Sustainable machining of titanium places high demands on process stability, tool technology and cooling and lubrication strategies. In industrial practice, titanium machining using minimum quantity lubrication (MQL) is often viewed critically. As part of a joint project with KNOLL, HAM investigated at the HAM Performance Center how the AerosolMaster 4000 ATS system performs under real-world conditions in titanium machining. The results clearly show that manufacturers can machine even challenging materials reliably and resource-efficiently when they consistently optimize the entire process.

Titanium machining is one of the most demanding processes in metal cutting. This is due to the combination of high strength and low thermal conductivity. As a result, the process generates high thermal and mechanical stresses at the tool cutting edge.

At the same time, titanium machining using minimum quantity lubrication (MQL) faces increasingly stringent and often conflicting requirements for sustainable manufacturing processes. Process stability remains a central point of discussion in industrial practice. While conventional emulsion systems continue to dominate everyday industrial operations, companies are increasingly seeking more resource-efficient alternatives.

Against this backdrop, the HAM Performance Center, in collaboration with technology partner KNOLL, investigated how MQL performs in titanium machining under real production conditions.

Titanium Machining: Balancing Process Reliability and Sustainability

In industrial practice, manufacturers usually machine titanium using intensive emulsion cooling. This approach helps control thermal stress and tool wear.

This approach has proven effective. However, it also involves significant costs in terms of media consumption, treatment, and cleaning.

This creates a clear conflict of objectives between process reliability and sustainable manufacturing. This is precisely why alternative cooling and lubrication strategies are becoming increasingly important.

Clinical trials at the HAM Performance Center with KNOLL

At the HAM Performance Center, HAM systematically analyzes and optimizes manufacturing processes as an integrated system comprising the machine, tooling, clamping technology and cooling and lubrication strategies. The goal is to simulate industrial processes under realistic conditions. In addition, the aim is to enable a direct comparison of different approaches under identical conditions.

As part of the project with KNOLL, HAM systematically investigated titanium machining using minimum quantity lubrication (MQL) and directly compared it with conventional emulsion cooling. The AerosolMaster 4000 ATS system was used for this purpose; it delivers a precisely metered oil-air aerosol directly into the machining zone, thereby enabling targeted lubrication with minimal use of lubricant.

For the study, we designed a special titanium component that integrates multiple machining operations, from roughing with iMachining to grooving, drilling, threading, and finishing.This made it possible to evaluate different load conditions and machining strategies within a single workpiece under identical conditions.

Results of Titanium Machining with Minimum Quantity Lubrication (MQL)

Direct Comparison Between Emulsion Cooling and MQL

The results clearly demonstrate that titanium machining with minimum quantity lubrication can be a process-stable alternative to conventional emulsion cooling. During the trials, the process showed no fundamental disadvantages in stability, provided that the machining parameters consistently matched the lubrication concept.

The test component was first machined using emulsion cooling and subsequently machined under minimum quantity lubrication. Clamping conditions, tools, and cutting parameters remained unchanged throughout the comparison. Under both conditions, the process produced the component within the same machining time.

Notably, process stability did not deteriorate when switching from emulsion cooling to MQL. In both cases, the process achieved the same surface finishes and tolerances. As a result, the process produced the component with identical quality under identical process conditions.

Different Machining Operations Under Identical Conditions

The comparative study covered a broad range of titanium machining operations. In addition to 1.5×D full-slot milling, the study investigated both HPC milling strategies with high radial engagement and HSC machining using trochoidal milling with reduced radial engagement and correspondingly higher cutting parameters. The test program was complemented by drilling and reaming operations up to 3×D as well as various finishing operations. This enabled a systematic evaluation of the influence of the lubrication strategy across different machining tasks within a single workpiece.

The results show that the decisive factor is not the amount of lubricant, but its targeted effect at the cutting edge. Equally important is the design of the titanium cutting tools employed. The key lies in the coordinated interaction between tool geometry, substrate material, coating, and lubrication strategy, as these factors have a significant influence on friction, heat generation, and chip formation.

