Embossing metal on a lathe – bespoke inscriptions for high-quality metal parts

Your turned part has been accurately turned to within a hundredth of a millimetre, the surface has been carefully ground and the thread has been precisely cut. At first glance, the component looks to be finished. But something’s missing – it still needs its own individual touch. Not to worry – you can easily add this using the right tool, e.g. by embossing. The production method for this is known as “embossing metal” or also “marking”. Metal is embossed for many different reasons: you can emboss a turned part to add a unique serial number so that it can be traced, technical information to identify the component, the date of production, or the customer’s name or logo. This process turns any metal part into a unique workpiece with a high-quality embossed look.

Unlike laser marking or engraving, embossing metal parts is a very simple and affordable process. Not only can all the work steps be performed on a single machine, there is also no need to laboriously position the component in the laser machine. Furthermore, the marking tool is compatible with conventional, manual lathes as well as modern turning and milling centres, meaning it can be seamlessly integrated into the production process.
Another advantage is the fact that the method is so versatile and variable: with a suitable marking tool you can not only inscribe the outer face of turned parts, but also emboss inclined, flat and convex surfaces. As a result, it can be used on most conventional materials used in the metal engineering sector (except hardened materials).
But that’s enough words of praise about marking as a technique – we want to understand how to produce the perfect inscription. The first step here is to choose the right marking system.

Tip: customise your text even further

Marking tools are supplied with a standard typeface as defined in the DIN 1451 standard. However, if you want a more interesting typeface, you can request different ones from the manufacturer or order bespoke logos and special characters. These should be provided as a .dxf file where possible.

Revolving or spring-return system? Which system should I use for which project?

When embossing metal, we distinguish between two different variants: the spring-return system and the revolving system. In the case of the revolving system, the marking tool with the marking roll rotates around the workpiece several times. The diameter of the marking roll must be precisely coordinated with the diameter of the workpiece.
The spring-return system differs in this respect: in this case, the marking roll is suitable for workpieces with different diameters because the tool does not move around the workpiece continuously, rather the embossing is performed by the part rotating once. The tool comes to a standstill upon reaching the end of the text and returns to the starting position by means of a return spring. As a result, workpieces of different shapes (inclined, convex, flat) can also be processed.

Revolving or spring-return system?

Revolving marking systems are primarily suited to medium and large production runs as the marking roll is tailored to the individual workpiece.
In contrast, spring-return marking systems are ideal when dealing with smaller production runs, varying shapes and different diameters

Step-by-step instructions for perfect embossing results

Embossing metal is a comparatively simple production method, so with a little practice you will soon obtain good results.
Step-by-step instructions for marking/embossing metal parts are provided below.

Clean the component: The component must be free of any contamination to ensure the individual segments of the marking tool and the marking roll make optimum contact on the workpiece without slipping.
Check the concentricity: The concentricity must be as precise as possible (0.03 mm)
Check the workpiece diameter: The workpiece diameter must satisfy very tight tolerances to ensure the text is not embossed at different depths. The maximum tolerance is +/- 0.025 mm.
Insert the marking tool: Thanks to its modular shank design, the marking tool can be flexibly inserted in the toolholder and positioned exactly on the workpiece circumference. Tip: you can correct the parallel alignment of the axes using the threaded pin.
Embossing depth: When choosing the embossing depth (ED), please note that it must always be larger than the concentricity (Ø 0.03 mm). You can use the following ap values as a guide, both for the revolving and the spring-return system: radial r = 0.075 mm, diameter Ø = 0.15 mm. Attention: if the embossing depth exceeds the recommended dimensions, the embossed text may end up distorted.
Choose and set up the drive: To ensure the tool is optimally held on the workpiece throughout the entire process, you not only need the text you are embossing, but also a “drive”. This drive can be designed in line with your individual requirements – e.g. with asterisks or hash symbols – and is also embossed in the material during the process. It can be removed afterwards if desired.
Emboss the metal: Now you can get going. When embossing the workpiece, the revolving system differs from the spring-return system.
1. Revolving system: in the case of the revolving system, the radial feed rate should be f 0.08 mm/rev. With this system, the marking tool moves around the metal component until the desired embossing depth has been achieved.
2. Spring-return system: With this system, the tool moves up to the workpiece when it is stationary. The tool is fed into the metal part to the required depth and the spindle continues running slowly until the tool is withdrawn.
Optional – remove the drive: As the final step in the process, the embossed drive text can be removed by reworking if desired, using methods such as parting off, finishing or chamfering.

Essential prerequisites for a perfect inscription

The surface of the component must be clean.
The embossing depth must have been set correctly.
The correct feed rate must be selected.
Deformation may occur when working on thin-walled workpieces. In this case, the full material thickness should first be used to emboss the text and the complete machining should take place towards the end.

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