has become so popular. The initial purpose for the development of Swiss machining was to produce minute parts for the manufacture of watches, which required that the pieces being produced be precision controlled to be able fit the design of a watch. Over the years, as the innovations of Swiss screw machining have spread, the ability to precision control the movement of tools has further increased its popularity.
Other Benefits of Swiss Screw Machining
Repeatability – Swiss precision machining can produce quality parts with exceptional repeatability.
Complexity – The guide bushings of Swiss machining make it possible to produce intricate parts with finesse more effectively.
Secondary Operations - The ability to complete multiple operations in a single cycle reduces the need for secondary machining.
RPMs – The unique design of Swiss screw machining makes it possible for the machines to operate at higher RPMs without vibrations for faster machining times and better finishes.
Automation – Bar feeding, several tools, multiple axes movement, and programming make it possible for Swiss screw machining to achieve precision machining without operator intervention.
Chapter 8: Swiss Screw Machining Points of Preparation
The effectiveness of Swiss screw machining, regardless of its many positive features, is dependent on proper preparation in order to achieve the machine’s production goals. Since Swiss screw machining is designed for detailed work, it is crucial that the same attention to details should be used in preparing for the machining process. The goal of proper preparation is the development of a smooth process that saves money and increases productivity.
Model
The initial rendering of a part for CNC Swiss screw machining begins with a detailed computer aided design (CAD) that should be clear and concise to help the operator provide the proper dimensions, tolerances, and surface finishes. It is the step that gets the process started.
Holes
Hole designs should be simple and straightforward to simplify processing. Certain types of complex holes are difficult for CNC Swiss screw machining.
Corners
The corners created by the tools in Swiss screw machining are programmed to be smooth and rounded. Sharp inner corners can be produced but are challenging for the tools of the machine.
Tolerances
As the machining tolerances increase, the amount of time Swiss screw machining spends on a part increases as well, which translates into higher costs and cycle times.
Wall Thicknesses
Wall thicknesses have to be properly designed to avoid metal chattering and warping. Thin walls can undermine the quality of a part and be inaccurate. It is essential to have a balance between aesthetics and the functionality of the component.
Conclusion
Swiss screw machining is a process for producing high precision parts in high volume using an automatic lathe that is programmed to perform every aspect of the cutting process.
The process for Swiss screw machining is subtractive manufacturing that removes material from a workpiece or headstock using Z axis motion as the bar is supported by a guide bushing in front of the turning tools. This design makes it possible for operators to turn and shape long diameters with exceptional precision.
The popularity of Swiss screw machining is due to how rapidly it can produce small high precision parts with repeatability and without flaws or errors.
The precision, accuracy, and exceptional tolerances of parts produced by Swiss screw machining has led to their popularity and use.
The method of material removal used by Swiss screw machining requires that the tools used for the process be of the highest quality due to the precision and accuracy of the cuts.
Leading Manufacturers and Suppliers
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