In high-hardness stainless steel applications, achieving consistent accuracy is not only a matter of machine capability—it depends on the stability of the entire machining system. This includes the cutting tool, the clamping method, and the tool holding solution.
In this case study, we present the four-axis machining of a SUS630 cover (50 HRC) using a fully integrated solution manufactured by our own factory:
our Milling Cutter, Self-Centering Vise, and Hydraulic Tool Holder.
The process focuses on stability, repeatability, and dimensional consistency, making it suitable for both sample validation and repeat production.
I. Part Overview: Typical Cover Structure with Coaxial Requirements
Case drawing
The cover shown in this case is a rotational-symmetry component featuring:
- · Multi-step outer diameters
- · Internal stepped cavity
- · A central hole that defines the functional axis
- · Strict coaxiality requirements between outer diameter, inner cavity, and center bore
Such parts are common in mechanical assemblies where axial alignment and step height consistency directly affect sealing, positioning, and long-term reliability.
II. Why a Four-Axis Machining Center Was Selected
Although covers are traditionally associated with turning processes, a four-axis machining center with a rotary table provides clear advantages:
- · Single setup, unified axis
All circular features are machined around the same rotational center, improving coaxial accuracy.
- · Process flexibility
End faces, outer steps, inner cavities, center holes, and chamfers can be completed in one setup, with optional indexing for back-side features.
- · Repeatable production logic
Once the process is validated, the same setup can be reliably repeated for future batches.
III. Workholding Solution: Our Self-Centering Vise
Meiwha Self Centering Vise
Stable workholding is essential when machining hardened materials.
In this case, the workpiece was clamped using our own Self-Centering Vise, mounted directly on the rotary table of the four-axis machining center.
Advantages of the Self-Centering Vise:
Automatic centering ensures the workpiece axis aligns with the rotary center
- · Consistent clamping force reduces deformation and positioning variation
- · Faster setup compared to manual centering methods
- · Ideal for rotational parts requiring coaxial precision
By using a Self-Centering Vise, the cover’s outer diameter, inner cavity, and center hole remain aligned throughout the entire machining process.
IV. Cutting Tools: Milling Cutter Designed to Match the Drawing
Meiwha CNC Milling Cutter
All cutting operations were performed using our own Milling Cutter, with tool diameters selected specifically according to the dimensions shown on the part drawing.
Milling Cutter strategy:
- · Tool sizes matched to step diameters and cavity widths
- · Conservative engagement to control cutting forces in 50 HRC material
- · Stable geometry for both roughing and finishing stagesAs a factory, we do not rely solely on standard off-the-shelf tools.
We design and manufacture Milling Cutters based on actual drawing dimensions and machining objectives, ensuring a better match between tool geometry and part requirements.
V. Tool Holding System: Hydraulic Tool Holder for Finishing Stability
CNC Hydraulic Tool Holder
All finishing operations were performed using our Tool Holder – Hydraulic Holder.
Why a Hydraulic Tool Holder was selected:
- · Uniform 360° clamping reduces tool runout
- · Improved damping helps suppress micro-vibration
- · Better surface consistency on step walls and end faces
- · More stable performance during long cutting cycles
For hardened SUS630, the combination of a precisely matched Milling Cutter and a Hydraulic Tool Holder plays a critical role in achieving repeatable surface quality.
VI. Machining Process and Strategy
Machining sequence (single setup):
- 1. End face machining to establish Z reference
- 2. Rough machining of outer diameter steps
- 3. Layered roughing of the internal cavity
- 4. Center hole machining under the same rotary axis
- 5. Finishing of internal steps and cavity bottom
Final finishing of outer diameters and chamfersAll operations are completed in one clamping, ensuring consistent axial alignment.
VII. Conservative Cutting Parameters for Hardened SUS630
To prioritize stability and tool life, conservative cutting parameters were applied.
- Rough Machining (Stability-Oriented)
- Spindle Speed (S): 3000–4500 rpm
- Feed Rate (F): 600–1000 mm/min
- Axial Depth (Ap): 0.3–0.6 mm
Radial Engagement (Ae): 0.5–1.0 mmFinishing Machining (Quality-Oriented)
- Spindle Speed (S): 6000–8000 rpm
- Feed Rate (F): 300–600 mm/min
- Axial Depth (Ap): 0.05–0.10 mm
- Radial Engagement (Ae): 0.05–0.15 mm
These parameters help maintain dimensional stability and consistent surface quality when machining 50 HRC material
VIII. Key Quality Control Points
- · Coaxiality between center hole, internal cavity, and outer diameter
- · Step height consistency across multiple levels
- · Surface texture uniformity on end faces and step walls
- · Clean chamfers and burr-free edges for assembly safety
IX. We Are a Factory: Integrated Milling Cutter, Vise, and Tool Holder Solutions
This case demonstrates more than a machining result—it reflects our manufacturing capability.
As a factory, we provide:
- · Custom Milling Cutters matched to customer drawings
- · Self-Centering Vises designed for precise and repeatable positioning
- · Hydraulic Tool Holders optimized for stability and surface quality
Customers can send us:
- · Part drawings
- · Material and hardness requirements
- · Machine conditions and spindle interface
- · Target accuracy and surface finish goals
We will design and manufacture a complete Milling Cutter + Self-Centering Vise + Tool Holder solution tailored to your application.
If you are machining hardened materials or precision cover components and require a stable, repeatable process, contact us. Share your drawing and machining requirements—we will deliver the Milling Cutter, Self-Centering Vise, and Hydraulic Tool Holder solution that best fits your production needs.
Post time: Jan-19-2026
