What Are The Different Metal Cutting Machines and Tools: What Are They Used For

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1. What Are The Different Kinds Of Metal Cutting Tools And What Are They Used For?

2. How to Choose a Metal Cutting Machine

When you think about shaping the future, literally, metal cutting machines play an integral role. These devices, which range from the ancient lathe to the modern abrasive waterjet cutter, have evolved to meet the demands of ever-more sophisticated metal cutting processes. If you’re curious about how metal is transformed from raw slabs into precision parts, this guide is tailored for you.

What Are The Different Kinds Of Metal Cutting Tools And What Are They Used For?

Metal cutting machines, integral to manufacturing and engineering, are categorized based on the technique they employ—mechanical, thermal, and non-conventional. Each type is tailored for specific materials and outcomes, enhancing precision, reducing waste, and optimizing performance.

Lathes

A lathe is a machining tool that rotates the workpiece on its axis to perform various operations such as cutting, sanding, knurling, drilling, or deformation, using tools that are applied to the workpiece to create an object with symmetry about an axis of rotation.

The lathe is one of the oldest machining tools, with its origins dating back to ancient Egypt. Over centuries, lathes have evolved from simple manual machines to sophisticated CNC machines that offer high precision and automation.

Lathes can vary greatly in price from a few thousand dollars for basic models to over $100,000 for large, complex CNC lathes.

Advantages

High precision and consistency
Versatility in processing different materials
Capability to produce complex designs
Automation options available in CNC lathes

Disadvantages

High initial investment for CNC models
Requires skilled operation and maintenance
Can be noisy and create significant vibrations

Applications

Automotive: manufacturing of gears, bearings, and crankshafts
Aerospace: production of components such as landing gear
Tool manufacturing: creation of bolts, screws, and other fixtures
Arts and crafts: woodworking and metal sculptures

Mills

Mills operate by using a rotating cutting tool to remove metal from the workpiece. Milling machines are capable of performing a variety of operations, from simple cuts to complex shapes and surfaces. They are distinguished by their configuration, either horizontal or vertical, and by their movement, controlled by manual or computerized numerical control (CNC) systems.

The development of milling machines dates back to the early 19th century. Originally designed to automate manual tasks, milling machines have evolved into highly complex CNC machines that offer unparalleled precision and speed.

The cost of milling machines varies significantly. Manual mills can start around $1,000, while CNC mills can reach prices over $100,000 depending on their capabilities and size.

Advantages

Versatility for different materials and shapes.
High precision with capabilities for complex geometries.
Scalable efficiency from small workshops to large-scale production.

Disadvantages

Significant initial investment and maintenance cost.
Requires technical skill to operate and program, especially CNC mills.

Applications

Automotive parts like gears and shafts.
Aerospace components for engines and fuselages.
Prototyping for research and development.

Saws

Saws are among the most commonly used mechanical cutting tools, designed to cut metal through a hard toothed blade. Depending on their design, saws can be categorized into band saws, circular saws, and reciprocating saws. Each type uses a different motion to achieve cutting—either circular for smooth cuts or back-and-forth for more detailed work.

The evolution of saws has been pivotal in industrial progress. Originating from manual hand saws, today’s machines have transformed into highly sophisticated equipment powered by electricity or hydraulics, offering more precision and efficiency.

Saws vary widely in price. Simple hand saws can cost as little as $20, while large, industrial band saws can exceed $10,000, depending on their specifications and capabilities.

Advantages

Ability to handle very thick materials.
Straight and relatively fast cuts.
More economical for straightforward, less complex cuts.

Disadvantages

Limited to certain types of cuts (primarily straight cuts).
Lower precision compared to more advanced cutting tools.

Applications

Construction and structural metal work.
Large scale manufacturing lines.
Cutting stock to size for further processing.

Drills

Drills are mechanical tools that use a rotating drill bit to bore holes into solid materials. The simplest versions are handheld devices, powered either manually or by electricity. More complex variants, like drill presses or milling machines, offer stability and precision for industrial applications.
The development of the drill is a key advancement in tool engineering. From bow drills used in ancient woodworking to modern power drills enhanced with electronic speed controls and synthetic diamond bits, drills have evolved significantly. This evolution reflects advancements in materials science and precision engineering.
For consumer models, prices can range from $30 to $300. Industrial drill presses and milling machines can cost from $1,000 to over $50,000, depending on the complexity and capacity.