Benefits Across the Entire Process Chain

The positive effects were not limited to the machining process itself. By supplying the cutting edge with a precisely metered aerosol, the process achieves a stable lubricating effect directly in the active cutting zone. In addition, downstream cleaning efforts were significantly reduced in certain applications.

For example, in a medical technology component, the process reduced the number of required cleaning and inspection stations from ten to four. Such practical examples demonstrate that the potential of minimum quantity lubrication extends far beyond the actual cutting process.

These findings are consistent with observations from industrial practice. Marc Schäfer from the HAM Performance Center summarizes the benefits as follows:

“On the one hand, we achieve the desired lubrication directly at the cutting edge, which increases tool life. With an oil consumption of only 3 to 25 ml/h, the process is resource-efficient, sustainable, and energy-efficient.”

Process Stability Is the Result of the Entire System

These results challenge a widely held assumption in industrial practice that minimum quantity lubrication inevitably reaches its process-related limits when machining titanium. Instead, the findings show that performance does not primarily depend on the coolant or lubricant itself, but on the consistent coordination of the entire process chain.

The key takeaway is that the stability of titanium machining does not result from individual process parameters in isolation, but from their systematic interaction throughout the entire manufacturing process.

Industrial Classification and Application Context

Demanding industrial applications clearly demonstrate the significance of these results, particularly where manufacturers machine titanium under high thermal and mechanical loads.

One example of this is the manufacture of complex lightweight components for high-performance applications. This is particularly evident in applications such as the titanium rim from JP Performance for the legendary Jaguar E-Type, where extreme loads and minimal tolerances come into play.

During the manufacturing process, the operation reduced a solid titanium blank weighing approximately 400 kg to a final weight of about 18 kg through high-volume machining. The machining took more than 160 hours and relied on high-speed machining based on complex 5-axis strategies, including simultaneous machining.

Among other things, the process used CAM strategies such as iMachining 2D and 3D to balance the demanding requirements for material removal, process stability, and cost-effectiveness. Additional challenges arose from deep cavities and tool lengths of up to 400 mm, which placed high demands on vibration stability and process reliability.

Titanium milling cutters developed specifically for such applications made it possible to machine the complex geometries with precision, even under these extreme conditions.

It is precisely these kinds of projects that clearly demonstrate that machining titanium to high standards is not made possible by high-performance tools or cooling lubricants alone. Rather, the coordinated design of the entire manufacturing process is what determines process capability.

Experience gained from industrial studies

Previous practical studies conducted as part of a titanium machining workshop also confirm these findings under real-world conditions. Even then, it became clear that successful titanium machining using minimum quantity lubrication depends less on individual parameters than on the coordination of the entire system. During the workshop, HAM fully machined and evaluated a complex titanium component using minimum quantity lubrication.

The results consistently show that stable processes depend not on individual control variables, but on the coordinated interaction of the entire process chain.

Conclusion: Sustainable Machining as a System-Wide Challenge

Research conducted at the HAM Performance Center in collaboration with KNOLL clearly demonstrates that minimum-quantity lubrication is a viable industrial alternative to conventional emulsion cooling in titanium machining.

HAM thus demonstrates in practice how coordinated process and tooling systems turn sustainable machining from a theoretical concept into an industrial reality.

The key factor here is not the individual technology, but the consistent coordination of process strategy, machine environment, and cooling and lubrication concepts.

The technical background is described in detail in the full user report from technology partner KNOLL.

Industrial Outlook

For the industrial implementation of such processes, the HAM Performance Center offers the opportunity to validate and systematically compare titanium machining under various cooling and lubrication strategies under real-world conditions. This bridges the gap between technology development and industrial application, particularly for companies that wish to specifically refine their machining processes toward sustainability and process reliability.

Der Beitrag Best Practice: Minimum Quantity Lubrication (MQL) in Titanium Machining – A No-Go? erschien zuerst auf HAM Präzision.

AMB 2026 in Stuttgart – International Exhibition for Metal Working

Sept 15 – 19, 2026 Messe Stuttgart, Germany

The AMB – the International Exhibition for Metalworking – will take place from September 15 to 19, 2026, at the Stuttgart Exhibition Center and is one of the most important trade shows for the metalworking industry in Europe. Held every two years, the exhibition brings together experts, decision-makers, and professionals from the machining industry and provides a platform for discussing the latest technologies and developments.

