Metal cutting is a crucial manufacturing process that shapes metal materials into various components and products. Recent technological advancements have introduced innovative metal-cutting methods beyond traditional blades and cutting tools. These innovative methods go beyond the limitations of blades, offering increased precision, efficiency, and versatility. In this blog, we will explore these cutting-edge methods of metal cutting and their advantages in the manufacturing industry.
Different metal-cutting methods
The cutting method works to cause a fracture in the metal that is processed. You can explore the top fabrication techniques used in the industry. We can classify metal cutting into broad categories:
Chip forming is a metal-cutting process that employs mechanical tools to remove material from a workpiece. In chip forming, we remove material gradually from the workpiece in small pieces, or “chips.” There are various operations that fall under the umbrella of chip forming, each utilizing the process to remove excess material. Here’s a brief overview of a few:
Turning is a fundamental cutting technique that uses a rotating workpiece and cutting tool to produce cylindrical shapes. The worker positions the cutting tool along the axis of rotation, and the material is chipped slowly from the workpiece.
Fabricators use drilling machines to produce round holes. Rotating drill bits gradually enlarge a hole as they penetrate the workpiece.
Milling is a versatile metal-cutting process that removes material from a workpiece by moving a cutting tool across its surface. This versatile process produces a wide range of shapes, including flat surfaces, slots, pockets, and contours.
Sawing is a multipurpose metal-cutting technique that uses a revolving metal-cutting blade with teeth to cut through several materials and forms. The metalworking, woodworking, and construction sectors frequently employ this technique.
A shearing machine, also known as a steel plate shearer, is a metal cutting machine that utilizes two blades, one moving linearly against the other, to cut sheet metal. It is primarily used for the straight-line cutting of metal plates.
Abrasive material removal
Abrasive material removal is a technique that utilizes hard, abrasive particles, often in the form of a rotating wheel or a high-pressure water jet, to remove material from a surface. It is used for several applications, including cleaning, cutting, polishing, and grinding. It can also produce highly precise surface finishes.
Grinding, a precision metal-cutting technique, utilizes an abrasive wheel to remove tiny amounts of material from a workpiece. We use this process to achieve precise dimensions, remove surface flaws, and finish the workpiece.
Water jet cutting
A water jet cutter uses an extremely high-pressure jet of water that is sometimes mixed with abrasive substances to cut a wide range of materials. It is a cold-cutting method and is perfect for cutting materials that are heat sensitive like aluminium and plastic.
Metal cutting using heat involves employing various heat sources, such as electric arcs, radiation energy, or exothermic reactions, to separate metal pieces. Thermal cutting, air carbon arc cutting, plasma arc cutting, electron beam cutting, and laser beam cutting are examples of this method. These processes offer high speed and precision in cutting metals of varying types and thicknesses.
Flame cutting, also known as gas cutting, is the oldest thermal cutting method. It has evolved from acetylene gas cutting and propane cutting to the now widely used natural gas cutting. Flame-cutting equipment is relatively inexpensive and can handle thick steel plates.
Laser cutting uses high-energy laser beams to vaporize and cut through material. This process offers exceptional accuracy, minimal heat distortion, and the ability to cut intricate shapes in a wide range of materials, including metals, plastics, ceramics, and composites.
Plasma cutting is a versatile metal cutting process that employs a high-velocity jet of ionized hot gas, known as plasma, to melt and remove material from a workpiece. This process provides high cutting speeds, minimal heat-affected zones, and the ability to handle a variety of materials, including thick and conductive metals, such as steel, aluminium, and copper.
Electrochemical cutting methods involve the use of electrical and chemical reactions to remove material from a workpiece. Some common electrochemical cutting methods include electrical discharge machining (EDM), etching, and electrochemical machining (ECM).
This process involves passing a strong electric current through an electrolyte solution between an electrode (tool) and the workpiece (anode). At the anode, the metal dissolves and transforms into metal ions, which are then carried away by the electrolyte.
How do you choose the metal-cutting methods?
|Method||Strengths||Weaknesses||Key parameter for selection|
|Laser cutting||High precision, minimal heat distortion, and a wide range of materials||High cost||Precisions|
|Plasma cutting||Fast, efficient, and handles thick materials||Not as precise as laser cutting||Speed|
|Oxy-fuel cutting||Fast, efficient||Not as precise as laser cutting; Wider kerf, higher heat-affected zone||Cost-effectiveness|
|Electrochemical machining||Excellent surface finish, high precision, complex shapes||Limited to conductive materials||Surface finish|
|Sawing||Versatile, cost-effective, wide range of materials||Not as precise as laser cutting or ECM||Versatile|
|Versatile, adaptable, complex shapes||Not as fast as plasma cutting or oxy-fuel cutting||Adaptability|
Venwiz: Your One-Stop Solution for Metal Cutting Requirements
Venwiz is a leading online CAPEX platform that connects businesses with a wide range of metal cutting service providers. Whether you need simple cutting services or complex machining projects, Venwiz can help you find the right vendor.
Venwiz’s FAAS Advantage
Venwiz seamlessly integrates FAAS into its platform, offering businesses a comprehensive solution for managing their metal-cutting operations. This integrated approach provides several advantages. Learn more about FAAS, including tips for selecting FAAS vendors.
- Extensive Provider Network: Venwiz connects businesses with a vast network of skilled metal-cutting vendors who are equipped to handle a wide range of projects.
- Streamlined Procurement: FAAS eliminates the need for lengthy procurement processes, allowing businesses to quickly and efficiently find the right service provider for their needs.
- Transparent Pricing: FAAS provides clear and transparent pricing models, eliminating any hidden costs or surprises.
- Real-time Project Tracking: Venwiz’s FAAS platform provides businesses with real-time visibility into the progress of their metal-cutting projects, enabling them to make informed decisions and optimize their operations.
Our top vendors for machine cutting are:
Sasa Enggtech Private Limited is a leading provider of high-precision metal cutting services, catering to diverse industries such as power & energy, metals & mining, and industrial machinery. Established in 2012, the company has garnered a reputation for exceptional expertise in CNC laser cutting, waterjet cutting, and CNC bending, ensuring precise and efficient metal processing. Sasa Enggtech’s commitment to quality is evident in its ISO 9001:2015 and 14001:2015 certifications, while its skilled team of engineers, technicians, and operators delivers consistent results that exceed customer expectations.
Exolloys Engineering Pvt. Ltd. is a leading provider of precision metal cutting services for the chemical industry. With over 20 years of experience, the company specializes in the fabrication, installation, and commissioning of pressure vessels, heat exchangers, vertical steel columns, and chemical storage tanks. Exolloys Engineering utilizes advanced CNC punching, laser cutting, and waterjet cutting machines to ensure precise and efficient metal processing, meeting the strictest quality standards of the chemical industry. Their team of skilled engineers, technicians, and operators ensures that every project is completed to the highest standards.
Varun Engineers is a leading manufacturer and supplier of a wide range of metal components and equipment, with a strong focus on precision metal cutting. Established in 2006, the company has garnered a reputation for its expertise in various metal cutting techniques, including plasma cutting, CNC flame cutting, broaching, and TIG welding. Varun Engineers’ expertise and dedication to quality have earned them the trust of various industries, including oil & gas, power & energy, metals & mining, and more.
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