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.
SAW CUTTING BENEFITS:
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.
LASER CUTTING BENEFITS:
Many laser-cutting machines now have digital controls. These technologies enable the laser to position and move across the material accurately. Cut pieces that are the proper size and shape are produced. Other benefits that laser cutting has over some of the other metal cutting techniques are lower maintenance and replacement costs. These costs also decrease the risk of material contamination and increase workplace safety.
This method of cutting metal can be performed on several materials. It is widely used to cut titanium, stainless steel, brass, copper, nickel, and copper plates and sheets. It should not be used with heat-sensitive or reflective materials since the former could deform, and the latter could damage equipment.
Waterjet cutting is a method for cutting metal using pressurized water to shape and resize the metal as necessary. The high-pressure water streams, or "waterjets," can be supplemented with aluminum oxide or garnet to aid in the cutting process and assure a thorough cut through even very thick or very dense materials.
WATERJET CUTTING BENEFITS:
Waterjet cutting is a "cold cutting" technique, meaning the sliced material is not subjected to heat or mechanical force. As a result, there is less chance of thermal distortion of the material during cutting operations due to a smaller heat-affected zone (HAZ). Additionally, it can cut much larger materials with finer tolerances than laser cutting and generates fewer slag-related byproducts.
This method works well for cutting various metals, including titanium, aluminum, brass, copper, nickel, steel, and steel. It can cut plates and sheets up to 6 inches thick.
Shearing is a metal cutting process that uses two slightly offset blades: a moving top blade and a stationary lower blade. To cut stuff, use this method. The upper blade drops as the material pulls down on the lower blade. The pressure exerted on the material causes deformation, which eventually causes strain and failure.
Shearing offers far superior adaptability to other cutting methods. In addition to cutting metal objects, shearing machines can bend, punch, and press them. The technique produces little waste because cutting operations don't generate chips, which can reduce overall material costs.
The most suitable materials for this cutting method are plates and sheets. When sliced, hollow materials may deform, whereas thick materials might require too much force. Typical materials include titanium, aluminum, brass, bronze, copper, nickel, stainless steel, and brass.
We hope this guide to several metal-cutting techniques has helped you decide which could be the most suitable for your needs.