Metal Machining

What is Metal Machining?
Machining is a subtractive manufacturing process that removes material from a workpiece to create a desired shape, size, and surface finish. Metal machining can produce simple to highly complex components with a high degree of precision and repeatability.
Modern machining is typically performed using computer numerical control (CNC), which precisely controls machine tools based on programmed instructions. CNC machining processes include milling, turning, drilling, Swiss machining, and micro machining.
How Does Metal Machining Work?
Machining uses cutting tools to selectively remove material from a metal workpiece. The appropriate machining process depends on factors such as part geometry, size, material, tolerances, and production requirements.
Milling uses rotating cutting tools to remove material from a stationary workpiece. It is commonly used to create flat surfaces, contours, pockets, slots, holes, and complex geometries.
Turning rotates the workpiece against a cutting tool and is commonly used to produce cylindrical components and features.
Drilling uses a rotating cutting tool to create round holes in a workpiece.
Swiss machining is a specialized form of CNC turning in which bar stock passes through a guide bushing that supports the workpiece close to the cutting tool. This reduces deflection and makes the process particularly well suited for small, slender, and complex precision parts. Swiss machines can combine turning with milling, drilling, and other operations to produce multiple features in a single setup.
Micro machining uses precision machining techniques to produce very small components or microscopic features. Specialized tooling and process control are used to achieve the dimensional accuracy and surface quality required at extremely small scales.
Other specialized machining methods include Electrical Discharge Machining (EDM), Electrochemical Machining (ECM), boring, broaching, reaming, and grinding.


Advantages of Metal Machining
Metal machining provides excellent precision and design flexibility across a wide range of part sizes, geometries, materials, and production quantities.
Advantages include:
High dimensional accuracy
Excellent repeatability
Complex geometries and fine features
Tight tolerances
High-quality surface finishes
Broad material compatibility
Ability to produce very small and intricate components
Suitable for prototypes through production quantities
Metal Machining Materials
Machining is used to manufacture a wide range of metal alloys and other materials, including:
Aluminum
Stainless Steel
Carbon Steel
Alloy Steel
Mild Steel
Hardened Steel
Titanium
Brass
Copper and Copper Alloys
Cast iron
Nickel Alloys
Cemented carbide
Material selection depends on the mechanical, environmental, thermal, electrical, weight, and cost requirements of the application. Machinability also varies by material and can influence tooling, production speed, achievable finish, and manufacturing cost.

Metal Machining Applications
Metal machining is used to manufacture precision components across nearly every industry.
Aerospace: Structural components, fittings, valves, fasteners, sensors, connectors, and precision mechanical components
Defense: Firearm receivers, triggers, hammers, ammunition feeding systems, missile structurals, rocket nozzle ejection systems
Industrial: Housings, pumps, valves, shafts, bushings, fittings, tooling, and automation components
Medical: Surgical instruments, implants, device components, miniature components, fittings, pins, and precision hardware
Technology: Housings, connectors, contacts, heatsinks, sensor components and miniature hardware
Transportation: Housings, shafts, valves, fittings, structural components, and other precision mechanical parts
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