We look forward to welcoming you in person at AMB 2026. Visit us in Hall 1 | Booth 1B66 and discover our precision tools made of solid carbide and PCD, as well as customized machining solutions for demanding cutting processes. In addition to our exhibition booth, you can look forward to exciting live demonstrations featuring HAM tools at various locations throughout the exhibition grounds, as well as a glimpse into our 360° Virtual Showroom.

Get your free trade show ticket!

It’s easy to secure your free admission to the trade show. Once you’ve registered, we’ll email your personal ticket code directly to you.

Here’s what HAM was like at AMB 2024:

Engaging conversations, innovative tooling solutions, and many personal encounters: AMB 2024 was a complete success for us. Get a glimpse of our booth and take a look back at the highlights.

Click here to read our report on AMB 2024.

Der Beitrag AMB – International Exhibition for Metal Working 2026 erschien zuerst auf HAM Präzision.

The HERMLE Open House will take place from April 21 to 24, 2026, in Gosheim under the motto “BUILDING TOMORROW. TODAY.” and will demonstrate how the future of manufacturing is already becoming a reality today. On display will be 20 machining centers featuring state-of-the-art machining technology, innovative automation solutions, and practical digitalization tools. Following a construction-related hiatus, the special exhibition will also return with the latest highlights in tool technology, software, and hardware. Expert representatives from all relevant fields will be available throughout the event for personal discussions.

In the showroom at the HERMLE Open House, you can see our tools in action. On display is the dry machining of the center section of a sports bow made of high-strength aluminum on a HERMLE C 400 – including volume machining as well as demanding 5-axis finishing operations such as pocket milling, flanging, facing, drilling, 5X finishing, and engraving. We will be using our HAMazing aluminum tools – end mills, drills, ball-end mills, and torus mills – developed in collaboration with Diebold, LANG and SolidCAM. Additionally, we will be present at the special show at Booth 1.2, where we will be available for personal discussions regarding tooling solutions, specific applications, and optimization opportunities.

For more information and to register: https://www.hermle.de/en/news-media/open-house/open-house-2026/

Der Beitrag HERMLE Open House 2026 erschien zuerst auf HAM Präzision.

The motto “100 Years of GROB” transformed the GROB factory grounds at the GROB In-House Exhibition 2026 into an impressive showcase of technology: Over 4,000 visitors flocked to the approximately 6,000 m² exhibition space to get a comprehensive overview of manufacturing today and tomorrow. With more than 40 machines in live operation and the presence of over 60 partner companies, the in-house exhibition became a vibrant innovation ecosystem and a true highlight for the industry.

We are also proud to have been part of this special anniversary. At our own booth, as well as together with GROB, TCM, and Haimer, we presented the digital tool cycle in action. The direct exchange with trade visitors impressively demonstrated how important open interfaces, networked processes and collaborative partnerships are for not just conceptualizing digitalization but actually bringing it into production.

The GROB In-House Exhibition 2026 offered inspiring days full of technical insights, valuable discussions and new perspectives. It confirmed once again: The future of production emerges from the interplay of innovation, networking and shared visions.

Der Beitrag Digital Manufacturing in Live Operation: Highlights from the GROB In-House Exhibition erschien zuerst auf HAM Präzision.

Intertool will take place from April 21 to 24, 2026, at the Wels Exhibition Center (Austria) and is one of the key gathering places for the industrial manufacturing sector. For four days, the focus will be on machine tools and the practical implementation of digitalization and automation in industrial settings. With around 350 exhibitors, approximately 10,000 visitors, and an exhibition area of 25,000 m², the trade fair offers a comprehensive overview of current technologies, processes, and solutions across the entire industrial value chain.

We’ll be at Hall 21, Booth 0926, and look forward to discussing challenging machining tasks and custom-fit tooling solutions with you in person.

For more information and to register: https://intertool.at/

Der Beitrag Intertool 2026 erschien zuerst auf HAM Präzision.

