Zerspanen

Zerspanen is a German term widely used in engineering to describe subtractive manufacturing processes in which material is removed from a workpiece in the form of chips by shearing action with a cutting tool. Its goal is to shape parts with specified geometries and surface finishes. Zerspanen includes a range of operations, notably turning (Drehen), milling (Fräsen), drilling (Bohren) and boring, as well as threading and grinding; broaching and sawing are sometimes included depending on the context.

At the heart of Zerspanen is relative motion between a cutting tool and the workpiece, causing chip formation and heat generation. The process is controlled by parameters such as cutting speed (v), feed rate (f), and depth of cut (ap), together with tool geometry, workpiece material, and cooling or lubrication. Tool wear, deflection, and vibrations influence accuracy and surface finish. Modern practice relies on computer numerical control (CNC) machines—lathes, milling centers, drilling machines, and grinding machines—to achieve high precision and automation.

Quality aspects include dimensional tolerances, surface roughness, and geometric accuracy. Metrological techniques such as coordinate measuring machines and profilometry verify results. Materials processed include ferrous and nonferrous metals, alloys, and, with appropriate tooling, some plastics.

Applications span automotive, aerospace, machinery, and toolmaking. Environmental considerations include coolant management and chip handling, with trends toward dry or minimum-quantity lubrication and improved chip recycling.