Processing of metals by cutting: methods, equipment and tools

Processing of metals by cutting is performed in order for the workpiece to acquire the desired shape. For this purpose, it is necessary to remove the excess. Such manipulation is carried out by using different cutting tools on special machines. In the machine-building industry the processing of metals by cutting is very important. After all, without this process it is impossible to make either ordinary cars or other appliances.

Application of technology

Cutting of metal by cutting is practiced with initial roughing operations and with final operations, which are called fine processing. After all, such actions sometimes need to be performed, observing high accuracy: up to fractions of a micron. And this is a very small value.

Processing of metals by cutting is also practiced for large machine parts. For example, for rotors of hydro turbines. The diameter of their working wheels can exceed the mark of 9-10 meters. Also, parts that are difficult to consider even under a microscope are also subject to sharp cutting. Through the processing, the element gets the desired shape, size, acquires the required quality of the surface. The length of service depends on this indicator.

Theory of cutting

This science is studying the cutting of metal in a similar way. It appeared at the end of the XIX century. Until now, it is engaged in both in Russia and abroad. The key issue is the chip removal speed by means of the machine, so that the tool's resistance is maximized. Many may think that achieving high speeds is not so difficult. But this is not so. The whole point is that the processing of metals by cutting develops heat. It heats and softens the tool for work, at the risk of disabling it. It is very important to choose the right cooling for the tool. But it does not always solve the problem. In addition, it can even damage the metal. Therefore, the speed of work depends in part on how correct the machine was chosen. Tool for metal cutting should be purchased taking into account the properties of the material and its properties.

Features of the use of machine tools

Metal-cutting machines are divided into types. They differ in the tool used. Also, the technology of processing metals by cutting with their help is different. The cutter is most often used. With its help you can perform operations of any complexity. All other tools are either its modification, or a combination of several types. There are two most common schemes of work:

• Turning, when the workpiece rotates, and the cutter moves slowly along its axis;
• Planing - they go both forward movements.

Machines for them are absolutely necessary.

Features of cutting metals

As it was said before, the process under consideration can occur atypically. And there are different ways of processing metals by cutting, for which the use of this or that equipment is envisaged.

In addition to turning and planing, the most common methods of work include milling and grinding. However, the first method is the most popular. Mechanical machining of metals by cutting different methods has much in common with sharpening. Therefore, if you learn this method, then with the rest of the future problems just do not arise. And everything will be very simple in terms of work. Below are the features of using machines of different types.

Application of lathes

The equipment for cutting can be different. One of the key types of machines is lathe. Its application was practiced in ancient times. Then it was activated thanks to rope adaptations like a bow for shooting. In such a sphere as metal cutting, turning at the present time is used to manufacture machine parts. And it is done so accurately and quickly that it will not be possible to reach such goals by mechanical means.

The base of the machine of this type is the frame. The workpiece must be clamped between the centers of the back and front headstock or in the chuck. In the support, fix the cutter. Install by means of a special box, reminiscent of automotive, the required speed of rotation for cutting. On the tool there is a running roller that moves from it and shifts the caliper along with the cutter. If there is a lead screw in addition to it, then by means of such a machine you can cut. When there is a rotating head instead of a tailstock, the tool is called a turret-turret. Such a cutting machine can perform various types of work. To handle products with a large diameter, tools such as a lobotome or a turning-lathe are used. There are other kinds of it.

Increase the durability of the lathe

Experts are constantly working to find suitable materials that can increase the durability of the working tool for cutting metal. Previously, machines were made on the basis of simple carbon steels, which have a simple composition in terms of chemistry. After that, materials with a high content of tungsten began to be used. With their help, it was possible to cut metals much faster. Therefore they began to be called high-speed. However, they eventually ceased to satisfy specialists in the field of mechanical engineering.

Then they were replaced by hard alloys of a special class, which are able to maintain strength even at temperatures up to 100 degrees. In recent years, the process, based on the processing of metals by cutting, has become even simpler. This was achieved through the use of materials with maximum resistance to high temperatures. Depending on the initial hardness of the workpiece, such as a tool, as well as the type of work, it can be processed at the desired speed, which is regulated by means of a special box.

Milling as a type of metal working

Such a method of operation is quite widespread and is quite high-performance. It is carried out with the help of a special milling machine. Machines with numerical control (numerical control) are used increasingly. Depending on the location of the support, they are divided into several types:

• Vertical;
• Horizontal;
• Portal;
• Longitudinal;
• Gear hobbing;
• Multi-spindle;
• Single-spindle and others.

Specialists in the manufacture of equipment of this type are constantly improving it so that the productivity of metal processing is higher. The material of the machines is constantly changing, and its design is also being modified. Like the cutter in planing, the milling cutter performs similar operations. But it combines several of its types. And it will work more productively. Due to this, milling considerably exceeds planing and gradually displaces it in production.

Features of grinding

Machines for this type of processing are used for grinding inside and outside of round surfaces, different planes, centerless machining, threads, cog wheels and much more. Such a tool for metals belongs to the category of the most productive. In addition to a special machine, there is another device. It is a grinding wheel that includes a large number of small cutting elements. They, in turn, are fastened with a special binding device. And each particle itself is a chisel. As you can see, we examined the equipment for metal processing. Below we will get acquainted with more modern techniques that allow it to be cut.

Features of plasma cutting technology

There are several techniques used for low-carbon metals. But plasma cutting is considered one of the productive. Therefore, its features and advantages should be discussed in more detail. Process technology is rapidly and constantly evolving. Plasma cutting of metals is widely used in various production areas: from construction of houses to mechanical engineering. Along with the oxygen-gas method, it is considered quite promising.