The JP Performance titanium rim is a globally unique project. A rim made of Grade 5 titanium – a material otherwise used in aerospace – was manufactured for the legendary Jaguar E-Type. It took over 160 hours of machining time to transform the 400 kg raw block into the finished 18 kg rim. The project began through a collaboration between Ladermanufaktur GmbH and JP Performance. We were directly involved as a tooling partner and played a decisive role in the manufacturing process with our high-performance titanium milling cutters.

Material & starting point: Grade 5 titanium

The journey to creating JP Performance titanium rims begins with a solid 400 kg block of titanium. Grade 5 titanium impresses with its high strength, corrosion resistance, and low thermal conductivity. These material properties make machining particularly challenging. Without the milling cutters specially developed for titanium, the transformation from raw block to high-end rim would not have been possible. Our tools ensured maximum stability, process reliability, and precision.

Manufacturing & machining: 160 hours of high-end machining

The production of the titanium rim is a prime example of high-end machining. Creating each rim from a 400 kg block of titanium requires over 160 hours of machining time. The process uses the following:

• 5-axis milling, including simultaneous machining
• CAM software: SolidCAM with strategies such as iMachining 2D/3D
• Machining methods: High-speed machining

Developed for extreme conditions, our titanium milling cutters ensure precision when machining complex geometries. Tool lengths of up to 400 mm placed special demands on stability and vibration damping.

Design & aesthetics of the titanium rim

The rim design is turbine-like, with deeply machined spokes and clearly defined contours. It combines the classic elegance of the Jaguar E-Type with state-of-the-art high-end manufacturing. Tailoring each contour to the capabilities of the tools and the machining strategy ensures precision. The result is technical perfection and aesthetics in a unique piece.

Technical challenges in titanium machining

Experts consider titanium a particularly challenging material for machining. The deep pockets and long milling cutters (up to 400 mm) create vibration risks and stability problems. The high strength and low thermal conductivity increase the risk of tool breakage and material overheating. In addition, the enormous material removal from the 400 kg raw block to the final weight of 18 kg must be precisely controlled.

Our solution consisted of optimized tool paths, adaptive cutting parameters, and continuous process monitoring. Every decision was based on our direct expertise in the manufacturing process.

Source: DMG MORI / YouTube, Video „JP Performance x DMG MORI Teaser: Machining a Complete Titanium Rim“, https://www.youtube.com/watch?v=vRAN-JgLzEs

Project facts at a glance

• Material: 400 kg titanium grade 5
• Processing time: >160 hours per rim
• Machine: DMG MORI DMU 85 H monoBLOCK
• Dimensions: Ø 560 mm x 371 mm
• Partners: HAM Präzision, DMG MORI, SolidCAM, Ladermanufaktur GmbH, AVANTEC Zerspantechnik, Rosswag Engineering

Conclusion: High-end rim from JP Performance

The titanium rim from JP Performance is a unique piece that is one of a kind worldwide. Our tools and expertise were crucial to its implementation. The project combines high-end machining, material expertise, and design at the highest level.

Der Beitrag JP Performance titanium rim: From a 400 kg titanium block to a high-end rim – our tools in action erschien zuerst auf HAM Präzision.

In machining, nothing works without the right tool. If you want to manufacture a component, you need a cutting tool that is suitable for the task. We rely on modern CAD/CAM systems right from the planning stage – in particular CAD/CAM grinding – to make processes more efficient and easier to plan. The digital process chain has long been a reality at our HAM Performance Center (HPC) too.

We usually fall back on tried-and-tested standard solutions. Catalog tools are readily available and have proven themselves reliable in many applications. But sometimes these tools reach their limits. Not every machining operation can be carried out economically or technically in a sensible manner using these tools.

What then? The answer often lies in customized solutions. Special tools offer exactly what standard tools cannot. They are individually tailored to the component and enable machining operations that would otherwise not be possible.

What often makes us hesitate when it comes to special tools

Special tools offer many advantages. Nevertheless, the decision to opt for a customized solution is not always easy. The most obvious reason is the price. Especially with smaller quantities, the question quickly arises as to whether the investment is worthwhile at all.

