Machining techniques are essential in engineering and production because they transform metal raw materials into complex, useful components. In order to accomplish desired shapes, dimensions, and surface finishes, these procedures include the exact removal of material from a workpiece.
In order to meet the ever-increasing demands of several industries, machining processes have evolved from simpler shapes to the most complicated forms. Achieving desired products and optimized output requires an understanding of the various machining processes.
In this article, we will discuss about 12 common types of metal machining processes that are primarily used in modern manufacturing.
1.Turning
Among the fundamental machining tasks is turning. Using a stationary cutting tool eliminates unwanted material from the external diameter of a rotating workpiece.
This is accomplished by rotating the workpiece. In most cases, a single-point cutting tool is utilized throughout the turning process, which results in the production of turning components.
Metal turning is done either by manual turning or using a CNC turning machine. Iron, aluminium, steel, titanium, brass, and nickel alloys are just a few of the metal materials for which this precision machining method is perfect.
In the modern era, CNC turning is mostly used to enhance precision and quality and save time. Objects like shafts, rods, and discs are formed by CNC turning. It can also create forms and detailed elements like bolts threads.
2.Milling
One method of subtractive manufacturing is milling, which involves cutting material from a workpiece that is stationary using a cutting tool that is in continuous rotation.
A milling cutter, workpiece, jig, and milling machine are the four fundamental components of any milling process.
To obtain the required form and finish, this traditional machining procedure makes use of multi-point cutting tools.
CNC milling machines produce products with tight tolerances because computer programs control the movement of the milling tools.
One common form of milling operation is end milling, while others include chamfer, face, thread, and slot milling. It is a multipurpose method used in many different fields to make complex parts, such as molds and dies, as well as flat surfaces and gears.
3.Boring
The traditional machining procedure of boring is a common one. It employs boring tools to enhance the surface finish of an existing hole and enlarge it.
Boring and reaming are similar in that they both involve the processing of an existing hole.
Nevertheless, this manufacturing method employs a single-point cutting instrument, in contrast to reaming. Boring is capable of attaining superior positional accuracy, which is another distinction between the two.
Boring is frequently performed on a lathe. CNC milling devices can also execute this machining procedure.
4.Grinding
Grinding involves the use of a rotating abrasive wheel to eliminate a relatively small quantity of material from the surface of the workpiece. Implanted abrasive grains on the grinding wheel act as microscopic cutting instruments.
Grinding wheel abrasives that are frequently employed include silicon carbide, aluminum oxide, and cubic boron nitride (CBN). Grinding is capable of processing a diverse array of metals as a result of the hardness of these granules.
The abrasive particles become dull as a result of repeated use, causing them to tumble off the tool, revealing new, sharp grains.
Surface grinding, cylindrical grinding, centerless grinding, and internal grinding are all grinding techniques that provide varying levels of accuracy and capabilities.
Consequently, the abrasive wheel is considered a cutting instrument that is capable of self-sharpening.
5.Planing
Planing, often called planar machining, is a method of subtractive manufacturing that can create expansive flat surfaces.
This type of machining involves clamping the workpiece to a horizontal table and then moving it back and forth under the motion of a fixed tool with one point on it. Planing is a versatile tool that may be used for machining flat surfaces as well as cutting slots.
6.Sawing
Sawing is a common way to do machining. One of the most important things that a machine shop does, even though it’s not as exciting as contemporary manufacturing processes.
During sawing machining, a cutting tool called a saw is used to remove undesirable material in a specific pattern. Abrasive saws, hacksaws, bandsaws, and circular saws are the four most common kinds of saws.
7.Broaching
Broaching is a widely utilized machining process that employs a broach to extract material from a workpiece. Broaching tools generally feature multiple teeth and are constructed from robust materials, including carbide and high-speed steel.
The broaching method removes material in one pass by pushing or pulling the cutting tool into the workpiece. This process produces precise components with superior surface quality.
8.Electrochemical Machining (ECM)
In this technique the material is removed from the desired workpiece through dissolution. It is especially advantageous for machining complex shapes and difficult materials, such as titanium and superalloys, while maintaining precision and surface quality.
9.Laser Beam Machining (LBM)
In laser beam melting (LBM), the workpiece is heated or vaporized by means of a focused laser beam. This method is appropriate for drilling, engraving, cutting, and welding applications. This technique guarantees precision and reduces thermal influence.
10.Electron Beam Machining (EBM)
Electric beam melting (EBM) uses an energy beam of electrons to melt away material from a workpiece. It is utilized in industries such as semiconductor and aerospace production for machining features on materials.
11.Abrasive Jet Machining
This method offers advantages, including the capacity to machine complex shapes and handle thin or delicate materials, as well as those exhibiting high hardness or brittleness. AJM (Abrasive jet machining) eliminates the formation of heat-affected zones, thereby reducing stress in the piece of work. This makes it an ideal option for the machining of materials that are sensitive to heat or delicate components.
12.Ultrasonic Machining
In order to remove material, ultrasonic machining makes use of vibrations. This technique is very helpful for machining materials that are hard and brittle, making it possible to achieve high precision and great surface finishes.
Cost Comparison Between Traditional and Non-Traditional Machining
Cost comparison between traditional and non-traditional machining depends upon several factors such as: labor charges, material expenses, equipment cost and ongoing operational expenditures.
Traditional machining techniques include turning, milling, drilling, and grinding, as well as using lathes, mills, and drills. Compared to traditional machining methods, these machines demand less initial investment.
Costly apparatus is frequently necessary for non-traditional techniques, including electrical discharge machining (EDM), laser cutting, waterjet cutting, and ultrasonic machining.
The operational costs of machining technologies typically include energy consumption, tooling fees, and the cost of coolant/lubricants. These expenses may fluctuate depending upon the materials that are being processed.
Machining labor expenses include operator salary as well as any additional labor required for setup processes, tool replacement, and part handling.
Costs associated with overhead, such as rent for buildings, insurance premiums, and administrative charges, are often payable regardless of whether traditional or non-traditional machining methods are utilized.
The determination of the cost-effective machining method will depend on criteria, including the specific application, material requirements, production volume, and the required level of precision.
Which Machining Technique Offers Better Value?
In terms of cost-effectiveness, investment, volume of production, labor costs, production waste, and time taken all have an impact on how economical a specific machining technology is. Materials compatibility will determine whether to use conventional or nonconventional machining. Traditional methods are better for metals. Calculating tooling and equipment expenses is critical.
Traditional machining requires tools and equipment but may cost more. Machining may require labor. More energy means higher running costs. It is possible for manufacturers to significantly reduce costs by evaluating these criteria. Make the production process more efficient.
Conclusion
In conclusion, each and every method of machining plays an important part in the manufacturing processes.
A more suitable method of machining can be applied according to the nature of the material and product efficiency.
If you want to know which machining service is best for your product, feel free to contact us. We have a lot of experience in manufacturing alloy products by using latest technologies.
