Metal production encompasses operations designed to alter the shape of metals to meet the requirements of a specific product. Central to these metal forming methods is cutting, a process far more intricate than merely slicing metal to a predetermined size.
The classification of metal cutting involves a diverse range of operations, all aimed at removing unnecessary material from a workpiece to ensure compliance with design specifications. Various cutting forms employ machines engineered to execute the process with efficiency and precision.
Processes involved in metal cutting include broaching, CNC machine cutting, the expanded metal process, laser cutting, stamping, etching, and perforation. These methods stress and shape metals to meet the demands of applications, each designed to achieve operations efficiently and precisely.
Broaching efficiently removes unwanted material using a sharp-toothed broach. Linear and rotary broaching are the two types, with linear moving in a line against the surface, and rotary involving a rotated broach. Broaching produces products like gears, fasteners, threading, pulleys, sprockets, and bushings, applicable to materials such as plastics, copper, and various grades of steel.
CNC programming is employed for various manufacturing functions, including cutting. This method offers advantages as instructions are directly fed into the machine, enabling quick and efficient cutting operations irrespective 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 included in 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, employs 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, akin 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.
