Formed metal processing

There are roughly four methods for making metal shapes.
• Mechanical processing
• Plastic processing
• Casting
• Other
Introduce each process and feature in sequence.
1. Mechanical processing
There are three machining methods for mechanical processing: cutting, grinding, and special machining.
O Cutting processing
It is a machining method that produces shapes by using blade like tools to cut and remove unnecessary parts from the workpiece. It is the most commonly used method because it can process a wide range of materials, with a good balance between accuracy and cost, and high universality. Processing using lathes, milling machines, machining centers, drilling machines, etc. is representative.
The lathe grabs the workpiece with a chuck and rotates it, using a cutting tool to make contact with it and cut it. Capable of machining cylindrical surfaces and cutting threads.
A milling machine and machining center fix the workpiece on a workbench and use a tool called a rotary milling cutter for cutting.
A drilling machine is a machine that fixes the workpiece on a workbench and uses tools such as drills or taps for drilling and tapping.
It is used in a wide range of products because it is a common processing method along with lathe machining and milling. In our daily lives, it is used for household appliances and automotive parts.
O Grinding processing
This is a machining method that uses grinding wheels to cut and remove unnecessary parts from the workpiece. It is similar to cutting processing, but can achieve higher accuracy because it is cut with a grinding wheel. On the contrary, the amount of cutting per unit time is very small, which is both costly and time-consuming. For this reason, most shapes are made through cutting, while grinding is usually only performed in areas that require precision.
The use of cylindrical and surface grinding machines for machining is typical. Cylindrical grinding machines can process cylindrical surfaces, while surface grinding machines can process flat surfaces to improve flatness, cylindricity, and surface roughness.
Used in places that require precision surfaces, such as automotive parts and sliding parts of machine tools.
O Special processing
Mechanical processing that is neither cutting nor grinding is classified as special processing. There are various types, representative of which are electric discharge machining and laser machining.
Electrical discharge machining (EDM) is a method of applying voltage between the workpiece and the electrode, causing it to discharge and using the generated hot molten material for forming. The electrodes use graphite electrodes or electrode wires with the same shape as the processed ones. Its characteristic is the ability to perform high-precision and micro machining, even for hard and difficult to cut materials that are difficult to machine in cutting.
Laser processing is a method of irradiating a workpiece with high-energy laser and using the generated hot molten material to evaporate and form it. Its characteristic is the ability to perform small and precise machining.
Electric discharge machining is used to carve the cavity of molds, precisely cut thin plates and keyways.
Laser processing is used for precision cutting of thin plates or opening small holes.
2. Plastic processing
Plastic processing includes not only stamping and forging, but also rolling.
O Stamping processing
It is a machining method that uses a large force to press the cutting tool or mold onto a plate-shaped workpiece for cutting or forming in conjunction with the mold.
Use shearing machines, stamping machines, turret punches, etc. It can accurately form sheets and can also be used in various products. Sheet metal processing is also classified as a generalized stamping process.
Widely used in the manufacturing of car body panels, household appliances, and other products using sheet metal.
Forged
It is a machining method that uses a large force to press or collide the hammer, mold, or workpiece to form with the mold. In order to facilitate deformation, the workpiece is often pre heated and classified into hot forging, warm forging, and cold forging according to temperature. In addition, it can also be classified according to whether there are molds with product shapes. Those with molds are called mold forging, while those without molds are called free forging.
The former uses air hammers and hydraulic presses, while the latter uses crank presses, etc.
Utilize the characteristics that endow the workpiece with strength for products such as engine parts and wrenches that withstand force.
O Rolling
This is a machining method where a tool called a punch is pressed onto a cylindrical workpiece to deform it into the shape of the outer circumference of the punch. It is named after the fact that the workpiece is formed while rotating and flipping. Commonly used for external thread processing, etc.
The main products available in the home center are bolts and screws.
3. Casting
It is a processing method of melting raw material metal in a furnace, pouring it into a mold with a product shape cavity (chamber), and solidifying it to produce products. Mainly used for mass production of complex shaped products. In ancient times, sand molds were used for sand casting, but now there are low-pressure casting, die-casting, and other methods that use molds.
Used for making engine parts, machine tool bases, motor parts, etc.
4. Others
There are also processing methods that are not within the larger framework. Powder metallurgy and metal 3D printers are relatively new processing methods that can process complex shapes and shapes that cannot be processed using previous processing methods.
O Powder metallurgy
This is a processing method of compacting metal powder from raw materials in a mold for forming the product, heating it with a furnace, and combining the particles to make the product. This method has fewer opportunities for use, but it can produce products with special properties that cannot be produced by other methods.
Used for making gears that are less stressed, special bearings that do not require oil supply, etc.
Metal 3D printer
This is a processing method of gradually stacking materials as a necessary part of the product to create the final shape, which has received much attention in recent years. Due to the small necessity of tool path and shape constraints, it is also possible to produce products with special shapes that cannot be completed by previous machining methods. Previously, it was used for rapid product testing, but it was also used for small and high value-added products.
This processing method has a relatively short history, but it is used to make blades for jet engines, brake parts for high-end cars, and so on.