With the rapid development of China’s CNC lathe manufacturing industry, higher demands are being placed on production efficiency and product quality. CNC lathes are now capable of machining parts with ever-increasing precision and increasingly complex shapes. The application of forming inserts is becoming more widespread. Forming inserts can be defined as non-standard, complex-profile inserts, such as forming lathe inserts, forming milling inserts, indexable forming inserts, and thread-forming inserts.

I. Applications and Market Prospects of Forming Blades

The application of forming blades can simplify the motion of machine tool spindles. While maintaining precision, the mechatronic design of CNC lathes can double processing efficiency. Operation of these machines requires prior training. For example, a forming turning tool is a specialized cutting tool designed specifically for machining shaped surfaces on rotating workpieces; its cutting-edge geometry is tailored precisely to the profile of the workpiece. When using a forming turning tool, only a single cutting pass is needed to produce the desired shaped surface. This method is simple to operate, highly productive, and ensures that the accuracy of the machined surface is independent of the operator’s skill level—instead, it largely depends on the machining accuracy of the CNC lathe and the geometry of the tool’s cutting edge. This approach guarantees consistent and interchangeable accuracy in both the shape and dimensions of the machined workpiece surfaces, with machining accuracies ranging from IT9 to IT10 and surface roughness values between Ra6.3 and Ra3.2.

Currently, formed blades are widely used in the electromechanical integration design of CNC lathes for various industries, including automotive, medical, hydraulic, rail transit, energy, bearings, aerospace, and watchmaking CNC turning. Operating these machine tools requires prior training. We believe that the market for molded blades will continue to grow. CNC lathe equipment

II. Analysis of Molded Blades

In the case of forming turning inserts and other tools, the normal functioning of the front and back rake angles should not be compromised. However, forming cutting edges are complex, with different orientations along the main cutting edge segments. It is therefore impossible to grind both the vertex angle and the back rake angle within a single segment. Instead, in the forming internal segments, the tool is designed to machine the longitudinal profile of the insert at a specific angle, allowing for adjustments to the front and back rake angles of the insert within the tool’s longitudinal profile.

III. Analysis of Profile Error in Formed Blades

For formed blades, contour accuracy is of paramount importance. The grinding accuracy of the formed blade profile is affected by mechanical factors, electrical factors, and wheel wear.