Key Benefits

The method of plasma cutting of metals has many advantages. One of them is the speed of work. Most often, the blanks for cutting have a thickness of up to 25 mm. In this case, their processing speed is approximately twice and even more than the same when using an oxygen-gas-type cutting. And it should be added that with a noticeable decrease in the thickness of the metal sheet, it can exceed it by 12 times. This advantage can significantly increase productivity and save time.

Another advantage of the method is high and high-quality burning speed. This characteristic is very important when cutting metal products. When the plasma method is about 2 seconds. For comparison: gas cutting with oxygen - 30, respectively, provided that the temperature is set at 1 thousand degrees at least. The brief interaction between the instrument and the metal is good, first of all, because in a couple of seconds the material will not have time to deform, as it can happen in another case.

Another undoubted advantage of the plasma method can be called the minimum amount of scale in operation. It can be easily removed. Cutting systems are also easily controlled and help to ensure the required tool height and good speed.

Save time and money

Plasma cutting also implies simultaneous work with several sheets, which saves time. With this method, you can process different types of materials:

• aluminum;
• Stainless steel;
• Copper and more.

It is impossible not to mention the safety of the use of plasma systems. They do not use combustible gases for work, open fire, there is not much heat. All this significantly reduces the possible risks for users when working with hot metals. The area of heat exposure is only 2 millimeters.

All the characteristics of plasma cutting positively affect the costs of secondary processing of materials. The work is carried out qualitatively, quickly and universally. To solve many problems, the listed advantages are more preferable than others.

Features of the laser method

To date, in the field of processing of metal products, many technologies have been introduced. They make it possible to greatly facilitate the work of designers, builders and other professionals whose work is somehow connected with this process. Laser cutting is currently considered the most advanced. It allows you to get great opportunities in the manufacture of metal products in terms of design and all kinds of configurations.

Such a promising technique is quite young, but it is already widely spread. Laser cutting of metal is carried out by means of focused technically powerful special installations. They are distinguished by high radial concentration. And they can cut not only aluminum or copper, but also wood and other materials.

Description of the method

With this method of cutting, oxides appear on the surface of the metal. They increase the energy absorption process and are able to maintain the temperature to the melting point. In the contact area, the laser beam produces maximum temperature values, so that the material begins to melt. But outside of this zone, it only heats up. At the same time, there is a supply of active gas, most often oxygen. It blows out the combustion products and allows you to significantly increase the cutting speed. Oxygen heats several layers by removing liquid metal and oxides.

All this happens at a time until the material is cut through to its full depth. After all, the gas stream near the separation lines can actively cool it. A small zone of thermal impact can ensure the creation of edges located in parallel at short distances from each other (of the order of 0, 2 millimeters). Very often, in order to achieve this or that accuracy in the cutting operation, it becomes necessary to introduce automated control by means of a computer. In such cases, you can program the creation of a product in its final form.

For laser cutting sheet metals most often used equipment based on solid-state and gas tools. The material cut thus becomes perfectly even. No mechanical machining of metals by cutting can provide this accuracy in view of operational execution and with a minimum amount of waste. Basically, for the processing of sheet metal, devices based on gas and solid-state lasers are used. The laser cut of the metal is perfectly smooth. It will be obtained without deformations, which are present in the mechanical section. In addition, laser cutting technology allows you to achieve significant work accuracy, minimal waste and fast execution.

Advantages

In the market of cutting of metal products, laser cutting is one of the most popular. It largely made the work with carbide materials more simple. After all, they are quite complex in terms of processing and often could deteriorate after such manipulations. For laser cutting is best suited:

• steel;
• Non-ferrous metals;
• Aluminum alloys.

Thick sheets are also much better processed. It will be easier to work with complex shapes of metal parts and make holes in very hard materials with a small diameter. Here, in terms of geometry, you can give vent to your imagination. The system can be automated. It is enough to create a special file with the specified program on the computer. Mechanical effects on the metal will not be - this is also important. Also, laser processing has the following advantages:

• The possibility of creating a complex contour cut.
• You can process almost any sheet metal, regardless of its thermal properties.
• High accuracy of work.
• Cutting is possible even on easily deformable and not too stiff materials.
• High productivity due to the use of high power laser.
• If the surface should be smooth, it is better to use a focused beam with adjustable power.

Gas method

Consider a fairly common method of exposure to metal, which has been actively used for many years. This is gas cutting. It is quite popular and economically profitable. In another way, it is also called oxygen, since in this case the process of action on the metal has a thermal character. There is a stream of oxygen after the end of work and removes the remnants of liquid oxide. First, the upper edge of the part is heated. Depending on the chemical composition of the material (eg steel), its ignition temperature can range from 1000 to 1200 degrees.

Gas cutting can be used for processing medium-alloy, low-alloy or carbon steel. The thickness of the metal sheet or other product should be a maximum of 300 millimeters. The gas-oxygen technique of metal processing has its advantages:

• Low processing costs.
• There is no need to work with the edge after the procedure is completed.
• Presence of direct and diagonal cutting of products from different angles.
• You can use thick metal sheets.

Is there a standard of work?

Many people are wondering whether metal processing has GOST or other standards regarding the processing of structures. So, according to existing rules and criteria, such a process has its own tasks. First of all, details must be given a particular configuration and dimensions. The technological documentation used requires this. For example, an approved project for the construction of the facility. Also the surface to be treated must always be clean according to accepted standards. The GOSTs enumerate the mechanical methods of processing metals by cutting, including turning, drilling, milling, as well as chiselling, pulling. The final processing of the products is also indicated. Each type of machining of metals corresponds not only to the specific equipment, but also the serial number.

As we saw, there are many ways of mechanical and automated processing of products for the purpose of cutting them. All this is widely used in construction, engineering, repair and other areas. Techniques are constantly being improved and supplemented with new ones, modern equipment is being created, which makes the process more and more simple each time.