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CNC Turning vs. CNC Milling: What’s the Difference for Precision Machining Services?

Acme Foundry’s custom machining division offers high quality CNC turning and CNC milling solutions. These precision machining services are both utilized across a range of industries to manufacture highly accurate metal parts with complex designs and close tolerances.

The basic difference between turning and milling is that the turning centers rotate the workpiece, while milling centers use a rotating tool against a stationary workpiece.

Understanding the Differences Between CNC Milling and Turning Services

The CNC Turning Process

Turning machines secure cylindrical metal workpieces (generally called bar stock) in a chuck. The chuck then rotates the entire workpiece at very high speeds. A metal cutting tool presses against the surface of the workpiece – controlled via precise CNC programming. The friction between the rotating workpiece and cutting tool carefully removes metal and eventually produces a finished component with all of the desired shapes and geometries.

The CNC Milling Process

In the CNC milling process, the workpiece is held in place rigidly. Instead, the milling tool itself rotates (like a drill or grinder) to remove metal from the workpiece at precise angles, depths, and shapes. This is how CNC milling centers are able to achieve such complex, close-tolerance geometries from solid blocks of metal.

Turning vs. Milling Services: Advantages and Disadvantages

In many applications which require custom machined cylindrical parts, CNC turning is able to produce components more quickly and economically compared to milling. However, the turning process is not as efficient or as versatile for the manufacturing of non-cylindrical parts. In those cases, CNC milling services are more efficient while wasting less scrap material. Indeed, some complex non-cylindrical parts are impossible to produce solely on a lathe, requiring a CNC mill or mill-turn workstation.

Over 115 Years of Quality Machining Services

Located in Coffeyville, Kansas, since 1905, Acme Foundry has evolved into one of the nation’s leading foundries and CNC machining service providers. We specialize in the custom machining of gray iron castings along with complete foundry solutions. Our company is an ISO 9001:2015 certified American manufacturer dedicated to superior quality, consistency, and customer service.

What Is Gray Cast Iron? Advantages and Disadvantages in Manufacturing Applications

Gray cast iron is a ferrous alloy metal commonly utilized in an array of foundry services. The material’s metallurgical properties offer unique advantages and disadvantages for a wide range of manufacturing applications. From cast iron automotive parts and industrial components to common household products, cast iron metal is one of the most common manufacturing materials across a variety of commercial industries.

Below, we discuss the unique molecular composition and material properties of gray cast iron. As one of the industry’s leading gray cast iron foundries, Acme provides quality production solutions for cored and engineered castings. Our foundry specializes in responsive manufacturing services for custom castings with highly complex geometries in order to meet our customers’ most challenging design requirements.

The Material Properties of Gray Cast Iron

The chemical / molecular composition of gray cast iron varies depending on the specific material and application. The gray color that the metal is named for is a result of graphite microstructures and the material’s 2.5% – 4% carbon makeup. The other primary element is silicon, which is 1%–3% of gray iron. For some applications, there will be an addition of manganese at 0.1% – 1.2%. Of course, the bulk of the material is made up of iron.

Gray Cast Iron Benefits

Gray iron’s workability means it can easily be cast into custom-designed components and assemblies. The material offers great compressive strength similar to low-carbon / medium-carbon steel counterparts which tend to be less workable and more expensive. 

One unique advantage of gray cast iron is the enhanced damping property of the material. The microstructure and density of the metal enables it to naturally dampen vibrations. This makes it an outstanding material choice for various automotive applications which require end-user comfort as well as for vibration-sensitive industrial equipment.

Finally, gray cast iron excels at withstanding thermal cycling. The material is able to undergo extreme temperature fluctuations without overly straining or developing stress fractures. Gray iron’s outstanding thermal properties are another reason it is an ideal material for various automotive and industrial applications.

Gray Cast Iron Disadvantages

The biggest disadvantage of gray cast iron is its low tensile strength. This results from the graphite flakes within the material – which also give it many of its benefits. Compared to other low-carbon / medium-carbon steels, gray cast iron is more prone to cracks due to impacts and other stress. The damage results from stress cracks forming along the graphite flakes throughout the material, making it an inherent disadvantage.

Over 115 Years of Quality Domestic Foundry Services

Founded in 1905 in Coffeyville, Kansas, Acme Foundry has remained one of America’s leading gray iron foundries. Our company specializes in providing custom, complex gray iron casting solutions. As an ISO 9001:2015 certified manufacturer, we ensure the utmost in quality, consistency, and efficiency through all of our unique foundry services.

Scott in Shell Core room

Why Choose Gray Iron Casting Over Ductile Iron Casting

Everything You Need to Know About the Applications and Benefits of Acme’s Gray Iron Casting Solutions

Acme Foundry is one of America’s leading manufacturers of high-quality gray iron castings. Our state-of-the-art foundry is equipped with some of the industry’s most capable core-making technology to provide your business with truly efficient and optimized custom casting solutions.

What exactly are the advantages of Acme’s superior gray iron casting services when compared to conventional ductile iron casting options?

Five Benefits of Gray Iron Casting vs. Ductile Iron Casting

  1. Osborn molding lineImproved Vibration Damping – Compared to ductile iron material, gray iron dampens vibrations more effectively. This is a critical attribute for precision machining applications that require minimum vibration to achieve close tolerances, as well as a multitude of applications that require reduced NVH attributes (noise, vibration and harshness).
  2. Increased Machinability – As a material, gray cast iron is much easier to machine than ductile iron. This is due to the metallurgical properties of gray iron, which allow it to be precision CNC machined faster, more reliably and consistently.
  3. Decreased Production Costs –  Because it is relatively easier to both produce and machine gray cast iron products, this material can offer significant cost savings in commercial applications that do not require the other metallurgical properties of ductile iron.

Five Common Product Applications for Gray Cast Iron

As a readily available, lightweight and affordable metal, gray cast iron is the ideal material for a wide range of commercial and industrial sectors. For example, any manufacturing application that requires enhanced vibration damping (e.g. equipment frames and fixtures). Other common product applications for gray cast iron include:

  • Cleaning and grinding 5Industrial valves and fittings
  • Compressors, pumped and other pressurized systems
  • Commercial construction equipment
  • Power plant components (e.g. diesel engine components)
  • Various vehicle and transportation system products

Your Single-Source Domestic Manufacturer of Premium Gray Iron Casting Products

At Acme Foundry, our core room is integrated with advanced engineering, design and testing equipment to ensure all of our gray iron casting products are manufactured to ISO 9001:2015 quality certification standards. From relatively simple custom castings to highly cored, complex components, Acme Foundry sets the bar with superior American manufacturing quality and consistency.