Added to this is the necessary expertise. Complex geometries and special requirements call for technical understanding and experience – not every company has this available in-house. Delivery time also plays a role. Special tools first have to be developed and manufactured, which takes time. The longer it takes for the tool to arrive, the later the component can be produced.

Another point is the coordination effort involved. Requirements must be discussed, drawings checked, and queries clarified. This ties up resources and costs time – a real bottleneck, especially in tight project phases.

And yet, those who opt for special tools have a lot to gain. Customized solutions enable machining operations that would not be possible with standard tools. They save time, improve quality, and make processes more efficient.

Why special tools are worthwhile

Combination solutions allow several machining steps to be combined. This saves machining time and reduces tool changes – a clear advantage in terms of non-productive time. At the same time, the risk of misalignment or inaccuracies is minimized, as machining is carried out in a single operation. The result: higher quality.

Space is also saved in the tool magazine, which increases flexibility – especially when changer space is limited. All these factors contribute directly to cost-effectiveness. The additional expense is quickly recouped, especially with complex or recurring components.

And what about the typical concerns? The costs are offset by efficiency and precision. The necessary specialist knowledge is simplified by the ISBE Sketcher and standardized in accordance with DIN standards. The coordination effort is reduced by digital processes. And thanks to our HAMmer FAST LANE, long delivery times are a thing of the past – complex special tools are designed and manufactured within minutes.

More than just the right tool

A good tool alone is not enough to manufacture a component efficiently and precisely. The entire process is crucial – and it begins long before the first chip is cut.

Many components interact during production. The machine, clamping, CAD/CAM programming, cooling, and tools must be perfectly coordinated. Only when all components work together harmoniously can a stable and economical overall process be achieved.

There is also more to the “Tool” module than meets the eye. After all, what makes a normal tool a perfect tool? It’s the details – from the geometry and coating to the coordination with the material and machining strategy.

What makes a tool perfect

A perfect tool starts with the right material. The first crucial point is selecting the appropriate carbide. Carbide is a sintered material whose main components are tungsten carbide as the hard material and cobalt as the binder. Depending on the intended use, other carbides are added to specifically modify the properties.

Due to the high sintering temperature of around 1500°C, carbide is naturally extremely heat-resistant – and, as the name suggests, very hard. The grain sizes range from less than 0.2 µm in the nano range to over 6.0 µm in the coarse grain range. This means that the mechanical properties also vary greatly. At HAM, we generally use carbide grades ranging from ultra-fine to fine grain in order to achieve an optimal combination of hardness, toughness, and wear resistance.

Bevor das Werkzeug beschichtet wird, durchläuft es unsere eigene Oberflächenbehandlung: das Hybrid Surface Finish (HSF). Dabei wird der Spanraum poliert, um den Späneabtransport zu verbessern, und die Schneidkante gezielt verrundet – für mehr Stabilität und längere Standzeiten.

Before the tool is coated, it undergoes our own surface treatment: Hybrid Surface Finish (HSF). This involves polishing the chip space to improve chip removal and specifically rounding the cutting edge for greater stability and longer service life.

Various hard coatings are used, depending on the application and material. Examples include:

• TiAlN / TiSiN: Multilayer or nanocomposite
• TiAlN: Monolayer or multilayer
• AlTiN supernitrides: Nanocomposite or nanolayer
• ta-C (DLC): Tetrahedral, amorphous carbon layer – also known as “rainbow layer”

A clear example of this is dome polishing. This technique makes the structure of a TiAlN-based multilayer coating visible—a process that not only looks impressive, but also provides valuable technical insights.

Grinding the perfect tool – a process with many components

A perfect tool is not only the result of good materials and precise geometry. Grinding itself is also a complex process in which many factors must interact.

It all starts with selecting the right grinding wheels. This is followed by programming – a step that often takes a lot of time. With CAD/CAM Grinding, tools can be designed quickly and easily and tracked digitally throughout the entire process. Parameters that have already been entered when preparing the quote do not need to be entered multiple times. This saves time and reduces sources of error.

The grinding machine must also reliably implement the required process parameters. And to ensure the right quality, precise measurement technology is needed. Modern systems measure the tool during the process – with micrometer precision—and compensate automatically. This minimizes the influence of human error and ensures a stable, uninterrupted process.

