Swiss Type Machining – The Ultimate Guide

You may be wondering what a Swiss machine is or what Swiss machining means. In this article we will take you through a detailed discussion on its meaning, benefits, limitations, history, etc.

What is Swiss Machining?

Unlike other machining processes, in Swiss type machining process, you will carry out a range of operations focusing on precision and complex geometrical parts.

Additionally, you will use Swiss type lather or screw machine to process small parts. These are specialized machines with multiple spindle lathing apparatus.

The special feature of Swiss machining is the possibility of carrying out multiple machining operations on the same piece simultaneously.

Benefits of using Swiss Type Lathe Machine

High Precision: During the operation, the Swiss-type machine has proven to be highly capable of achieving tight tolerances and top-notch surface features.

Setup Time is Low: With bar feeder and automated system, you can handle numerous continuous machining operations.

Long, Slender Parts: The compact design allows the machining of long, slender parts with minimal deflection.

Material Efficiency: Swiss-type lathes are produced to allow least possible material waste in order to easily direct new parts from bar stock.

Versatility: Balanced Swiss type lathes are flexible and can allow a number of materials including ceramics, metals and plastic.

Quality Assurance: Swiss-type machines feature an inherent accuracy that results in quality and reproducibility of products.

Limitations of Swiss Type Machining

Initial Investment: You should also be aware that Swiss-type lathes are typically more expensive than conventional ones from the start.

Material Limitations: Swiss-type machines can handle a broad ceramics, metals and plastics. However, it still can be not suitable for the light brittle materials such as excess tool wear or breakage.

Limited Workpiece Size: Swiss lathes were invented so as to handle intricate machining of small parts with more exactness.

Programming Complexity: It requires more knowledge to code Swiss-type turning centers for complicated parts than you would have when using similar conventional lathes.

Bar Stock Requirements: In Swiss-type machining, movement of the block takes place through the feed of bar stock fed by machines.

Tooling Costs: The cost of tooling may be considerable; however, this aspect is exceptionally noticeable for the parts that are complicated. This may bring about the need for using a specialized tooling solution.

Swiss Machining History

At the time when innovations were happening in the Swiss watchmaking industry, craftsmen had already discovered special-lathe-machines for making watch components. During the 19th century, Swiss watchmakers, began to produce miniature and intricate parts with utmost precision.

Automated lathes were later developed and equipped to grind the part from bar stock leading to high-volume manufacturing of small components. Gradually, Swiss screw machines were updated by using new technologies and installing functions to raise the level of productivity and precision.

CNC Swiss Machining vs Conventional CNC Turning

Looking at CNC Swiss machining and conventional CNC turning, you realize that they both are designed to handle cylindrical pieces. However, there are various differences between them as we will discuss below.

Machine Design

In a Swiss-type lathe machine the cutting tool is held intact by a collet or chuck while the piece is attached to a spindle that allows rotation.

Conventional CNC turning on the other hand, has its cutting tool moving linearly while the piece is loaded on a collet/chuck.

Part Complexity

CNC Swiss machining is capable of handling only parts with smaller diameters and not larger pieces. It handles these pieces accurately and precisely.

Conventional CNC turning also has the capacity to handle complex designs; however, it has limited capability.

Tooling

When it comes to the cutting tools, you can incorporate a wide range of tooling systems. This allows you to have a wide range of machining flexibility.

With conventional CNC turning you may not be able to achieve the level of tool changing capability as in CNC Swiss machines.

Material Handling

In CNC Swiss machining material handling is automated as it uses bar feeders that make loading simultaneous hence handling high volumes.

Working with a conventional CNC turning machines requires loading of each bar into the machine manually.

Setup Complexity

Setting up a Swiss-lathe machine may require highly skilled operators since it is a slightly complex process.

Conventional CNC turning is quite simple in terms of setup and may not require highly skilled individuals for the process.

Cost Consideration

You need to invest a lot of money in acquisition and setting up of a CNC Swiss machine.

Conventional CNC machines also require high initial amount but they are cheaper than Swiss-type lathes.

How Swiss Lathe Machining Process Works

Material loading: First, you need to load your pieces into the bar feeder as long bar stock. From there your feeder will automatically feed the pieces into the lathe machine.

Bar stock support: For precise and better results, the machine is designed with a guide bushing that hold the pieces close to the cutting tools.

Workpiece clamping: At the main spindle, the machine features a collet that holds the bar stock. Through the spindle the workpiece can now rotate as the tools stays in the same place.

Simultaneous machining: The machine is loaded with various cutting tools designed to perform different operations at the same time. Such operations include turning, drilling, milling, tapping, etc. As the spindle rotates the bar stock, they get into contact with the cutting tool removing the unwanted sections as specified.

After the material removal, the machine again automatically eliminates the waste in the form of chips to avoid any kind of buildup. Also, the already machined piece can be removed from the bar stock through a parting tool. Get the piece inspected for quality standard and proceed to the next cycle.

Best Materials for Swiss Machining Process

Copper

Copper material is a good and compatible option for Swiss machining since it offers good thermal and electrical properties. Swiss machine makes pins, sockets and electrical connect from copper material.

Brass

Since brass has perfect machining properties, Swiss machining utilizes it to make decorative parts, connectors, valve bodies, fittings, etc.

Nylon

Nylon is also a good material for Swiss machining operations because it results into precise and accurate components. Such components include insulators, gears, and bushings.

Titanium

Titanium may have low thermal conductivity and high strength. However, Swiss machining has to use if for making parts like medical devices that require biocompatibility and corrosion resistance.

