The Art of Metal Fabrication: Techniques and Tools provides an overview of the tools and techniques used in the process of making metal. This includes topics such as CNC milling, deep drawing, welding, and extrusion.
Extrusion
Metal fabrication using the process of extrusion is an effective means of manufacturing complex shapes from metal bars. This is because the material is pushed through a die under tremendous pressure. The result is an elongated grain structure, which gives the material greater mechanical strength.
Depending on the type of extrusion, the cross section of the final product can be relatively large or small. The length of the product can also be relatively long or short.
The starting work is usually a round billet. It is then heated in a controlled atmosphere furnace. It can be shaped into different shapes through continuous casting. This allows the raw material to be finished and ready for service.
Extrusion can produce parts with a good surface finish. However, the process can lead to defects. A good way to minimize these defects is to take the proper precautions.
For example, the use of a lubricant such as oil helps to keep the materials from slipping and moving. Impurities on the surface of the billet can find their way into the extruded product. This can lead to a poor overall aesthetic.
The process of extrusion is typically used in applications where the shape of the part must be fixed. This is especially beneficial for parts with complex cross-sectional profiles. It can also be useful for parts with undercuts, grooves, and T-slots.
The most common extrusion processes are hot and cold. The choice of temperature affects the extrusion ratio and the length of the product. The amount of material in the billet can also influence the extrusion ratio.
The extrusion process can be used to produce a number of materials, including copper, steel, aluminum, concrete, and polymers. The process is also capable of producing metal tubes and pipes.
Forging
Metal forging is one of the oldest metal working processes. It involves heating the metal to a high temperature in order to change its physical properties. This process gives rise to stronger parts. Forged parts are also more durable than cast parts.
Today, forging is often used in metal part manufacturing. However, it is not the most economical process for short production runs. The cost of furnaces, machinery, and dies can be high.
In addition, the quantity of metal in the workpiece needs to be carefully controlled within extremely narrow limits. This ensures that the forged object is reliable for critical applications.
There are several types of forging techniques. Each has its own benefits and disadvantages. For example, hot forging is more flexible than cold forging.
Cold forging requires less heat and is less ductile. However, the forged part has a smooth surface finish. The parts are also a less expensive option.
Depending on the type of metal, forging can be performed at various temperatures. Forging is usually the optimum process for parts that are critical to performance. Forging can produce a variety of shapes, including near net, seamless, and roll ring forms.
Forging can be done using a wide range of materials, including carbon steel, alloy steel, and titanium. Compared to machining, forging has higher fatigue strength and creep resistance. It can also be applied to a variety of different applications.
During forging, the grain structure of the metal is restructured. This improves the strength of the forged part and the yield strength. It is also an effective process for reducing the hardness of the metal.
Forging is commonly used to produce large equipment and parts. It can produce pieces that weigh ounces to 60,000 pounds.
Deep Drawing
Deep Drawing is a forming process used to produce parts in metal. The process is similar to metal stamping, but differs in several ways. Its main advantage is that it requires fewer stages to produce a finished product. It is ideal for making small component parts, such as kitchen sinks or aluminum cans. It also is useful for assembling housings and containers.
The first step is to determine the appropriate shape for the part. This can be done by studying the material. It can be determined by its properties and the forces that are involved in the formation of the part wall. The best shape will depend on the type of material and the amount of force required to draw the part.
The next step is to calculate the optimum blank size. This is done by studying the thickness, thinning, and the flow of the material. In addition, the optimum sheet thickness may vary according to the type of lubrication and the temperature of the tool.
The lubrication of the tool and the working material will help reduce friction. This reduces the force that is required to draw the sheet metal and improves the surface finish of the finished part. Various types of lubricants are available, including soap, oils, heavy duty emulsions, and wax films.
The corners of the blank are important because they affect the flow of the metal. If the corner is too sharp, it can cause the material to tear or start tearing at a different location. The radius on the edge is another important feature of the deep drawing process.
During the process, the flow of the metal will increase in the corner region of the blank. However, if the blank is not square, the flow of the metal will be uneven and it will not be able to be drawn as well.
CNC milling
In metal fabrication, CNC milling can be a useful tool for producing parts in a faster, more precise, and more efficient way. The process involves using several different types of cuts to remove material from a workpiece.
Most milling operations include a few main steps. The first of these is a roughing operation. This involves cutting round inserts to rough the surface of the part. The second is a finishing operation. This includes the application of a surface finish such as anodizing.
The third is a turning operation. This creates grooves or helical paths in the workpiece. It also helps to prepare the piece for welding. The last is a semi-finishing operation. This uses dovetail cutters and conical cutting heads.
A wide or narrow cutter can create a faster or slower feed rate. This will have an effect on the height of the ridges and the finish of the final product. Depending on the application, a broader or finer toothed cutter may be more appropriate.
The process of milling requires many tools. Each tool is designed to perform a specific task. These tools have a certain number of cycles and must be replaced before they can be used again.
Some of these tools are dovetail cutters, conical cutting heads, and side milling cutters. Each of these tools has its own benefits and drawbacks. The conical cutters can produce a round edge and round recesses. They are ideal for finishing applications.
In addition to these tools, a number of auxiliary equipment is available to support opposing processes. These include a two-machine stand, which allows simultaneous processing of parts. This reduces tool collisions, increasing productivity. The machine interface can also be used to load a CNC machine program. Smart Steels has your back if you need a bespoke steel fabricator.
Welding
Welding is a process of attaching two metals together. The process includes applying heat to form a fusion between the two parts. It is an important part of metal fabrication.
There are several types of welding processes. Each is effective for specific applications. However, there is no single welding technique that is suitable for all applications.
One of the oldest methods of welding is spot welding. This is typically used for thin metals such as copper. The weld current is concentrated at a small spot. This helps to prevent unnecessary heating to the rest of the metal sheet.
Another common type of welding is metal inert gas (MIG) welding. This process is particularly effective on silicon bronze, magnesium, and stainless steel. It produces a neat, tidy weld. It also requires the use of a shielding gas.
Using quality welding techniques is crucial to ensure that the parts are assembled correctly. It helps to protect the workers involved, and it can help to ensure that consumers are satisfied with the product. A poorly-made weld can cause damage to the product, which could lead to breakage or even damage to the consumer.
In addition to the welding process, there are other processes that go into the creation of a finished product. Some of these include drilling, honing, milling, and grinding. Each process can be done manually or robotically. The final product may be a simple cookie cutter, or it can be an elaborate piece of furniture.
For a more decorative finish, it is usually necessary to have full welds on all of the seams. In addition to this, the welded parts will have to be cleaned, and any solvent or grease will be removed.
