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Metal Cutting Techniques in Fabrication and Machining
Metal fabrication and machining represent subtractive manufacturing processes, wherein material is skillfully and precisely removed from metal blocks or sheets. While the concept of metal cutting may seem straightforward, achieving optimal results relies on the use of appropriate equipment. This post delves into the intricacies of metal cutting for both fabrication and machining purposes.
Metal Cutting for Fabrication
Cutting sheet metal stands as a foundational process in metal fabrication. Prior to bending, the sheet metal must undergo cutting to create an initial outline, often referred to as a blank. Subsequent cutting operations shape holes, notches, vents, and louvers. CNC lasers, CNC punches, and shears are the primary tools employed in these metal cutting processes.
Hydraulic Shear
A hydraulic shear serves as a mechanical cutting method for straight lines and square edges of sheet metal. Typically employed as the initial step before proceeding to other processes, it can also be utilized to segment large pieces into smaller, more manageable sheets. Driven by hydraulic or mechanical force, the shear rapidly lowers a cutting blade to sever the sheet metal. Back gauges ensure precise length control, contributing to repeatability.
CNC Punch
Utilizing tooling to punch into sheet metal, a CNC punch follows programmed instructions for precise movement on the X and Y axes, accurately positioning the sheet under the punching ram. This controlled process can create patterns, ranging from fully punched holes to partially punched louvers and vents. While cost-effective for high-volume parts, tooling costs may pose challenges for lower volumes, making it crucial for metal fabricators to determine the most cost-effective method for each project.
Laser Cutting
Metal cutting with a laser cutter involves a highly focused monochromatic, collimated beam supplemented with gas to generate intense heat, melting or vaporizing the metal. CO2 lasers utilize a mixture of carbon dioxide, nitrogen, and helium for laser amplification. Laser cutting offers smoother edges and lower setup costs compared to punching. A laser cutter with flying optics keeps the sheet metal stationary, while the laser moves, providing increased speed and versatility.
Metal Cutting for Custom Machining
When removing material from a metal block, distinct equipment is employed in the metal machining process. Key tools include mills, lathes, routers, and waterjet cutters.
CNC Lathe and Turning Centers
A CNC lathe rotates the workpiece on a spindle against cutting tools to perform operations like cutting, knurling, or drilling. Ideal for creating symmetrical objects with rotational symmetry, lathes are suitable for crafting spheres, cylinders, or cones. CNC turning centers, more advanced than lathes, offer increased versatility with up to five axes.
CNC Mill
In contrast, a CNC mill operates in a linear fashion, performing operations across multiple axes. Milling machines can work on 3, 4, or five axes, providing flexibility based on part complexity. Horizontal mills have a spindle parallel to the worktable surface, suitable for deep heavy cuts, while vertical mills have a spindle perpendicular to the worktable, ideal for shallower cuts on smaller parts. CNC mills handle functions like tapping, drilling, boring, reaming, as well as more intricate tasks such as slot and keyway cutting, planning, and die sinking.
Custom products with tight tolerances are our specialty. Metalli has all the cutting equipment needed to meet your fabricating and machining needs. Contact us and let us quote your next metal project.
With a vision of boosting thermal management through innovation, Metalli is dedicating to creating a better thermal management solution for your application.
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