Main 5 Ways to Cut Metal for Parts Manufacturing

Picking the proper cutting method is necessary for achieving precision, efficiency, and cost-effectiveness in your projects.

However, with so many different techniques - including plasma cutting, torch cutting, and using circular saws - it can be overwhelming to find the best fit for your specific needs.

In this blog, we'll explore five main ways to cut metal for manufacturing parts that can elevate your DIY or industrial-scale ventures.

Read on as we break down each method's advantages and disadvantages while offering helpful tips to ensure successful results!

Traditional And Advanced Methods For Cutting Metal For Parts Manufacturing

Sawing

Sawing is one of the most common and versatile methods for cutting metal in parts manufacturing.

It's a technique I've used on various DIY projects, and it's advantageous when you need to cut through sheets, bars, or tubes made from different types of metal alloys.

Traditional saws like hacksaws can be highly effective for smaller tasks by hand, while power saws equipped with steel circular saw blades can easily handle larger jobs.

What I appreciate about using saws for cutting metal is their ability to balance efficiency and precision. Depending on your blade and saw type choice, you can achieve clean cuts without excessive force or compromising accuracy.

For example, an angle grinder fitted with an abrasive wheel can slice quickly through thick metal surfaces while still maintaining a degree of control over the cutting process.

Similarly, band saws offer great flexibility regarding material size and shape because they rely on continuous loops of sharp-toothed bands to perform their cuts—ideal if you require intricate contouring or precise angles during fabrication workflows!

Drilling

Drilling is another traditional method of cutting metal, often used for creating holes in various materials.

It involves using a drill bit to cut through the metal until the desired shape is achieved. This method is commonly used when a precision circular or cylindrical shapes are required.

However, drilling can be time-consuming and unsuitable for large-scale production due to its relatively slow process.

To increase efficiency, some manufacturers use computer-controlled drilling machines that can create multiple holes simultaneously with greater accuracy than manual methods.

Milling

Milling is a process that involves rotating a cutting tool while feeding it into the workpiece and removing chips from the material until the desired shape or size is achieved.

Milling can produce complex shapes and contours with high accuracy and precision, making it ideal for creating prototype parts or small production runs.

Different milling machines are available today, including vertical, horizontal, and gantry-style mills. Each machine has advantages depending on the cut material, the required precision, and the production volume.

For example, vertical mills are great for cutting slots or pockets in flat surfaces, while gantry-style mills are perfect for large-scale manufacturing projects such as aircraft components.

Shearing

Shearing involves using a sharp blade to slice through metal sheets in a straight line. Shearing is an excellent choice for those looking to cut large volumes of sheet metal quickly and efficiently.

One advantage of shearing is that it produces clean, precise cuts without warping or distorting the sheet metal.

In addition, this method works best with thinner materials up to 0.25 inches thick, making it ideal for producing components like brackets, panels, and shims.

I've also found that shearing provides excellent repeatability, ensuring you can achieve consistent results every time you use this method.

However, it's worth noting that while shearing may be efficient and accurate with thin metals, attempting to shear thicker sheets can result in poor edge quality or even damage the cutting tools.

Therefore, when working with thicker metals or requiring more intricate shapes and cuts from your parts manufacturing operations, other methods, such as plasma cutting, might be recommended instead!

Waterjet Cutting

Waterjet cutting is a highly advanced method for cutting metals in parts manufacturing. This technique uses high-pressure water streams mixed with abrasive materials to cut through metals precisely and accurately.

What I love about waterjet cutting is that it doesn't rely on heat or friction, making it possible to cut through thin metal sheets without warping or damaging them.

It's also great for creating intricate shapes and designs because the stream can easily navigate tight corners and curves.

One of the best things about waterjet cutting is that it's eco-friendly compared to other methods like plasma or laser cutting since no harmful emissions are involved.

Also, this technique has a low noise level during operation, making it easy to work with even in crowded workshops.

With its versatility and ability to handle many different materials, from metals to composites, waterjet cutting is becoming increasingly popular for DIY projects and industrial-scale applications.

Laser Cutting

Laser cutting uses a high-powered laser beam that melts or vaporizes the metal cut, leaving a smooth edge with little to no burrs. This technique is preferred when dealing with thinner materials such as sheet metal but can also work well on thicker metals.

Not only does laser cutting offer precise cuts, but it's also an efficient option for parts manufacturing. The process is fast and automated, which makes it ideal if you need multiple identical parts quickly.

Additionally, laser cutting machines are programmable via Computer-Aided Manufacturing (CAM) software, allowing repeated levels of replication in production runs, making them incredibly versatile options in any fabrication setup.

Plasma Cutting

Plasma cutting is a modern and popular metal cutting method that uses a high-temperature plasma arc to melt and cut through metal.

