What is Machining Process?
Any processes that involves cutting, shaping, or any other method of removing the material from a work piece is called as Machining. It is often done as final step in a manufacturing process, although it can take place in any point of the manufacturing process.
Machining involves broad range of processes, in which material is removed from a work piece using power-driven tools to create the desired shape. The word can refer to wide variety of different processes, from simple tasks like drilling a hole to more complex ones like CNC milling a complex shape.
Machining Processes:
There are many different types of machining processes, each of which has its own advantages and disadvantages. Some of the most common include:
1. Conventional Machining Process
Any manufacturing process in which the material removal from the work piece by direct contact of cutting tools on the work-piece to get the desired shape.
a) Drilling – In this machining process a drill bit is fed into the work piece, to create a hole in the work piece. The material is removed from the work piece as the drill bit is rotated into it. Drilling is typically used to create holes of various diameter and depths.
b) Boring – In Boring process, the tool is used to enlarge the size of the previously drilled hole in the work piece. Boring can be done to produce a smooth finish on the inside of the hole or to enlarge the hole to a specific size. The boring process can be performed on a variety of materials, including wood, metal, and plastic.
c) Milling – Milling operations involve the use of rotating cutting tools to remove material from the surface of a work piece. It can be used to create flat, curved, or irregular surfaces, contoured surfaces, and complex shapes. The milling process can also be used to create threads, grooves, and other types of features on a work piece.
d) Turning – Turning is a machining process in which the work piece is rotated against a cutting tool. The cutting tool is fed into the work piece, and material is removed from the work piece as it is rotated. It is typically used to create cylindrical shapes of any size.
e) Grinding – Grinding is a machining process in which the work piece is moved against a rotating abrasive wheel. The abrasive wheel removes material from the work piece as it is moved. It can be used to create a smooth finish on the surface of the work piece.
f) Broaching – Broaching is a machining process that uses a toothed tool, called a broach, to remove material from a work piece. It is performed by pushing or spinning the broach through the work piece. It is commonly used to create keyways, slots, and other internal shapes. Broaching can also be used to create external shapes, such as splines and serrations.
g) Sawing – This process is to create shorter length of extruded bars or similar structures and shapes, by using the Cut-off machines (or) simply called as Saw machines. Its speed depends on the type of material, for example softer materials like Aluminium alloys require high cutting Speed whereas, some high temperature alloys can be cut off on low cutting speed
h) Gear forming – In gear forming, the teeth of a gear are being cut while it is meshed with another gear. The gear being cut, is called the blank, which is usually softer than the cutter gear. For spur gears, the blank is usually rotated in a lathe. It is usually manufactured from hardened steel.
i) Gear Generation – The gear generation process is used to cut the teeth of a gear. The cutter gear has the same tooth form as the gear being cut, but is usually made of hardened steel. The gear blank is rotated and the cutter gear is fed into the blank. The cutter gear cuts the teeth of the gear blank.
AJM – In Abrasive Jet Machining (AJM), a high velocity [about 300m/s] of dry air (or) Nitrogen (or) CO2 are mixed with abrasive particles is used to remove the material from the work piece.
CHM – Chemical machining is a process of removing material from a work piece using chemicals. It is also known as etching. The process is used to create intricate designs or to remove material from a work piece that is difficult to machine using traditional methods.
ECM – Electro Chemical machining (ECM) is a method of removing metal from a work piece by passing an electric current through it. The current reacts with the metal to form a metal oxide, which is then washed away by a flow of water.
EBM – An electron beam machining (EBM) system uses a beam of high-energy electrons to vaporize material in a very precise manner. The electron beam is generated by an electron gun and is then accelerated and focused by an electromagnetic lens system. The focused beam is then directed at the workpiece, which is usually mounted on a table that can be moved in the x, y, and z directions.
IBM – Ion beaming machining (IBM) is a process that uses a focused beam of ions to remove material from a work piece. The ions are accelerated to high energies and then directed at the surface of the work piece. The ions interact with the atoms in the surface, causing them to be ejected from the surface. The material that is removed is carried away by the ions in the beam.
PCM – Photo chemical machining (PCM) uses light to remove material from a work piece. The process is similar to conventional machining, but uses light instead of mechanical force to remove material. Photo chemical machining is often used to create small, precise parts from thin sheets of metal.
USM – In Ultra Sonic Machining (USM), the ultra sonic waves are used to remove or erodes the material from the work piece by means of vibrations at a frequency of 20KHz.
EDM – Electron Discharge Machining (EDM) is a process that uses electrical discharges to remove material from a work The work piece is placed in a dielectric fluid and a high-voltage current is passed through it. The electrical discharges erode the material, removing tiny bits of it with each discharge
ECG – In Electro Chemical Grinding (ECM) process, the metal is removed by both grinding and Electro-chemical process. About 90% of the metal is removed by the Electro-chemical process, whereas the balance 10% only is removed by grinding process.
LBM – Laser Beam Machining (LBM) is a process that uses a laser beam to remove material from a work piece. The laser beam melts, vaporizes, or abrades the material, depending on the power of the laser and the properties of the material.
PAM – Plasma arc machining (PAM) is a thermal process that uses a plasma torch to remove material from a work piece. PAM can be used to cut, weld, or machine a variety of materials, including metals, plastics, and ceramics with great surface finish and tight tolerance.
