The Basics of Live Tooling

In the world of modern manufacturing, the ability to quickly and efficiently produce high-quality parts is crucial for maintaining a competitive edge. One technology that has become increasingly important in this regard is live tooling, a versatile machining process that allows for the seamless integration of multiple operations within a single setup.

Understanding Live Tooling

Machining a workpiece is performed by rotating it in the spindle and advancing the cutting tool, which is mounted on the carriage. Consequently, due to the limitations of the standard lathe layout, drilling holes is possible only from the face of the workpiece and only along the central axis, with the drill remaining stationary while the workpiece rotates. Until the invention of live tooling, all such operations were performed in secondary processes on a milling machine.

Tool holders for CNC lathe have undeniable advantages:

• Global standardization and versatility. The same tool holder can be used on any other CNC machine with the same type of turret.

• The ability to set up and preset outside the machine.

• Saving time.

• Tool holder for CNC lathe is relatively inexpensive, and in the event of tool and holder collisions with the workpiece, it is often only these elements that get damaged, rather than the expensive components of the CNC machine.

• The ability to configure the lathe turret for each specific job. The engineers are limited by previous setup or pre-engineered positions in the lathe turret, but only by number of positions/posts in the revolver of the CNC machine.  For example, for part X today, you need a long boring bar mounted in position No. 1, and tomorrow, due to the geometric constraints of part Y, you can place a parting tool or any other turning cutting tool in the same position.

Types of tools holders

CNC tool holder is classified by the type of machining and the type of tool to be mounted in the fixture and size. The main types include:

• Radial turning holder (OD)

The most common type of holders for mounting tools with a square shank for machining the outer diameter of the workpiece. The tool in such holders is positioned perpendicular to the axis of rotation of the part (radially). The holder design always includes a slot for the tool and a clamping plate for fixation.

• Axial turning holder (OD/FACE)

Structurally identical to radial tool holders, except that the tool is positioned parallel to the axis of the spindle rotation (axially). Mainly used for holding tools for face grooving. They can also be used for external and internal turning. In addition, various machine tool accessories for CNC machines are often used together with the tool holders.

• Boring bar holders (ID)

Used for mounting round shank boring bars for inside diameter (ID) machining. The bar is positioned against the face of the workpiece. Usually they have three clamping screws because the tool often needs to be clamped along a longer length. Typically, two nozzles for coolant supply are located externally.

Applications of Live Tooling

Live tooling has a wide range of applications across various industries, including:

Automotive Manufacturing: Live tooling is extensively used in the production of automotive components, such as engine parts, transmission components, and suspension systems, where the ability to perform multiple operations on a single machine is highly valuable.

Aerospace Industry: The aerospace industry, which requires the production of highly complex and precision-engineered parts, has been a major adopter of live tooling technology, particularly in the manufacturing of aircraft components and engine parts.

General Machining: Live tooling has also found widespread use in general machining applications, such as the production of consumer goods, industrial equipment, and a wide range of other parts that require secondary operations beyond simple turning.