It is especially useful for cutting thick metals quickly, precisely, and without producing too much heat or debris. I have used this method on several DIY projects, such as cutting steel sheets for custom shelving units.

Plasma cutters come in different sizes and strengths, from hand-held models for small projects to large industrial machines for heavy-duty applications.

The process involves sending compressed gas (such as nitrogen or argon) through a nozzle at high speed into an electrical arc, creating a plasma stream that heats the metal surface until it melts and forms a clean cut.

One advantage of plasma cutting over other methods like sawing or drilling is its ability to produce intricate shapes easily, making it ideal for manufacturing parts with complex designs or contours.

Electrical Discharge Machining (EDM)

This technique uses a charged electrode to create an electrical arc that erodes material away from the workpiece, allowing for intricate and precise cuts.

EDM is particularly useful for cutting hard materials such as titanium or tungsten carbide, where traditional sawing or milling methods would be difficult or impossible.

Factors To Consider When Cutting Metal For Parts Manufacturing

Material Properties And Thickness

Metal properties and thickness influence the cutting method choice to preserve structural integrity.

Plasma cutting suits thick metals, while thicker sheets need forceful tools like abrasive wheels or circular saw blades, ensuring clean cuts without warping.

Thicker materials also extend processing time, impacting production efficiency if not managed well.

Precision And Accuracy Requirements

Precision and accuracy in cutting depend on material properties, part quantity, cost impact, noise/dust concerns, and quality control standards.

Production Volume And Cost

When you're making a lot of something, using fast and precise methods like waterjet or laser cutting is crucial for maintaining quality and meeting demand.

For smaller or customized projects, traditional tools like hacksaws or angle grinders, though less fancy, can be cheaper and still create good results if used well.

Environmental Impact

Sawing: Traditional sawing methods produce a lot of dust and noise pollution, which can harm the environment and workers' health.

Waterjet Cutting: Although waterjet cutting does not generate heat or hazardous fumes, large amounts of water are used. This can lead to excess water waste and potential pollution from chemicals used in the wastewater treatment process.

Laser Cutting: Laser cutting uses much energy and produces hazardous fumes that need proper ventilation and disposal. The cut materials must also be carefully managed due to their potential hazard.

Plasma Cutting: Plasma cutters generate high levels of heat that can cause air pollution from gases produced during the cutting process.Electrical Discharge Machining (EDM): EDM uses electricity to erode metal, which releases particles into the air that can harm workers' health if not properly ventilated.

Efficiency

Efficiency in cutting methods varies. Laser and plasma cutting are swift and precise, ideal for thick metal sheets in industrial settings.

Conversely, traditional methods like hacksaws are less efficient but still handy for smaller tasks or where precision isn't paramount.

Safety

Ensure proper safety by wearing gear like goggles and gloves, maintaining a clutter-free workspace, using the right tools for the task at hand, and keeping tools well-maintained.

Seek guidance from experienced individuals before starting metalworking projects to prioritize safety and prevent serious injuries.

Best Practices For Cutting Metal For Parts Manufacturing

Ensure Proper Safety Precautions

• Wear proper safety gear, including eye and ear protection, gloves, and a dust mask.
• Keep your workspace clean and organized to avoid tripping hazards or potential accidents.
• Ensure your cutting tools are well-maintained and properly functioning before use.
• Use clamps or other fixtures to secure the material you're cutting to prevent slipping or movement during the cutting process.
• Always be aware of where your hands and body are with the cutting tool, and only attempt to cut freehand with proper support or guidance.
• Never operate machinery under the influence of drugs, alcohol, or medication that impairs judgment or reaction time.
• Always follow manufacturer instructions for the operation and maintenance of equipment.

Use Quality Cutting Tools And Equipment

Use good quality tools for precise cuts. Check tool blades for sharpness and quality to ensure smoother cuts and less material damage.

Investing in durable equipment boosts productivity, especially tools with adjustable settings for different metal thicknesses.

Quality tools last longer, reducing downtime and repair costs.

Properly Maintain And Clean Cutting Tools

Keep cutting tools sharp and well-lubricated by following manufacturer guidelines. Regular maintenance prevents wear, damage, and accidents.

Clean tools after each use to prevent rust and buildup, using soap, water, or specialized cleansers for metalworking equipment.

Conclusion

Different cutting methods exist for metalworking, each with its own advantages and drawbacks in terms of precision, cost, safety, and environmental impact.

To optimize your metal cutting process, prioritize safety, use high-quality tools, select the right method for your requirements, and maintain your equipment properly. Following these steps will help you succeed in your metalworking projects.

It's essential to consult with trusted industry experts or manufacturers like DEK so we can provide insights that are tailored to your unique situation.

By analyzing these various factors diligently while also considering their advantages and disadvantages, we can choose a suitable cutting method for your parts manufacturing.

Contact us now!