The process of metal processing is roughly divided into three categories, namely metal forming, metal cutting and metal joining. In this article, we will focus on the latest technologies applied to metal cutting.
Cutting is the process of bringing material to a specified form by removing material using various tools. Its finished parts shall meet specified requirements in terms of size, workmanship, design and aesthetics. There are only two products of cutting - scrap and finished product. After the metal is machined, the scrap is called metal swarf.
The cutting process can be further divided into three categories:
- The ones that generate chips are classified into one category, also known as CNC machining.
- Classify materials that are burned, oxidized or evaporated into one category.
- The two are mixed, or other processes are classified into one category, such as chemical cutting.
Drilling holes in metal parts is the most common example of a first class (chip generating) process. Using a torch to cut steel into small pieces is an example of the combustion category. Chemical grinding is an example of a special process that uses chemicals etching, etc., to remove excess material.
cutting technology
There are many process technologies for cutting metals such as:
- Manual techniques: eg sawing, chiseling, shearing.
- Mechanical technology: such as precision punching, grinding and milling.
- Welding/combustion techniques: eg by laser, oxy-fuel combustion and plasma combustion.
- Erosion technology: machining with water jet, electrical discharge or abrasive flow.
- Chemical techniques: photochemical etching or processing.
As you can see, there are many different types of metal cutting methods, and knowing and mastering these is a good starting point that will enable you to take advantage of all the techniques available to navigate this exciting field.
Several metalworking techniques
It is impossible to cover all of these techniques in one article. We'll pick six of them and explain what they are, their respective tools and possible use cases.
metal marking
Direct part marking is a range of techniques for permanent marking on metal for traceability of parts, industrial part labeling, decoration or any other purpose. Metal has been marked since humans started using metal tools such as axes and spears, and metal marking is as old as the invention of smelting technology. However, current technology has advanced to a level that allows humans to create complex marks with high precision for any product imaginable. Marking can be achieved by a variety of techniques including metal engraving, embossing, die casting, stamping, etching and grinding.
metal engraving
Engraving is a technique mainly used to engrave patterns, words, drawings or codes on metal surfaces to obtain products with permanent markings, or to use engraved metal to print engravings on paper. Engraving mainly uses two technical means: laser and mechanical engraving. Although laser technology is already very versatile and easy to use, it provides us with the highest quality metal engraving process because it is computer-aided and precisely pre-orders various surfaces for the best engraving results. Mechanical engraving can be done by hand, or by more reliable pantographs or CNC machines.
Metal engraving technology can be used for: personalized jewelry, fine art, photopolymer laser imaging, industrial marking technology, engraving sports competition trophies, printing plate making, etc.
metal stamping
Metal stamping is not a subtractive machining process. It is the use of molds to fold metal sheets into various shapes. Household utensils that we come into contact with, such as pans, spoons, cooking pots and plates, are stamped. Punch presses are also used to make ceiling materials, medical equipment, machine parts and even coins. Its products are widely used in medical, electronic, electrical, automotive, military, HVAC, pharmaceutical, commercial and machinery manufacturing industries.
There are two types of metal stamping machines, mechanical and hydraulic. Sheets of stainless steel, aluminum, zinc, and copper are typically cast, punched, and cut into three-dimensional objects by these machines. They have very high product turnover due to their relative ease of processing. Punch presses can be arranged in tandem to process metal stock, using different step operations to finally convert them into finished parts and separate them from the processing line.
Presses are versatile and capable of producing a wide variety of products. These products come in different sizes and designs, and most are for industrial use. Usually, you can just send the sample and sheet metal to a company that does metal stamping and get what you want.
metal etching
Etching can be achieved by photochemical or laser processes. Laser etching is currently a popular technology. Over time, this technology has developed exponentially. It refers to high-precision etching by using a coherently amplified beam of light on a metal surface.