To ensure that this process runs smoothly, all of our partners work hand in hand:

• Vollmer VGrind infinity as a flexible grinding machine
• ISBE Sketcher for tool design
• BLUM laser measuring bridge for in-process measurement
• and HAM‘s tool expertise

Implementation in practice: From component to solution

Unser Beispielbauteil: ein pneumatischer Zylinderboden. Für das G1/8-Gewinde fehlten Wechslerplätze – die Lösung war ein Sonder-Stufenbohrer, der vier Operationen auf zwei reduziert.

Our example component: a pneumatic cylinder base. There was not enough space for the G1/8 thread – the solution was a special step drill that reduced four operations to two.

Instead of centering, drilling, countersinking, and cutting, machining is now performed in a single operation. The core hole and countersink are combined, and the thread is milled and checked. This saves time, reduces tool changes, and increases efficiency.

Key technical data for the component:

• Material: EN AW-2007
• Dimensions: 110 × 110 × 40 mm
• Machine: Hermle C12U
• Control: Heidenhain TNC 640
• Workpiece clamping: LANG zero point clamping system
• Tool clamping: Schunk HSK-A63
• Cooling: MMS, KSS

Technical data of the special tool:

• Material: VHM K40 10
• Dimensions: Ø12 × 103 mm
• Grinding machine: Vollmer VGrind infinity LINEAR
• Control: NUMROTO
• Workpiece clamping: Schunk hydraulic expansion chuck
• Measuring instruments: BLUM TC 76-N, BLUM LC50

Practical implementation: Live demonstration in the workshop

Our compact video shows how all the process components described interact in reality. From the digital design of the special step drill to precise grinding and final use on the pneumatic cylinder base—every step is part of a well-thought-out, efficient, and proven process.

The live demonstration clearly shows that with the right combination of CAD/CAM technology, machine expertise, and tooling know-how, even complex requirements can be implemented quickly and economically.

Der Beitrag CAD/CAM grinding in practice: From digital twin to ready-to-use special tool erschien zuerst auf HAM Präzision.

For around a year now, HAM and Seekircher have enjoyed a close partnership based on practical knowledge transfer, technological progress, and a passion for precision. Alex and Aline founded Seekircher in 2024, and we have been partners from the very beginning.

In this short time, HAM and Seekircher have developed a collaboration marked by mutual learning, a spirit of innovation, and joint projects. On top of technology workshops, joint customer projects and an intensive exchange of experiences, this week’s motto was “from practice for practice.”

During a one-day workshop, the entire process was examined using the example of HAM’s in-house production in the field of turning and milling: from 3D CAD modeling to CAM programming with SolidCAM, tool management and warehouse organization with ToolBase and WinTool, to topics such as tool selection, machining strategies, efficiency improvements, and automation potential.

The participants focused special attention on standardized solutions, creating templates, and optimizing software and processes. The goal: to simplify processes, create transparency and increase productivity in the long term.

The open atmosphere encouraged lateral thinking – and that is precisely what made the day so valuable. At the end of the day, the participants showed beaming faces and a consistently positive mood. They also shared numerous ideas for further optimization.

Strengthened with fresh ideas and new impulses, we leave this valuable day. We carry these ideas forward into production, to our customers and partners, to increase competitiveness.

A big thank you goes to Alex and Valentin, whose expertise and passion made this workshop a real success.

Conclusion:
A workshop that shows how partnership-based cooperation promotes innovation and sustainably strengthens competitiveness in modern machining.

Or simply: HAMazing!

Der Beitrag Practical experience meets precision: HAM and Seekircher optimize turning, milling, and manufacturing processes erschien zuerst auf HAM Präzision.

There have been some exciting developments at our showroom in Schwendi-Hörenhausen: new machines, exciting additions, and fresh ideas for tomorrow’s manufacturing. These developments mark the next step in our strategy, which is why our showroom has now become the HAM Performance Center (HPC). And because our virtual tour provides a one-to-one digital representation of this location, we have also updated it accordingly.

You can now experience the digital process chain for machining online. Anytime. From anywhere. With just one click, you can dive right in and discover how modern manufacturing works today – networked, efficient, and practical.