WJM – Water Jet Machining (WJM) is a process that uses a high-pressure stream of water to remove material from a work piece. The water stream can be used to cut, abrade, or erode the material.WJM is typically used to machine hard or fragile materials that would be difficult to machine using traditional methods. It can also be used to machine very large work pieces or to create very precise shapes.
Difference between Machining and Grinding
| Machining |
| Involves cutting tools for material removal to form the desired shape. |
| Used to cutting away excess material |
| Suitable for removal operations where accurate parts must be fabricated from blocks of material |
| Able to achieve complex shapes and intricate designs |
| Used for metals and plastics, as well as a wide range of other materials with sufficient hardness for the operation of the machine tools |
| Manufacture components for large-scale production, such as automobiles,etc. |
| Grinding |
| Uses abrasive force to remove off small portions of the material’s surface in order to achieve the desired end result. |
| Used to create various shapes |
| Also can be used for finishing tasks such as buffing, polishing or sanding. |
| Much more quick and efficient |
| Used only for metals, as it is not effective for materials that are softer than metals, such as ceramics and plastics. |
| Smaller-scale applications like tool sharpening, refinishing the surface,etc. |
MATERIALS
In terms of materials, machining is typically used for metals and plastics, as well as a wide range of other materials with sufficient hardness for the operation of the machine tools. There are a wide variety of materials used in the machining process. Each material offers unique benefits and should be carefully chosen to ensure the best results for a particular manufacturing project.
Steel is the most popular machining material due to its strength and versatility, while aluminum, copper and plastic are also widely used. With the right material and careful selection, machining can be an efficient and cost-effective means of producing a finished product.
Common metals used in machining include steel, aluminum, brass and bronze.
Plastics
Plastics are another common machining material, due to their low cost and ease of machining. However, plastics are not as strong as metals and can be damaged easily.
Ceramics
Ceramics are harder than metals and can be used for cutting tools and wear-resistant parts. However, they are brittle and can break easily.
Composites
Composites are materials made from two or more different materials. They can be strong and lightweight, making them ideal for many applications.
But also, the choice of material is dictated by the properties required for the finished part, such as strength, hardness, wear resistance, corrosion resistance or conductivity. Zastata is a professional and experienced machining option, uses a strictly controlled environment to offer high performance and high-quality products. We have a wide range of premium machining materials and equipment’s to help you achieve the capability of your desired component requires.
Some of the Heat treatment processes Zastata provides to enhance material properties are
- Normalizing
- Annealing
- Quenching
- Tempering
- Carburizing treatment process,etc.
Zastata also performs premium quality testing procedures such as
Along with conventional Inspection services provided, Non-destructive testing like fluorescent penetration, magnetic particle, radiographic, or other inspections may also be performed. Final dimensional inspections, alloy test results, and NDT are validated authentically with expertise prior to shipment.
Finishing Processes
Zastata provides varying range of finishing Processes some of them are listed below,
- Polishing, Sanding, Deburring, Grinding, etc.
- Peening & shot blasting – to roughen a smooth surface is required.
- Painting and Powder coating – to enhance physical wear resistance, prevents corrosion and also improve physical appearances.
Machining Certifications
Zastata chooses manufacturers based on required certifications and product applications. Our manufacturers are certified to:
ISO 9001:2015 (Quality Management System)
ISO 14001:2015 (Environmental Management System)
ISO 45001:2018 (OH & SMS)
AS9100 Rev C (Aviation, Space and Defence)
ISO13485:2016 (Medical Devices)
IATF16949:2016 (Automotive Quality Management System)
Quality Documentation
Zastata has good understanding and experience with Quality documentation like:
APQP – Advanced Product Quality Planning
FMEA – Failure Mode Effective Analysis
PPAP Level 3 – Production Part Approval Process
SPC – Statistical Process Control
MSA – Measurement System Analysis
OUR MANUFACTURER LOCATIONS
Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.
COUNTRIES WE EXPORT
Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.
UK
USA
AUS
Denmark
Germany
Canada
France
China
INDUSTRIES WE SERVE
Advantages:
- Any type of simple, complex and intricate designs with thin sections can be machined.
- Suitable for both Ferrous, Non-ferrous materials and wide range of alloys, even for wood, plastics, ceramics.
- High production
- Increased Profit with less effort.
- Good dimensional accuracy
- Smooth surface finish can be achieved
- High reliability
- Requires less Human Labour.
- Uses modern techniques and machineries / instrumentalities.
- High efficiency
Applications:
The application of machining is in all types of industries and only limited by the human minds.
- Aerospace Industry
- Automobile Industry
- Agriculture
- Marine Industry
- Electronic Industry- Mobile phones, semi-conductors,etc.
- Military and defence Industry
- Healthcare Industry
- Jewelry
- Shoe
- Furnitures
- Construction & Architecture
- Oil and Gas Industry
- Automation & Robotics Industry, etc.
Require post machining inspection.
Frequent design changes in the component cannot be integrated into the existing layout.
It is clear that , with wide range of machining processes and techniques that requires high skill and experience for proper execution. Zastata is your best companion in providing the premium casting services including investment casting, and other casting services.
Zastata exhibits production complex with state-of-the-art casting equipments, and skilled crew of engineers, complemented by a professional technical team. We also pride ourselves on high-quality part manufacturing with fast lead times.
As its evident after reading the information provided above, the uses of machining process are vast. This technology is used directly or indirectly in almost every industry imaginable. In any given sector, the amount of equipment that uses any types machining or parts produced using those techniques is so vast that it is impossible to list them. Contact us with your requirements and we will ensure a long term working relationship.