Advantages

High precision and control.
Versatility with various materials.
Efficiency in producing cylindrical holes.

Disadvantages

Limited to drilling holes; not suitable for other types of cuts.
High-speed drilling can lead to overheating and wear.

Applications

Creating fastening holes in automotive parts.
Developing components in aerospace manufacturing.
Assembling electronic gadgets with precision.

Grinders

Grinders, which utilize abrasion and friction to smooth or cut surfaces, are essential in material finishing and are used to refine the surfaces of metal parts.

Starting from manual stone and pedal-operated grinders, the technology has advanced to electric and pneumatic grinders that deliver precise and efficient performance.

Depending on their size and capability, grinders can cost anywhere from $8,000 to $80,000.

Advantages

Ability to produce fine finishes and precise cuts.
Effective in shaping and deburring metal pieces.
Versatile across various industries for different applications.

Disadvantages

Risk of overheating the material.
Requires protective gear due to debris and sparks.

Applications

Smoothing welded joints in construction projects.
Shaping metal components in automotive manufacturing.
Finishing metal artworks and sculptures.

Planer Machines

Planer machines are used to shape metal by moving the workpiece across a stationary cutting tool. They are ideal for large components that require straight, flat surfaces.

The evolution of planer machines began in the early 19th century, adapting over decades to meet the increasing demand for precision in metal fabrication.

Costs can vary significantly, generally ranging from $10,000 to over $100,000, reflecting the size and sophistication of the machinery.

Advantages

Capable of handling very large pieces of metal.
Produces flat and angular surfaces with high precision.
Cost-effective for certain specific applications.

Disadvantages

Relatively slow compared to other cutting machines.
Limited to certain types of cuts, reducing versatility.

Applications

Creating slots and grooves in large metal sheets.
Shaping dies for forging and stamping processes.
Smoothing rough surfaces in construction materials.

Shearing Machines

Shearing machines cut materials by applying a shearing force that exceeds the material’s ultimate shear strength, making them perfect for cutting sheets and plates.

Shearing machines have been a part of metalworking since the Industrial Revolution, with technological advancements enhancing their efficiency and safety.

These machines can cost from $1,500 for simple models up to $50,000 for large, industrial-grade machines.

Advantages

High efficiency and speed in cutting thin and medium-thickness materials.
Produces clean cuts with minimal waste.

Disadvantages

Not suitable for very thick or very hard materials.
Precision can vary depending on the type and condition of the blades.

Applications

Trimming and shaping metal sheets in automotive manufacturing.
Cutting components for HVAC systems.
Fabricating metal bodies for electronic appliances.

Boring Machine

Boring machines are designed to enlarge and achieve precise dimensions on already existing holes. Utilized in a myriad of applications, these machines are crucial for the meticulous tasks required in high-precision industries.

The development of boring machines traces back to the need for more accurate artillery during the 18th century, evolving significantly with the advent of industrialization.

Boring machines can range from $5,000 for basic models to over $500,000 for those equipped with CNC technology and advanced features.

Advantages

Exceptional precision in enlarging holes.
Capable of achieving desired finishes with adjustable cutting parameters.
Versatile in handling a variety of materials.

Disadvantages

High initial cost of advanced models.
Requires skilled operation and maintenance.

Applications

Aerospace components manufacturing.
Creating high-precision holes in automotive parts.
Assembly of complex machinery components in heavy equipment.

Hobbing Machine

Hobbing machines are specialized tools used for cutting gears, splines, and sprockets. They operate through a cutting process involving a hob and a workpiece, which rotate concomitantly to produce gears.

Hobbing machines were first developed in the late 19th century as a response to the increasing complexity of machinery and the need for precise gear systems.

Prices vary from $20,000 for smaller units to $400,000 for large-scale, industrial-grade machines.

Advantages

High efficiency in producing gears and sprockets.
Able to produce a large range of gears with different complexities.

Disadvantages

Limited to gear cutting; cannot be used for other machining tasks.
Can be costly for small-scale operations.

Applications

Gear manufacturing for automotive industries.
Producing gear systems used in wind turbines.
Creating gears for industrial machinery and equipment.

Gear Cutters

Gear cutters are specialized tools used to create precise gear shapes and sizes. They function by removing material from a metal workpiece to form the teeth of a gear.