Laser is the cleanest way to etch marks because it does not involve the use of caustic reagents, or noisy drilling or grinding processes. It simply uses a laser beam to vaporize material as instructed by a computer program to create precise images or text. Due to the continuous advancement of technology, its size has become smaller and smaller, and researchers or laser hobbyists can now also buy new and cheaper laser equipment.
chemical etching
Chemical etching is the process of exposing a portion of a sheet of metal to a strong acid (or etchant) to cut a pattern into it and create a designed shape in the grooves (or cuts) in the metal. It is essentially a subtractive process, using etchant chemistry to produce complex, high-precision metal parts. In basic metal etching, the metal surface is covered with a special acid-resistant coating, parts of the coating are scraped off by hand or mechanically, and the metal is placed in a bath of strong acid reagent. The acid attacks the metal parts uncovered by the coating, leaving the same pattern as the coating scrapes, and finally removes and cleans the workpiece.
Photolithography refers to the photographic process of acid-resistant layers on metal surfaces. A key difference between this method and motorized or manual scratching techniques prior to chemical etching is that the applied acid-resistant layer is also treated with irradiation to create a photoresist layer (photoresist layer), which helps to create a highly Precise and reproducible patterns.
There are various machines in this field. They include fiber lasers, CO2 and UV machines.
metal grinding
Grinding is the physical grinding of a workpiece with a cutting tool (abrasive), typically for trimming rough edges, deburring, grinding welds, removing chips, producing sharp edges, or giving metal parts a unique finished appearance. Usually, grinding is the last operation after a part has been engraved, stamped, etched or any other form of metal working.
Below are the six main types of grinders and the different types of applications they have.
-Abrasive belt grinders: mainly use an electric belt coated with abrasive to work on metal surfaces to obtain the desired finish.
- Grinder: This is a very cheap hand tool that mainly uses a bench-top fastened electric grinding wheel to grind agricultural tools, small metal parts, etc. by rotating.
- Cylindrical grinder: This type of grinder mainly works on cylinders, cams or a combination of the two. It consists of a rotating grinding wheel and a feed system that feeds the workpiece into the grinding machine. Some models of cylindrical grinders feature a built-in cooling system that keeps the workpiece as close to room temperature as possible for optimal grinding results.
- Surface grinding machine: This is the most commonly used type of grinding machine, and surface grinding is mainly a finishing operation. Grinders spin a grinding wheel to polish a metal surface to give it a more refined appearance or a desirable functional surface.
- Drill grinder: This grinder is mainly used for grinding various types of drills.
- Coordinate grinder: This type of grinder is used for finishing fixtures and molds. Their main function is the grinding of drill bushes and pins. They can also be used to complete complex surface grinding that is not done on a milling machine. These grinders allow us to make drills with high precision and complex geometries.
As can be seen from the above examples of grinding machines, grinding machines can be used in many fields, including the manufacture of engine blocks, aerospace, marine and automotive parts, and molds for other metalworking.
metal milling
Milling is the process of cutting material from a metal surface to form the final shape. A milling machine consists of a milling cutter that rotates on a spindle and a table that can move in multiple directions relative to the work surface. As the table moves along the X and Y axes, the spindle typically moves vertically, milling complex shapes according to a pre-designed design. Milling machines can be operated either manually or automatically by a numerical control system (CNC). Can perform a variety of complex operations, including grooving, plunging, drilling, thread milling, edge milling, and more.
The two common types of milling machines are: horizontal milling machines and vertical milling machines. Milling is the main process for making engine blocks, gear components, threads and other parts. They are mainly used for milling flat surfaces, but of course they can also machine irregular surfaces. They can also be used to make drills, boring heads, hobbing and grooving, etc.
Asset Metal is a professional Custom Metalized CNC processing manufacturer, with advanced CNC processing equipment, including turning, milling, pickaxe; Machined accessories are mainly used in toys, electronics, intelligent parts, unmanned aircraft and vehicles
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