Verified tooling case study · TURN / 05
Custom Polygon Turning Tool for an External Hexagonal Profile
A custom tooling system that produces an external hexagon on the turning machine and eliminates a separate milling setup.
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Process problem
The hexagon required transfer to a separate milling setup
The conventional route for an external hexagonal profile on a steel component involved transferring the part from the lathe and milling the faces in another setup.
BORACO solution
Simultaneous tool and workpiece rotation generates the non-circular profile
BORACO designed and manufactured a polygon turning tool in which the spindle-mounted tool and workpiece rotate simultaneously under a controlled kinematic relationship. The image shows one tooling system with and without its shank.
Manufacture and inspection
Across-flats size, symmetry, concentricity, and runout
Inspection covered dimension across opposite flats, consistency and symmetry of all six faces, profile concentricity with the workpiece axis, and cutting-edge position and runout. Direction, speed ratio, dimensions, and machine data remain confidential.
Project outcome
Hexagonal profile produced on the turning machine
The tool produced the external hexagon on the same turning machine and eliminated part transfer and a separate milling setup. No numerical time or cost claim is published.
FAQ
What is polygon turning?
A controlled process using a rotating tool and rotating workpiece to create a non-circular profile.
FAQ
What was the confirmed benefit?
The hexagon was produced on the lathe without a separate milling setup.
FAQ
What information is required?
Drawing, side count, profile size, material, tolerances, engagement length, and machine synchronization data.