Gear cutting technology has evolved from manual craftsmanship to advanced CNC machinery, significantly enhancing accuracy and speed. Prices for gear cutters can range from $10,000 to over $200,000 depending on complexity and automation level.

Advantages

High precision in gear production.
Capable of producing complex gear geometries.
Efficient production speeds with modern CNC gear cutters.

Disadvantages

High cost of advanced machines.
Technical skill required for operation.
Maintenance and setup can be intensive.

Applications

Automotive transmission systems.
Aerospace gearboxes.
Industrial machinery.

Broaching Machines

Broaching machines use a toothed tool, or broach, which removes material with a linear motion to cut irregular shapes such as splines, keyways, and gear teeth.

Broaching has been used since the 19th century but has seen significant advancements in precision and automation with the integration of CNC technology.

Standard broaching machines range from $15,000 to $100,000.

Advantages

Exceptional surface finish and consistency.
High productivity for certain shapes like keyways.
Capable of handling a variety of materials.

Disadvantages

Not versatile—each broach is designed for a specific shape or size.
High initial cost for custom broaches.
Requires significant setup time for each new task.

Applications

Fitting keyways in industrial motors and pumps.
Machining slots in automotive parts.
Creating custom shapes in firearm components.

Die Cutting Machines

Die cutting machines employ hardened steel forms or dies to cut shapes out of metal sheets. They work using a press-like mechanism that shears the material into desired forms efficiently.

The evolution of die cutting started with manual presses and has progressed to highly automated machines that enhance precision and speed.

Depending on their size and automation level, these machines can cost anywhere from $10,000 to $200,000.

Advantages

High repeatability for large production runs.
Excellent precision for complex shapes.
Minimal waste of materials due to tight nesting capabilities.

Disadvantages

High initial cost for custom dies.
Limited to thinner materials.
Setup and changeover can be time-consuming for new designs.

Applications

Creating intricate components for electronics.
Fabrication of parts in automotive manufacturing.
Producing decorative metal items and fixtures.

Router Machines (Metal Routers)

Metal routers are advanced tools that use rotary cutting heads to shape, hollow out, and cut various metal materials. These machines are typically guided by computer numerical control (CNC) systems.

Originating from woodworking routers, metal routers have been adapted for harder materials, integrating CNC technology for enhanced precision.

CNC routers for metal start around $20,000 and can exceed $100,000 for high-end models.

Advantages

Versatile tooling allows for a wide range of operations.
CNC operation enables intricate designs and repeatable processes.
Faster production times compared to manual machining.

Disadvantages

High skill level required for operation and maintenance.
Initial setup and programming can be complex.
Investment in CNC technology is significant.

Applications

Aerospace components requiring intricate designs.
Automotive parts with complex geometries.
Custom signage and architectural metalwork.

Punch Press Machines

A punch press is a type of machine press used to cut holes in material. It can work either mechanically or hydraulically and is known for its high precision and efficiency.

The punch press has evolved from simple manual devices to complex CNC-operated machinery that offers greater control and speed.

Prices can range from $5,000 for basic models to over $100,000 for large-scale, advanced models.

Advantages

High efficiency and productivity.
Capable of producing complex shapes with precise tolerances.
Low operational cost over time.

Disadvantages

High initial investment.
Requires regular maintenance to prevent wear and tear.
Limited to punching thin to medium-thick materials.

Applications

Manufacturing electrical components.
Creating cut-outs in sheet metal for automotive parts.
Fabricating metal enclosures and housings for machinery.

Ironworker Machines

Ironworkers are versatile machines used to cut, bend, and notch sheet metal and plate. They operate by using hydraulic force to shear metal, making them suitable for heavy-duty tasks.

From manual lever-based designs, ironworkers have transitioned to hydraulic systems that enhance their capacity and efficiency.

Depending on capacity and features, ironworkers can cost from $10,000 to $50,000.

Advantages

Versatility in performing multiple tasks with one machine.
High durability and capability for handling substantial metal pieces.
Relatively fast operation compared to other cutting methods.

Disadvantages

Not suitable for precision cutting of very detailed parts.
Can be dangerous if not operated properly.
Significant physical space required for operation.

Applications

Construction projects requiring steel framework.
Shipbuilding and large scale manufacturing.
Production of structural steel components like beams and frames.

