Types of Machining Processes

What is Machining?

Machining is a way to make things. It cuts away bits of stuff to make new shapes. It is like when you cut paper to make a shape. Machining does this with metal and other hard stuff.

Machining is big in many jobs. Cars, planes, and even tools for doctors use machined parts. Some machining is done by hand. But most is done by computers now. This is called CNC machining.

9 Core Types of Machining Processes

Turning

Turning is when a piece spins. A tool cuts it as it spins. Think of how a pencil sharpener works!

• How it works: The piece spins. A tool stays still and cuts.
• Tools used: Lathes (big spin machines)
• What it makes: Round parts like shafts
• What it cuts: Metals, plastics

CNC turning is very fast. It can make parts 25% faster than other ways.

Drilling

Drilling makes holes. You have seen a drill make a hole in a wall.

• How it works: A spinning bit cuts a round hole
• Tools used: Drill machines, big or small
• What it makes: Holes in things
• What it cuts: All kinds of stuff

Drills wear out 30% faster in hard metal than in soft metal.

Milling

Milling uses a spinning tool with many cutting edges. It can make flat surfaces or shapes.

• How it works: The tool spins and moves to cut shapes
• Tools used: Milling machines
• What it makes: Flat parts, slots, gears
• What it cuts: Metals, wood

CNC milling is 50% faster than doing it by hand!

Grinding

Grinding makes things smooth. It uses a rough wheel to rub off tiny bits.

• How it works: A rough wheel spins fast and rubs on the part
• Tools used: Grinding machines
• What it makes: Very smooth parts
• What it cuts: Hard metals, glass

Grinding can make a part as smooth as a mirror!

Electrical Discharge Machining (EDM)

EDM uses sparks to cut metal. It’s like tiny lightning bolts.

• How it works: Sparks jump from a wire to the metal and melt tiny bits
• Tools used: EDM machines
• What it makes: Parts with odd shapes
• What it cuts: Very hard metals

Sinker EDM machining can cut the hardest metals.

Sawing

Sawing cuts things into pieces. It’s like the saw in your dad’s tool box.

• How it works: A blade with teeth cuts through the part
• Tools used: Band saws, circle saws
• What it makes: Smaller pieces from big ones
• What it cuts: Metals, wood, plastic

Band saws cut 10 times faster than some other saws for soft metals.

Broaching

Broaching uses a long tool with teeth to cut shapes.

• How it works: A tool with many teeth pulls through the part
• Tools used: Broaching machines
• What it makes: Slots and holes with shapes
• What it cuts: Metals

Broaching can make a key slot 70% faster than milling!

Planing

Planing makes flat surfaces on big parts.

• How it works: A tool moves in a line to cut flat
• Tools used: Planer machines
• What it makes: Flat surfaces on big things
• What it cuts: Big metal parts

Planers can make a flat surface to 0.02 mm.

Electrochemical Machining (ECM)

ECM uses electricity and chemicals to melt away metal.

• How it works: Electric current and chemicals take away bits of metal
• Tools used: ECM machines
• What it makes: Parts with hard-to-cut shapes
• What it cuts: Very hard metals

ECM can cut metal at 1-3 mm³ per minute without tool wear.

How to Choose the Right Process

Picking the right way to cut metal is big. Here’s what to think about:

• What is it made of? Soft or hard?
• What shape is it? Simple or hard?
• How exact must it be? A little off or just right?
• How many do you need? One or lots?
• How much can you spend? A little or a lot?

Here’s a table to help pick:

Non-Traditional vs. Traditional Machining

There are old ways and new ways to cut metal. Let’s see how they are not the same:

Traditional ways (turning, drilling, milling):

• Good for most metals
• Fast
• Lower cost
• Not good for very hard stuff

Non-Traditional ways (EDM, ECM, laser cutting):

• Good for very hard metals
• Can cut odd shapes
• More costly
• Slower but more exact

Applications by Industry

Each job has its own best ways to cut metal:

Cars

Cars use lots of turned and milled parts. Engine parts must be very exact. Automotive CNC machining helps make these parts fast.

Planes

Planes need strong but light parts. EDM and ECM help cut hard metals for jet engines. 5 axis machining makes complex plane parts.

Medical

Doctor tools and parts that go in the body need to be very clean and exact. Grinding and milling make these small, exact parts.

Building

Big buildings use sawed and planed beams. These processes cut big pieces of metal for buildings.

Emerging Trends

The world of cutting metal is always changing. Here are new things:

• Robots doing the work
• Machines that can do many cuts at once
• Green cutting that wastes less

Summary

There are many ways to cut metal. Each way has its best use:

• Turning for round parts
• Drilling for holes
• Milling for flat parts
• Grinding for smooth parts
• EDM for hard metals

If you need help with a big job, talk to experts. They know the best way to cut your parts.

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