Metal Cutting- Manual to Industry 4.0

by Marshall Machine We are Marshall We make CNC Machines

There are various industries that involve metal cutting. Whether it’s automobile industry or any sort of manufacturing industry, cutting various kinds of metals emerge as a compulsory step. To serve this purpose, there are various metal cutting machines. Over the years, the metal cutting machines have also received a makeover. Back in time, metals were cut using manual machines but with the advances of technologies and industry 4.0 knocking the door, many new metal cutting machines came into existence. These machines made it possible to cut metals precisely in various shapes and sizes in less time.

The most modern metal cutting machines are capable of cutting every kind of metal using various techniques.

How to choose the cutting techniques for cutting metals?

As we all know there are n numbers of metals comprising of different attributes. Some metals are hard, some are not. Some metals are malleable and ductile, some are not. And, so, it is not possible to cut every metal with the same method. Different kinds of metals require a different kind of metal cutting processes.

The technique of cutting metal is selected as per the attributes of the metal, the demand for precision, and the indications of the end result.

Here are the basic metal cutting methods that are commonly used in the industries:

The manual process of metal cutting using hand tools

Before industry 4.0 took over, there were no competent machines to cut heavy metals in a precise way. Smaller cutting tasks were carried out by hand cutting tools like hacksaws and shears. Though it was easy to shape and cut pliable metals with these manual tools, cutting less pliable metals was a big challenge.

If you are dealing with very pliable metals and the cutting job is less, you can use the manual methods. However, these methods are really outdated and offer no good results.

If you want to cut metals into very fine pieces, using manual methods is not at all recommended as the amount of force applied to cut the metal may break the entire workpiece.

In order to remove excess metal, you can use a chisel. This tool can also be used to get a precise shape of the workpiece. There are various kinds of chisels available including a hot chisel and cold chisel. You can select any as per the job in hand.

However, we would recommend you to use more modern techniques involving industry 4.0 enabled machine tools.

Machines for metal cutting

The industrial revolution has given us many robust machines to cut and shape even the most robust metal. These machines have enabled the industries to take up larger projects and finish them with ease, precision, and in no time.

There are various machines ranging from simple grinders to smart CNC machines for cutting metals. They are used as per the cutting needs.

Lathe

A lathe machine is a commonly used machine used for metal cutting and shaping. In this machine, a sharp tool spins rapidly over the material to cut the metal in the desired shape and size. It works with a high degree of precision.

Grinder

Grinding machine is the machine of choice for giving a smooth finish to the final product. This machine uses a rotating wheel or blade comprising of an abrasive material that eliminates metal from the surface making it smooth.

Water jet

This machine uses water mixed with an abrasive agent to cut the metal. A stream of water is directed on the metal to cut it and shape it. It is used for cutting the metals that are sensitive to extreme temperature and heat.

Punch

High pressure is exerted on the metal allowing the blades to pierce through it and cut it into the desired shape. This is the best cutting and shaping method for robust metals. Some machines even punch 1000 times per minute making the process really quick.

Flame and plasma

Flame and plasma method is also a potent metal cutting method. In this method, flammable gas is used to cut the metal by creating hot flames cutting through the metal. The metal is melt and burnt to give out the desired shape. This method also guarantees a high degree of precision.

The latest method for metal cutting

The latest method for metal cutting compatible with industry 4.0 is laser cutting. Hereby, laser beams are concentrated on the metal to heat it and cut through it to get the desired shape of the end product. This method churns out precise results. However, it is slower and more expensive than other cutting methods using smart CNC machines.

These were the various metal cutting methods used in various industries before and after the industrial revolution.