Aluminum

Aluminum offers good resistance to corrosion, low density and perfect machinability and makes parts like consumer goods, automotive fittings, etc.

Nickel

For parts that require features like electrical conductivity, high-temperature strength corrosion resistance, nickel comes in handy.

Plastics

Parts made from plastics through Swiss machining offer benefits like low cost, low friction, low density and corrosion resistance.

Carbon Steel

Carbon steel can be machined easily through Swiss machining to make parts like pins, shafts and fasteners.

Accuracy in Swiss Type Machining

Generally, Swiss machining is specifically designed to offer precision to parts that come with tighter tolerances and complete surface finishes. Depending on the choice of machines, some can hold up to 5 µm accuracy. These can offer a repeat of less of equal to 2 µm. Other machines offer even better accuracy levels.

Remember, high levels of accuracy can only be made possible through thorough attention to detail at every level of the process. The kind attention in this regard requires expertise and experience.

Swiss Machining Capability in Material Fabrication

This process gives you the opportunity to run high-volumes of pieces in a short period of time. It is important to note that one Swiss machine can carry out all the operations simultaneously in a short time.

For metals like stainless-steel, a Swiss lathe machine can work with diameters of up to 2inches enabling the design of unique features. Other metals like nickel, titanium etc. can give parts with tolerances of 0.0001 inches.  Generally, we can conclude that Swiss machining is one of the best machining operations that offer perfect machining capabilities.

Comparing Swiss Machining to Traditional Milling

Swiss machining and traditional milling both have different capabilities as is discussed below.

Workpiece Geometry and Size

Swiss machining is generally designed to handle small, and intricate pieces focusing mostly on precision.

Traditional milling on the other hand can handle both small and larger pieces with complex geometries.

Machine Setup

Since Swiss machining can handle highly complex designs, its setup and operations also require experts with good experience.

Setting up a traditional milling machine does not require much because its easy and straightforward.

Tooling

Swiss machining requires the use of special cutting tools meant for smaller cuts.

Traditional milling can accommodate a large number of tools that are easily available and also cost effective.

Accuracy or Precision

Swiss machining is definitely known for its precision capabilities producing parts that offer tighter tolerances.

Traditional milling is also capable of offering accurate and precise parts but not to the level of Swiss machining.

Swiss Machining Vs CNC Machining

You need to understand that there are tasks that both the Swiss machining and CNC machining can handle. However, there also features that make them unique and different from each other. Comparing the two in terms of:

Design and Application

Swiss machining is recognized as a method of machining components of accurate dimensions and complex shapes with a smaller diameter.

CNC systems are a kind of universal set of tools and can be used for parts of smaller dimensions, and large-size objects. These processes are handled with an arbitrary degree of intricacy.

Setup and Tooling

Swiss machines mostly have an intricate setup that needs specific equipment tools. This is related to the design of machines and intended purpose.

Simple parts or operations may have a more straightforward CNC set up and tooling process. This is due to the fact that CNC machines have fewer physical issues and complications.

Precision and Tolerances

Swiss machining is a perfect choice in matters high precision capability and tight tolerances, relating especially to long and delicate parts.

In terms of precision, CNC machining could be equal or even better than the Swiss machining for the majority of components. However, some certain types of parts may require Swiss machining’s higher level of precision.

Cost and Efficiency

Swiss machining during the initial stages may seem to be pricier since the tools and machines involved are more complicated.

Having to work with CNC machining means you will need to save on costs when handling non-complex or larger pieces.

Applications of Swiss Machining

Medical Devices

Swiss machining is regularly thought of as one of the most progressive and precise technologies in the medical industry. It is very necessary for the fabrication of components like surgical instruments, orthopedic implants, dental implants, catheter, and others.

Aerospace

With weight reduction as key and precision being a core requirement, the Swiss machining is a great achievement for aerospace industry. All these airspace parts are made at this place: of fittings, connectors, fasteners, fuel system parts, and actuators.

Electronics

Swiss machining is applied during the manufacturing of different electronic elements, for example, flat cables, pins, sockets, terminals, and other micro components.

Automotive

In automobile sector, Swiss machining is applied for fabrication of accurate parts of engine as well as transmission system. The fact that prototyping can achieve superior-quality results and detailed geometry is its primary advantage in automotive applications.

Watchmaking

Watchmaking was the foundation of Swiss machining process, where unprecedented attention to detail and precision were the main factors to success. For the production of watch movements, this metal is used, for instance, cutting of parts like gears, pinions and screws. It also provides smaller parts, such as escapements and jewels, essential for mechanical and electronic timepieces.

Defense and Firearms

Swiss machining is used in the output of items such as surgical weapons, defense devices, and tactical gear during the production process.

Optics and Instrumentation

The case of industrial production based on photonics, optics, and instrumentation is a good example of Swiss machining. This is where abilities in making optical units are, for instance, used in lenses and in mounts of optical equipment.

Telecommunications

The connectors, adapters, housings, and other small parts, which are used in network devices, fiber optics, are made through Swiss machining.

Conclusion

In general, the exceptional precision, efficiency, and flexibility of Swiss machining companies make it a prevailing procedure for making small, detailed parts in almost all major industries, where high accuracy and tight tolerances are usually the indispensable needs.

More Resources:

Electrical Discharge Machining – Source: TSINFA

Aluminum CNC Machining – Source: TSINFA

Swiss Machining – Source: XOMETRY