Metal production involves operations aimed at shaping metals to meet specific product requirements. At the core of these metal forming methods lies cutting, which is a far more complex process than simply slicing metal to a predetermined size.
The categorization of metal cutting encompasses a wide array of operations, all focused on removing unnecessary material from a workpiece to ensure it adheres to design specifications. Various cutting techniques utilize machines engineered to execute the process with efficiency and accuracy.
Metal cutting processes encompass broaching, CNC machine cutting, the expanded metal process, laser cutting, stamping, etching, perforation, and more. These methods stress and shape metals to meet application demands, each tailored to achieve operations efficiently and precisely.
Broaching efficiently removes unwanted material using a sharp-toothed broach. Linear and rotary broaching are two types, with linear moving in a line against the surface, and rotary involving a rotated broach. Broaching produces products such as gears, fasteners, threading, pulleys, sprockets, and bushings, applicable to materials like plastics, copper, and various steel grades.
CNC programming is utilized for various manufacturing functions, including cutting. This method offers advantages as instructions are directly input into the machine, enabling quick and efficient cutting operations regardless of the type of cutting.
The expanded metal process is an unconventional method involving the expansion of solid sheets or coils to form a mesh, cut by a knife to create a specific design. Stretching and cutting occur simultaneously in this process to achieve the desired design.
Laser cutting, typically integrated into CNC processes, delivers highly precise and accurate cuts with exacting tolerances. The laser beam, an acronym for light amplification by stimulated emission radiation, is a focused radiation wavelength. CNC programming enhances the precision of laser cuts, ensuring nearly flawless results.
Metal etching, an artistic cutting method, involves cutting the surface of metal to create designs, shapes, or patterns by cutting grooves and fine lines. Various etching methods include chemicals, acids, stamping, photofabrication, water jet cutting, and lasers, resulting in close tolerances and a smooth finish when executed by a skilled craftsman.
Metal fabrication, covering a range of processes to shape, configure, transform, and manipulate metals, utilizes cutting as a significant process in sizing and shaping pieces for fabrication.
Similar to etching, stamping alters the surface of metals to form designs or patterns. Stamping uses various processes, including cutting, bending, drawing, and blanking, each requiring a different tool or die. Stamping’s major benefit lies in its ability to quickly and efficiently produce finished products.
Perforating, similar to expanding, involves punching metal sheets with force to create uniquely shaped holes. Perforated metal serves diverse functions, from decorative pieces to protective coverings for machines.
The Swiss screw machine, a precise machining process, removes excess material by turning a part through a cutting tool, becoming a staple in metal production.
Tube fabrication, a classic form of metal fabrication, shapes and manufactures tubes into various diameters, sizes, and lengths. This involves bending, enlarging, and cutting tubes from different metals to produce parts, components, and products.
Water jet or hydro cutting employs high-pressure water to remove excess material from metals, enhanced with abrasives for precision and accuracy in the cutting process.