Thread Cutting Machines

Thread cutting machines are specialized tools designed to create threads on the inside (tapping) or outside (threading) of a workpiece. These machines can be manually operated, such as tap and die sets, or powered, such as lathe threading or dedicated threading machines. Historically, thread cutting was labor-intensive and lacked precision, but modern advancements have introduced machines that can produce threads with remarkable accuracy and speed.

Advantages

Ensures threads are uniformly cut to exact specifications.
Reduces the time and effort required for threading operations.
Capable of handling a variety of materials and thread types.
Minimizes material wastage and operational costs.

Disadvantages

Requires precise setup and operation.
High-speed operations can lead to rapid wear and tear.
Not all materials are suitable for all threading machines.
Can be noisy and pose safety risks if not properly managed.

Applications

Production of bolts, screws, and engine components.
Metal beams, pipes, and fasteners.
Small-scale threads for electronic components.
Creation of custom bolts and fittings for machine assembly.

Thermal Cutting Machines

Thermal cutting machines represent a different approach by using heat to cut through metal. These include plasma cutters, laser cutters, and oxy-fuel cutting equipment. Each uses a unique method to generate sufficient heat to melt or even vaporize metal, facilitating smooth, precise cuts in a fraction of the time traditional methods might require.

Torches

Torches for metal cutting emerged as a solution for industries requiring efficient cutting processes for thick metal plates. Plasma cutting machines, developed during World War II for faster production of war supplies, use ionized gas to cut through electrically conductive materials at high speeds. Oxy-fuel cutting, on the other hand, uses a combination of oxygen and a fuel gas to melt metals, making it ideal for thicker and heavier plates.

Advantages

Both plasma and oxy-fuel cutting are faster than traditional mechanical cutting methods.
Plasma cutters offer precise cuts with minimal kerf.
Capable of cutting a wide range of metals and alloys.
Suitable for both small workshops and large-scale industrial applications.

Disadvantages

Initial setup and maintenance costs can be high.
Requires trained operators for optimal performance and safety.
Mostly suitable for conductive metals.
Generates fumes and requires adequate ventilation.

Applications

Steel frameworks and structural components.
In the automotive industry, it’s utilized in the cutting and shaping of components
Creating intricate designs and custom parts.
Detailed artistic projects using metals.

Laser Cutting Machines

Laser cutting machines use a high-powered laser beam focused on a small area to melt, burn, or vaporize the metal. Introduced in the 1970s, these machines revolutionized precision metal cutting, offering unparalleled accuracy and speed.

Advantages

Allows for complex cuts with tight tolerances.
Produces smooth finishes that often require no further treatment.
Can be fully automated with minimal human intervention.
Modern lasers are energy-efficient and have a lower operational cost over time.

Disadvantages

Higher upfront costs compared to other cutting methods.
Requires regular maintenance and calibration.
Best suited for thinner metal sheets.
The intense laser beam can pose safety risks if not properly managed.

Applications

In electronics, it’s used for precise cutting of components.
Manufacturing of intricate devices and implants.
Cutting and shaping aerospace components.
Detailed cutting for custom designs.

Non-Conventional Cutting Machines

Non-conventional cutting machines break away from traditional mechanical and thermal methods, employing unique technologies such as erosion or ultrasonic energy to slice through materials. These innovative approaches allow for precision cutting of highly sensitive materials without altering their inherent properties.

Water Jet Cutting Machines

Water jet cutting machines utilize a high-pressure stream of water, sometimes mixed with abrasive substances, to cut a variety of materials. This technique was developed in the mid-20th century and has since revolutionized cutting processes in several industries due to its versatility and efficiency. The water jet cutting machine, typically integrated with CNC (computer numerical control) technology, allows for intricate cutting of hard materials like stone and metal with minimal waste and without thermal distortion.

Water jet cutting machines vary widely in price, generally ranging from $20,000 for basic models to over $150,000 for advanced systems equipped with extensive capabilities and higher precision.

Advantages

Capable of achieving intricate cuts with high precision close to design specifications.
Able to cut a wide range of materials, from metals to composites, without changing tooling.
No Heat Affected Zone (HAZ): Reduces the risk of altering the material properties during the cutting process.
A good waterjet offers very low operating cost relative to production and eliminating secondary processing that heat processes often require.
Waterjet machines are very affordable and offer the most versatility to small shops.

