Metal Cutting

Metal cutting refers to removing metal material from a workpiece to create a desired shape or
form. It involves applying a cutting force with a sharp tool, such as a cutting blade or laser, to
remove material and create a precise, finished product. This process is crucial in many industries,
including manufacturing, construction, and fabrication. There are various metal cutting methods,
including mechanical cutting, thermal cutting and chemical cutting.

Machining: Machining is a semi-finishing or finishing process essentially done to impart

required or stipulated dimensional and form accuracy and surface finish to enable the product to

• fulfill its basic functional requirements

• provide better or improved performance

• render long service life

Types of cutting tool

• Single point cutting tool

The cutting tool, which has only one cutting edge, is termed as single point cutting tool. Single
point cutting tools are generally used while performing turning, boring, shaping and planing
operation. The important elements in single point cutting tools are rake angle, principle cutting
edge, nose etc.

Types of single point tools are as follows :

(a) Solid type tool bit

(b) Brazed tip tool

(c) Long indexable insert tool

(d) Throwaway indexable insert tool

• Multi point cutting tool

A cutting tool which has more than one cutting edge is multi point cutting tool. Multi point
cutting tools are generally used while performing drilling, milling, broaching, grinding etc.
Important elements are cutting edge, helix angle, the number of teeth.

Differences Between single point cutting tool and multi point cutting tool.

Types of cutting process

• Orthogonal Cutting

In orthogonal cutting, the tool approaches the work piece with its cutting edge parallel to the
uncut surface and at right angles to the direction of cutting (90 degree).

• Oblique Cutting

In oblique cutting , the cutting edge of the tool is inclined at an acute angle with the direction of
tool feed or work feed, the chip begin disposed of at a certain angle (less than 90 degree).
Orthogonal Cutting Oblique Cutting

Types of Metal Cutting Process

Metal cutting processes include a variety of methods for removing material from a workpiece,
including turning, milling, drilling, grinding, sawing, shearing, punching, and stamping. The
choice of process depends on the job's specific requirements, such as material type, part size and
shape, and desired surface finish. There are several types of metal-cutting processes, including:

1. Turning: A process where a single-point cutting tool moves along the surface of a rotating
workpiece to remove material and produce a desired shape.

2. Milling: A process where a multi-point cutting tool moves perpendicular to the surface of a
workpiece to remove material and produce a desired shape.

3. Drilling: A process where a rotary cutting tool is used to create a cylindrical hole in a
workpiece.

4. Grinding: A rotating abrasive wheel removes material from a workpiece to produce a desired
surface finish.

5. Sawing: A continuous or reciprocating blade cuts a workpiece into desired lengths.

6. Shearing: A process where a sharp blade is used to cut a workpiece along a straight line.

7. Punching: A sharp tool is used to remove a portion of a workpiece to create a hole or notch.

8. Stamping: A process where a punch and die set is used to deform a workpiece into a desired
shape.

Each metal-cutting process has its own set of advantages and disadvantages, and the choice of
process depends on the job's specific requirements, such as material type, part size and shape,
and desired surface finish.

Types of chips

A metal chip is a fragment or piece of metal produced during machining or metal working
processes, typically due to material removal from a workpiece.
There are following types of chips formed during the materials removal.

1. Continuous Chips: Continuous chips arise during the machining of ductile materials at high
speeds and minimal friction between the tool and the workpiece, resulting from the
continuous plastic deformation induced by the tool.
Examples: Ductile materials like mild steel and copper.
2. Discontinuous or Segmented Chips: Discontinuous or segmented chips are generated when
machining brittle materials, featuring breaks or gaps in their structure due to the inherent
material characteristics.
Examples: Brittle materials that is prone to fracturing.
3. Continuous Chips with Built up Edges: Continuous chips with built-up edges occur when
the chips accumulate on the tool's edge during machining, resulting in an irregular, uneven
chip. These chips form irregularly due to the accumulation of material on the tool edge,
which can affect machining accuracy and surface finish.

CNC MACHINE

Computer numerical control (CNC) is a manufacturing method that automates the control,
movement and precision of machine tools through the use of preprogrammed computer software,
which is embedded inside the tools.

CNC is commonly used in manufacturing for machining metal and plastic parts. Mills, lathes,
routers, drills, grinders, water jets and lasers are common cutting tools whose operations can also
be automated with CNC.

How computer numerical control works?

With CNC, each object to be manufactured gets a custom computer program, usually written in
an international standard language called G-code, stored in and executed by the machine control
unit (MCU), a microcomputer attached to the machine. The M-code language is also used in
conjunction with G-code in CNC operations.

While G-code controls the movement and functioning of the machine, M-code controls the
operation's external movements. The program also contains the instructions and parameters the
machine tool follows, such as the feed rate of materials and the positioning and speed of the
tool's components.

Early in the process, engineers create a computer-aided design (CAD) drawing of the part to be
manufactured and then translate the drawing into G-code. The program is loaded onto the MCU,
and a machine operator performs a test run without the raw material in place to ensure proper
positioning and performance. This step is important because incorrect speed or positioning can
damage both the machine and the part.
When everything is ready, the CNC machine runs its program and completes jobs with precision
as instructed. The jobs could involve anything from creating something from scratch to cutting a
workpiece or printing anything.

Why is computer numerical control important?

Numerical control enables machines to produce items more quickly and with better surface
finishes without the need for manual machining or extensive human participation.

The following are the importance of CNC systems:

Cost reduction: CNC machines are cost-effective and bring down the cost of production due to
precision manufacturing. Energy consumption is decreased as a result of increased production
efficiency, scalability and less material waste, which also lowers operating expenses. The weight
of potential financial obligations related to worker safety is also lessened, which helps with cost-
cutting.

Waste reduction: The software used to run various kinds of CNC machines results in little to no
waste during the manufacturing process due to simulations and repeated optimizations.

Improved worker safety: CNC machines minimize the chance of accidents and guarantee
worker safety because there is less need for human interaction. Most modern CNC machines are
self-sufficient and can be handled remotely by people for software upgrades, design changes or
other preventative maintenance.

Human error reduction: Since human error is eliminated in the manufacturing process with
CNC, it is thought to offer greater precision, complexity, speed, flexibility and repeatability. This
ultimately results in fewer defects in the manufactured products.

Contour machining: CNC provides capabilities such as contour machining, which enables
milling of contoured shapes, including those produced in 3D printing and designs.

Faster MCU programming: Some CNC systems are integrated with CAD software and
computer-aided manufacturing software, which can speed the process of programming the MCU.

Improved operational intelligence. Integration with enterprise resource planning software and
related applications, such as enterprise asset management software, can facilitate operational and
business intelligence processes and help improve plant performance and maintenance.