The virtual tour takes you through all the relevant components. From process design and simulation to storage and tool preparation to use on the machining center. We clearly present each step and demonstrate how you can optimally integrate your processes. Thus the individual systems communicate with each other via interfaces and integrate flexibly into your existing production.

So with our HAM Performance Center, we are laying the foundation for THE technology center of the future – a place where digital innovation and manufacturing technology come together.

Whether you’re looking for inspiration, looking for specific solutions, or simply curious – updated content, new videos, and exciting insights directly from practice await you in the virtual HAM Performance Center.

Start now: Discover the 360° virtual HAM Performance Center

Do you have questions about the digital process chain? We are happy to help.

Der Beitrag A new look behind the scenes – our virtual HAM Performance Center is here! erschien zuerst auf HAM Präzision.

Turning, milling, drilling, reaming, threading, measuring – all in a single integrated process. Sounds like the future, but it has long been a reality in modern manufacturing companies. Complete turning-milling machining combines high-precision machining steps into an efficient process that saves time, reduces errors and sustainably improves processes.

This is exactly what we demonstrated in our workshop. How CAM programming, tool strategy and machine concept combine to form a coherent solution. From the digital model to the finished component. With real workpieces, real machining strategies and real results.

In this article, we take you on a practical journey. You will learn how we transform complex requirements into clear solutions. And you will see why tool selection, CAM system and process thinking are now more decisive than ever for quality and competitiveness. Welcome to the world of complete turn-mill machining. Welcome to the “Drevolution“.

From past challenges to today’s precision

Anyone involved in modern turn-mill complete machining today should understand the hurdles that had to be overcome in the past. The production of complex components often began with the creation of elaborate 2D drawings. Every line, every dimension had to be interpreted precisely. This often resulted in ambiguities that developed into real problems in production.

Programming was also carried out directly on the machine. This was not only time-consuming but also blocked valuable machine running time. Any manual input error could lead to downtime. In addition, tools were often not managed centrally. Whether a suitable tool was available or even suitable at all could often only be determined during set-up. In many cases, the first part produced only served as a test piece – rejects were almost inevitable.

Digital thinking. Made efficiently.

Today, things look very different. Modern production begins with a well thought-out 3D model, for example in Step or SolidWorks format. It is no longer programmed directly on the machine, but using powerful CAM systems that also enable simulations. Even before the first cut is made, it is possible to check how the tool will behave in the installation space, whether there are any collisions and whether all the machining steps mesh properly.

Tool data, geometries and cutting values are available centrally. Customers are increasingly demanding digital twins to supplement their own systems, for example for CAM programming or collision-free assembly planning. Tool management is thus becoming an integral part of a digitized, end-to-end process.

At HAM Präzision, we live exactly what we teach in our workshops. Our goal is not only to understand processes, but to consistently optimize them. Error prevention, maximum process reliability and short production times are our daily focus. After CAM programming, we can go straight to the machine – without rejects, without time-consuming set-up, without long searches for the right tool or room for interpretation of drawings. This end-to-end process is a decisive advantage, especially in our one-off and small series production.

The advantages speak for themselves: machine downtimes are avoided, tools are centrally managed and available at all times, manual programming errors are a thing of the past. The result is an end-to-end manufacturing process that combines maximum precision with impressive efficiency. What we are experiencing is not a slow change, but a noticeable further development in machining. A new way of thinking. A real turning revolution.

What “Drehvolution” means to us

For us, “Drehvolution” describes a holistic approach that begins long before the first chip – namely, with the design of the tool. In this early phase, we lay the foundation for precise, economical and consistent production. Our goal is to design each process step in such a way that maximum precision goes hand in hand with high efficiency. This includes the consistent use of digital tool data and well thought-out process planning right from the start.

The demands on production are constantly increasing. Customers expect shorter delivery times, consistently high quality and reliable prices. At the same time, qualified personnel are becoming increasingly rare. We meet these challenges with innovative solutions that closely interlink and coordinate planning, production and tool management.

