Metalcutting

Metalcutting refers to a family of material removal processes in which a cutting tool shears metal away from a workpiece to produce a desired shape, size, and surface finish. It is a fundamental method in manufacturing and is typically contrasted with metal forming, where material is reshaped primarily by deformation rather than removal.

Common metalcutting processes include turning, milling, drilling, boring, broaching, shaping, planning, and grinding. Turning uses a rotating workpiece and a stationary tool to create cylindrical features. Milling employs rotary cutters to remove material from a non-rotating workpiece, producing flats, slots, and complex contours. Drilling makes holes, boring enlarges them, and tapping cuts threads. Broaching yields precise profiles, while grinding provides fine finishes and tight tolerances through abrasive wear.

Tools and materials vary with the process. Cutting tools are commonly made from high-speed steel, carbide, ceramic, or polycrystalline diamond, and are designed to form and evacuate chips. Workpiece materials range from steels and aluminum alloys to titanium and copper alloys, with distinct behaviors in chip formation, heat generation, and wear.

Key process parameters include cutting speed, feed rate, and depth of cut, which together determine material removal rate, surface integrity, and tool life. Coolants or cutting fluids are often used to manage heat and clear chips. Non-traditional machining methods such as laser cutting, waterjet, electrical discharge machining, and ECM are related techniques for materials that resist conventional cutting.

Applications span automotive, aerospace, electronics, and general manufacturing, where precision and efficiency are critical. Safety and environmental considerations, including chip handling and coolant management, are routinely addressed in industrial practice.