Metal Cutting Methods
Totaly Pavlina
Cutting processes have always been an integral part of the manufacturing industry, what many do not know is that there are varying methods of cutting metal, Each process has different capabilities, limitations, and costs associated. While some Methods have been around as early as the mid-1800s, others are relatively new. In this post, we will break down the five processes that give the manufacturing industry the ability to cut through metals.
Shearing is a process that is often referred to as die cutting and originated in the mid-1800s when looking for a way to cut leather for the shoe industry. Now the process is used for a variety of different materials and is a way metal can be cut without chipping or the use of heat. This process uses a moving blade to push against the fixed workpiece. Within the process of shearing, there are various operations. Below we have highlighted the most popular two.
Abrasive cutting methods include operations such as grinding, lapping, and waterjet cutting. These cutting methods all remove excess material through erosion. These operations are much faster than heat processes like EDM & laser, offer better edge quality, and typically provide some sort of cost savings for manufacturers. Abrasive material removal is categorized by various operations which are broken down below.
Metal cutting by heat includes operations such as plasma cutting and laser cutting. Both of these processes use hot, high-powered light to cut away excess material. Laser cutting which originated in the 1960s and plasma cutting which was introduced in 1957 have long been some of the most well-known methods of metal cutting. Despite both of these operations being widely accepted methods of cutting, they do create thermal damage, significant distortion, and require some finishing processes. Laser and Plasma cutting operations are characterized below.
Electrochemical cutting methods include processes such as electrical discharge machining (EDM), etching, and electrochemical machining (ECM). These operations perform a cut through an electrical and chemical reaction.
With so many processes and operations available today manufacturers have a plethora of options for cutting metals. While each one has its advantages and disadvantages, there is no one-size-fits-all. Industry professionals often decide on the operation to implement after a thorough investigation of the project.
ICS was founded in 2019 after our owners recognized a need to enhance the waterjet cutting service experience by implementing technology and management strategies that allow for the most efficient process possible.
Metal cutting is a manufacturing process in which a larger piece of material is separated into smaller pieces or parts. There are numerous metal cutting methods available, each of which offers distinct benefits and limitations that make it suitable for different manufacturing projects. Below, we highlight some of the most common, outlining how they work, what advantages and disadvantages they have, what types of metals they cut, and what applications they are used in to help industry professionals choose the best method for their needs:
This cutting method offers several advantages over some of the other metal cutting methods. For example, it allows for close tolerance cutting, which reduces the amount of waste generated during cutting operations. Additionally, it offers both fast cutting speeds and high cut quality, which results in quicker turnaround without a need for further finishing procedures. Altogether, these result in lower overall project costs for some applications.
Sawing accommodates a variety of metals, including, but not limited to, aluminum, brass, bronze, copper, high-temperature alloys, nickel alloys, stainless steel, and titanium. It can cut these materials in bar, plate, pipe and tube form. However, it is best suited for cutting materials with greater thicknesses or varying cross-sections since the equipment can have difficulty keeping thin, flat material stable as it is cut.
Some of the industries that regularly rely on saw cutting to help produce their parts and products include aerospace, architectural, biotechnology, chemical, food processing, marine, packaging, and pharmaceutical.
Laser cutting is a cutting method that employs high-powered, focused beams of light to heat, melt, and cut through material without touching it directly. It can utilize a variety of cutting and removal mechanisms to suit different materials and cutting requirements. In addition to separating larger pieces into smaller pieces or parts, the laser technology can also be used to etch or engrave materials for functional and aesthetic purposes.
Today, many laser cutting technologies come with computerized controls. These systems help position and move the laser across the material precisely and accurately, ensuring the cut piece has the proper shape and size. In addition to high cutting precision and accuracy, other advantages laser cutting offers over some of the other metal cutting methods include smaller maintenance and replacement costs, lower chance of material contamination, and greater workplace safety.
This metal cutting method can be used on a wide range of materials. It is often employed to cut plates and sheets made from aluminum, brass, copper, nickel, stainless steel, and titanium. It is not suitable for use with heat-sensitive or reflective materials since the former may deform while the latter may cause damage to the equipment.
Laser cutting finds application in the manufacturing operations of a wide range of industries. Some of the industries that regularly use it include aerospace, architectural, biotechnology, chemical, food processing, marine, packaging, and pharmaceutical.
Waterjet cutting is a cold cutting method, meaning it does not require a material to be heated or stressed by machinery. As a result, it generates a smaller heat affected zone (HAZ) during cutting operations, which reduces the risk of material thermally distorting. Additionally, compared to laser cutting, it cuts thicker materials to tighter tolerances and produces less slag byproducts.
Waterjet cutting can make 2D and 3D cuts, depending on the equipment. This quality allows manufacturers to make simple and complex components for various industries. Examples of waterjet cut parts and products include engines, turbine blades, and control panels for the aerospace industry and pipes and pumps for the marine industry.
Shearing is a metal cutting method that uses a moving upper blade and a stationary lower blade that are slightly offset from one another to cut material. As the upper blade descends, it pushes the material down on the lower blade. The pressure exerted deforms the material, eventually causing it to strain and give way. This forms the cut.
Compared to other cutting methods, shearing is much more versatile. In addition to cutting, shearing machines can also be used to bend, punch, and press metal materials. The process also produces virtually no waste since no chips are generated during cutting operations, which can help reduce overall material costs.
This cutting method is best suited for plate and sheet materials. Thick materials may require too much force to cut, while hollow materials may deform when cut. Typical materials used include aluminum, brass, bronze, copper, nickel, stainless steel, and titanium.
Whether you need saw cutting, laser cutting, waterjet cutting, or shearing services for your project, AAA Metals has got your back! We can cut a broad selection of metals into various shapes, sizes, and quantities to exacting specifications. To learn more about our cutting capabilities and how to determine which one is right for you, contact us today. To discuss your cutting requirements with one of our experts, request a quote.
A large piece of material is cut into smaller bits or parts during the manufacturing process of metal cutting. There are many different ways to cut metal, and each has advantages and restrictions that make it appropriate for certain manufacturing projects. To assist business professionals in selecting the ideal solution for their needs, we've highlighted some of the most popular below. We've described how various metal-cutting methods work, their benefits and drawbacks, what kinds of metals they cut, and for what applications they utilize.
Using a saw blade, or a tool with sharp metal teeth, to slice the material into smaller, more manageable pieces or precise shapes and sizes is known as sawing or saw cutting. Circular and band saw cutting are the two main saw-cutting techniques manufacturers employ. A band saw uses an extended straight blade that delivers continuous, consistent action. This contrasts with circular saw cutting, which involves a circular blade that slices material as it spins.
This form of cutting has several benefits compared to other metal-cutting techniques. For instance, it enables cutting with a small tolerance, which lowers the quantity of waste produced during machining operations. It also provides high cut quality and faster processing rates, allowing for quicker turnaround without additional finishing treatments with metal cutting tools. For some applications, this collectively leads to lower overall project costs.
Among the metals, you can see titanium, stainless steel, brass, bronze, copper, high-temperature, nickel, and copper. It is possible to shape these materials into bars, plates, pipes, and tubes. It is best suited to materials with greater thicknesses or varying cross-sections because machinery can have problems holding thin, flat material stationary as it is cut.
Without actually contacting the material being processed, laser cutting uses intense, focused beams of light to heat, melt, and slice through it. Various cutting and removal techniques can accommodate different materials and cutting requirements. You can also use laser technology to etch or engrave materials for practical and aesthetically pleasing purposes and cut bulky items into smaller pieces or sections.
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