What types of machining process are there? Guide to machining processes

Machining Cutting Mechanism

Processes typically involve a cutting tool, which can be contact or non-contact. Processes such as CNC Milling or CNC Turning involve the physical contact between a cutting tool and workpiece. An example of a non-contact process would be Laser Cutting or Waterjet Cutting - the "tool" in this case directs cutting media which provides the cutting action.

Types Of Machining

This group of processes involves the use of Rotating Cutting & Deformation Tools to form any manner of shapes, contours and surfaces.

One of the most flexible and well known group of processes available, Machining is suitably applied in both low and high volume applications.

Machining can be performed at a relatively high material removal rate, and high levels of finish and accuracy can be achieved without the need for further processing.

• Turning
• Milling
• Turn-Milling
• EDM (Electrical Discharge Machining)
• Drilling and Reaming
• Honing & Burnishing
• Broaching & Slotting
• Gear Cutting & Hobbing
• Boring
• Routing, Trimming & Edge Preparation

TURNING

This group of processes includes Turning that is performed on Manual and CNC Lathes, from conventional to large workpiece sizes.

• • CNC Turning (at conventional sizes)
• • Sliding Head CNC Turning
• • Large Turning (at sizes greater than 1500mm length or 650mm dia)
• • Manual Turning

MILLING

This group of processes includes Milling that is performed on Manual and CNC Milling Machine , from conventional to large workpiece sizes.

• • CNC Milling (at conventional sizes)
• • Large CNC Milling (at sizes greater than 1500mm square, or Longer than 4500mm in either X or Y directions)
• • Manual Milling (at conventional sizes)

TURN-MILLING

This category encompasses machining solutions where Turning AND Milling are performed on a single machine. Material is removed both by rotating the workpiece in a chuck as with turning, and by a rotating cutting tool in a milling spindle.

This process enables high levels of production and design flexibility, with both turning and milling operations being performed within a single setup.

Not only can reduced setup time be a benefit, but in many cases increased accuracy through the elimination of error introduced during setup.

ELECTRICAL DISCHARGE MACHINING (EDM)

This group of processes include Machining that is performed on Electrical Discharge Machines, or Spark Erosion Equipment.

Electrical Discharge Machining (EDM) works by using a rapidly recurring electrical discharge between a "die" and the electrically conductive workpiece, material is gradually removed from the workpiece.

A simple die can make complex shapes in a workpiece as it can be moved in all directions, only removing material at points where the die is closest to the workpiece. The die must be very close to, but not in contact with the workpiece, this is what ultimately causes the electrical "spark".

• • • EDM Spark Erosion
  • • EDM Wire Erosion
  • • EDM Hole Drilling

DRILLING & REAMING

This group of processes includes Drilling and Reaming that is performed on Manual  and CNC  Machinery, from conventional to large workpiece sizes.

• • CNC Drilling
• • Deep Hole Drilling
• • Radial Drilling
• • • Reaming

HONING & BURNISHING

This group of processes includes Honing and Burnishing that is performed on cylindrical bores and components, from conventional to large workpiece sizes.

• • Honing
• • Burnishing

BROACHING & SLOTTING

This group of processes includes Broaching and Slotting. Either process can be performed on dedicated broaching machinery or conventional milling and turning machines.

Broaching & Slotting both use toothed tools to quickly remove material. The processes are often used to produce internal and external shapes such as keyways, slots, squares, hexagons, straight sided splines and other irregular shapes.

The processes are best suited for medium to high volume production due to the cost of tooling.

• • Linear Broaching
• • Rotary Broaching

GEAR CUTTING, SPLINING & HOBBING

This category encompasses all types of gear manufacture that involves removal of material to create the required geometry.

Gears can be produced using a number of processes, such as hobbing, shaping, milling, power skiving, etc.

The process is typically driven by the type of gear required. Gears can be produced using manual machines and CNC machines from one off volumes to high volumes.

The most common types of gears are Spur, Helical and Bevel however this is not an exclusive list.

Gears can also be produced using several “Bulk Forming Processes”

BORING

This category contains machining processes typically known as Boring. Boring is the process of enlarging a hole that is already present in the work piece using a single point cutting tool.

The Boring process has been adapted to suit a selection of workpieces from conventional sizes to large.

• Vertical Boring (at conventional sizes)
• Large Vertical Boring (at sizes greater than 1000mm Diameter)
• Horizontal Boring (at conventional sizes)
• Large Horizontal Boring (at sizes greater than 1000mm in Diameter / Height / Width)
• Jig Boring

ROUTING, TRIMMING & EDGE PREPARATION

These processes are used to cut or create edges typically in Plate, Pipe or Moulded sheet materials.

Routing and Trimming is a particularly prominent process in the post-processing of plastics and composites. Edge preparation is commonplace in fabrication with plate and pipe materials.

• • CNC Routing
• • CNC Trimming
• • Edge Preparation

ELECTROCHEMICAL MACHINING (ECM)

Electrochemical Machining uses the same mechanism as metal plating, however it works in reverse. The component forms the anode of the electrical circuit, this is placed in close proximity to an electrode (cathode). A high-amperage direct current is then passed between the component and the electrode through an electrolyte, such as salt water.

Metal is removed by anodic dissolution and is carried away in the form of a hydroxide in the electrolyte for recycling or recovery.