Learning About Various Metal-Cutting Methods
A large piece of material is chopped 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. To assist business professionals in selecting the ideal solution, we've highlighted some of the most popular. Then, we've described how they operate, their benefits and drawbacks, what kinds of metals they cut, and their applications.
Top 4 Metal Cutting Methods
1. Saw Cutting
Using a saw blade, or a tool with sharp metal teeth, to divide the material into smaller, more manageable pieces or precise shapes and sizes is known as sawing or blade cutting. The manufacturers' two main saw-cutting techniques are circular blade cutting, and band saw cutting. The band saw cutting employs an extended straight blade that delivers continuous, consistent action. This contrasts circular saw cutting, which uses circular saw blades that slices material as it spins.
BENEFITS PROVIDED
This form of cutting has several benefits compared to other metal-cutting techniques. It enables cutting with a small tolerance and lowers the waste produced during cutting operations. It also provides high-cut quality and faster production rates, allowing for quicker turnaround without additional finishing treatments. This collectively leads to lower overall project costs.
MATERIALS USED
Aluminum, brass, bronze, copper, high-temperature alloys, nickel alloys, stainless steel, and titanium are just a few metals that you can circular saw. You can cut these materials into bar, plate, pipe, and tube shapes. However, as the equipment can have trouble keeping thin, flat material steady as it is cut, it is best suited to materials with increased thicknesses or variable cross-sections.
SECTORS SERVED
Aerospace, architectural, biotechnology, chemical, food processing, marine, packaging, and pharmaceutical industries frequently use saw-cutting to help produce their parts and goods.
2. Laser Cutting
Without actually contacting the material being cut, laser cutting uses intense, focused beams of light to heat, melt, and slice through it. It can use various cutting and removal techniques to accommodate materials and cutting requirements. You can also use laser technology to etch or engrave materials for practical and aesthetically pleasing purposes. In addition, it can cut up larger items into smaller pieces or sections.
BENEFITS PROVIDED
Many laser-cutting machines now have digital controls. With these technologies, the laser can be placed and moved across the material precisely and correctly. This results in cut pieces that are the right size and shape. Laser cutting has benefits over other metal cutting techniques, such as lower maintenance and replacement costs, a decreased risk of material contamination, and increased workplace safety.
MATERIALS USED
You can cut a variety of materials with this technique for metal. It is frequently used to cut plates and sheets of titanium, stainless steel, brass, copper, nickel, and copper. Heat-sensitive or reflecting materials should not be used with it since the former could deform, while the latter could harm the machinery.
SECTORS SERVED
Many different metalworking industries use laser cutting in their manufacturing processes. Aerospace, architecture, biotechnology, chemicals, food processing, marine, packaging, and pharmaceuticals are a few of the sectors that frequently employ it.
3. Waterjet Cutting
Waterjet cutting is a technique for cutting metal that uses pressurized water to shape and size the material as needed. Aluminum oxide or garnet can be added to the high-pressure water streams, or "waterjets," to help with the cutting process and ensure a thorough cut through even very thick or stiff materials.
BENEFITS PROVIDED
Waterjet cutting is a "cold cutting" technique, which means that no heat or mechanical force is applied to the material being sliced. This lowers the possibility of material thermal distortion by producing a smaller heat-affected zone (HAZ) during cutting operations. It also has fewer byproducts of slag and can cut much larger materials to tighter tolerances than laser cutting.
MATERIALS USED
Many different types of metal, including titanium, aluminum, brass, copper, nickel, steel, and steel, can be cut well with this technique. In addition, plates and sheets up to 6 inches thick can be cut using it.
SECTORS SERVED
Depending on the equipment, 2D and 3D cuts can be made using waterjet cutting. This characteristic enables producers to create specific and intricate components for various sectors. Engines, turbine blades, and control panels for the aerospace sector, as well as pipes and pumps for the maritime industry, are a few examples of waterjet cut parts and products.
4. Shearing
A moving top blade and a fixed lower blade that are slightly offset from one another are used in the metal cutting technique known as shearing. This technique is used to cut material. The material presses down on the lower blade while the upper blade falls. The pressure applied deforms the material, eventually leading to strain and failure. It creates a cut.
BENEFITS PROVIDED
Shearing is substantially more adaptable than other cutting techniques. Shearing machines can bend, punch, and press metal items in addition to cutting them. Since no chips are produced during cutting operations, the technique generates almost no waste, which can help lower overall material costs.
MATERIALS USED
Plate and sheet materials are the most suitable candidates for this cutting technique. Hollow materials may deform when cut, whereas thick materials may require excessive force to cut. The typical materials are aluminum, brass, bronze, copper, nickel, stainless steel, and titanium.
SECTORS SERVED
Many industries use components made of sheared metal. Examples include discs, pipes, pumps, rings, and tubing for aircraft engines.