Disadvantages

Compared to methods like laser or plasma cutting, water jet cutting is slower.

Applications

Used for cutting composite materials used in aircraft manufacturing.
Ideal for cutting intricate designs into metals and polymers used in auto parts.
Allows for the creation of detailed artistic pieces in a variety of materials.

TechniWaterjet

For over 35 years, TechniWaterjet has been at the forefront of water jet technology, engineering solutions that enhance operational efficiency. Their cutting systems are renowned for precision and versatility, capable of handling materials from stainless steel to granite without requiring tool changes. TechniWaterjet systems are designed to improve productivity, offering features like remote motion control to streamline workflow and minimiwze downtime.

Here are a few capabilities of Techniwaterjet cutters:

Cutting parts with a true angle up to +/- 60 degrees.
Continuous rotation, increasing accuracy and efficiency.
Positioning accuracy to ± 0.1 degrees.
Multi-pass cutting for edges with different angles, such as chamfers and counter sinks.

Our Intec™G2 Quantum® Pump is 60% more efficient than standard hydraulic intensifiers and is the most quiet water jet pump on market.

Electric Discharge Machines (EDM)

Electric Discharge Machines, also known as spark machining, erode material using electrical sparks. Developed during the late 1940s, EDM has evolved into a preferred technique for machining complex shapes in hard materials like titanium and alloys.

EDM systems can cost anywhere from $50,000 to over $150,000, based on complexity and specifications.

Advantages

Capable of producing intricate molds and parts that are difficult to machine using conventional methods.
Provides excellent surface finishes, reducing the need for post-processing.
Effectively machines carbides and other hard materials without mechanical stress.

Disadvantages

Primarily used for conductive materials, limiting its use.
Material removal rates can be slow, impacting productivity.
High energy consumption and electrode wear can increase operational costs.

Applications

Ideal for dies, molds, and fixtures.
Aerospace and Automotive: Used for manufacturing complex components.
Produces small, intricate parts for medical implants.

Ultrasonic Cutting Machines

Ultrasonic cutting machines operate by generating high-frequency sound waves that are transferred to a blade, causing it to vibrate and cut through material with minimal pressure exerted. This technique is particularly effective for soft, brittle, or delicate materials.

Developed primarily for materials like textiles and food products, these machines have adapted to a broader range of applications over the years. Prices typically range from $10,000 to $50,000.

Advantages

Produces clean, precise cuts without fraying or unraveling.
Consumes less energy compared to traditional cutting methods.
Capable of cutting a variety of materials, from food to carbon fiber composites.

Disadvantages

Less effective on harder materials.
Not suitable for high-volume cutting tasks due to speed limitations.
Higher initial costs for industrial-grade machines.

Applications

Used for cutting synthetic and natural fibers.
Ideal for slicing multi-layered products.
Cuts complex shapes in composite materials.

How to Choose a Metal Cutting Machine

Selecting the right metal cutting machine involves more than just comparing prices and models. It requires a deep understanding of your project’s specific needs and the capabilities of different types of cutting technologies. Here’s what you need to consider:

Material Compatibility: Ensure the machine is suitable for the type of metal you plan to cut, whether it’s stainless steel, aluminum, or titanium.
Cutting Precision and Capabilities: Depending on the precision required in your projects, choose a machine that can deliver the exactness you need without compromise.
Machine Size and Work Area: The dimensions of the machine and its work area should be sufficient to handle the sizes of metal sheets or parts you intend to work with.
Power and Energy Consumption: Evaluate the energy efficiency of the machine, as this can significantly affect operating costs.
Speed and Productivity: A machine’s cutting speed can impact your overall productivity; thus, assess what speed is optimal for your operational requirements.
Ease of Use and Automation Features: Automated features such as CNC (Computer Numerical Control) can greatly enhance precision and reduce labor costs.
Maintenance and Support: Consider the maintenance regime required and whether you have easy access to parts and support services.
Cost: Finally, balance all the above factors with the cost of the machine to ensure it fits within your budget without compromising necessary features.

Conclusion

In this guide, we’ve explored essential factors to consider when choosing a metal cutting machine. Whether your focus is on enhancing precision, increasing productivity, or managing costs, understanding these elements ensures you select a machine that meets your specific needs. Remember, the right equipment not only improves efficiency but also supports innovative manufacturing processes, pushing your projects towards success.