Complete machining as the key to efficiency

Modern complete turning-milling machining combines all work steps – turning, milling, drilling, threading, deburring and measuring – in a single machining center. The process runs continuously with just one reclamping, supported by automated loading and unloading systems such as bar or gantry loaders for a smooth material flow.

A look at the time involved shows the progress: whereas modeling, drawing creation, checking and programming often used to take more than 800 minutes, it now takes around 500 minutes with CAM programs and digital tool data. Manual programming and downtimes in particular are eliminated, saving several hours of time.

This efficiency is the result of high-performance CAM systems in combination with central tool management. Tools are digitally recorded and available at all times, minimizing machine downtimes and significantly reducing sources of error.

Additional challenges and solutions

In addition to technical implementation, modern manufacturing presents numerous challenges that can be specifically addressed through integrated turn-mill complete machining. In terms of economic efficiency, every minute counts today. The time from quotation to finished product must be kept as short as possible. At the same time, fewer personnel are employed, but they have to take on more responsibility and tasks.

Competitiveness is also under pressure. Delivery deadlines must be met, prices must be calculable and processes must be planned. Automated tool management provides support here, as it ensures that all operating resources are available at all times. This avoids unnecessary machine downtime due to missing tools.

Digitalization offers enormous potential, but is not yet fully exploited in many companies. Although industry four point zero is frequently mentioned, full implementation often fails due to limited financial resources, a lack of specialists or the complexity of the systems.

Added to this is the increasing time pressure in day-to-day business. Delivery times are getting shorter and customers are making changes at ever shorter notice. Sometimes adjustments even reach us during ongoing production. Without digital models and precise CAM programming, such changes would be almost impossible to implement realistically.

And finally, the focus is on quality. Optical and functional repeatability is essential today. Automated deburring ensures that every manufactured part meets the exact same requirements and remains constant in terms of form and function.

From digital model to the integrated process

The work begins on the screen long before the chips start flying. The basis for stable complete turn-mill machining is a complete 3D model of the component. This can be integrated quickly and directly into SolidWorks and forms the basis for CAM programming. This allows machining strategies to be simulated, checked and specifically adapted long before the workpiece reaches the machining center.

However, a challenge arises with models that are not designed for mid-tolerance. This is because the CAM system implements exactly what the model specifies. For example, it does not automatically recognize whether a diameter is between plus zero point one and plus zero point two. In such cases, we therefore specifically program a grinding allowance that appears to be a deviation in the simulation, but corresponds exactly to the target dimension in actual production.

For consistent and precise complete machining, all components must be coordinated with each other. The machine with its kinematics and cooling functions, the workpiece clamping, the tool holder, the CAM strategy, the selected cutting values, the type of cooling and, of course, the tools used themselves. Whether PCD or solid carbide, whether with special cutting edge geometry, coating or coordinated helix angle – every detail contributes to process reliability and repeat accuracy. A stable, reproducible production process can only be achieved when everything works together.

Turning-milling complete machining in live application

This interaction was demonstrated live during our workshop. The focus was on the complete machining of a base body for a PCD tool made of steel. From cutting, turning, milling, drilling, reaming and threading to automatic deburring and measuring, every step was carried out directly on site.

A Mazak Integrex i 100H S, equipped with the Mazatrol control system, was used. For workpiece clamping, we used gripper jaws on the main spindle and specially machined jaws on the counter spindle. Tool clamping was ensured by Capto C6 in combination with hydraulic expansion technology. Classic emulsion ensured reliable cooling.

A particular highlight was the integrated measurement during the machining process. The TC62 3D touch probe from Blum Novotest was used in this configuration for the first time. The measurement data was processed directly and fed back to the machine for correction. The result was a consistently precise component – with no manual reworking and no loss of time.

The CAM programming was implemented with SolidCAM. Among other things, powerful strategies such as iMachining were used, which enable uniform machining with optimum loading of the cutting edges. The tools we used were precisely matched to the material and the machining task. The cutting material, cutting values, geometry and surface technology interlocked perfectly.

The result was a functional, dimensionally accurate basic body – completely manufactured in a single clamping operation. Fast, safe and with maximum precision.

Watch the video to see what this process looks like in reality. Immerse yourself in the practice of modern turn-mill complete machining – precise, efficient and live.

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