What is metal processing - Metals and their processing

Metal processing using modern technologies

Despite the emergence of new innovative materials, metal remains the basis of industry and construction. New mechanical engineering technologies make it possible to develop new methods of metal processing, which is the main task of technologists and designers. Metal processing using new technologies is carried out in order to improve quality, increase processing accuracy, productivity and reduce waste.

There are three main areas of metal processing:

Shaping using high-precision plastic deformation methods.
The use of traditional methods of metal processing, but characterized by increased accuracy and productivity.
Use of high energy methods.

The choice of the optimal metal processing method is determined by production requirements and serial production.

For example, very heavy equipment designs cause increased energy consumption, and reduced manufacturing accuracy of individual parts and assemblies leads to low equipment productivity. Some technologies cannot provide the necessary strength properties and microstructure of the metal, which ultimately affects the durability and resistance of parts, even if manufactured with minimal tolerances.

New metal processing technology is based on the use of non-traditional energy sources that provide its dimensional melting, evaporation or shaping.

Turning and milling of metals

Mechanical processing of metal, associated with the removal of chips, is developing in the direction of manufacturing particularly high-precision products, mainly in small-scale production. Therefore, traditional machines are giving way to quickly reconfigured metalworking complexes with CNC (Computer Numerical Control).

Numerical Program Control - a machine operating on numerical program control is capable of performing certain actions that are assigned to it using a special program. The operating parameters of the machine are set using numbers and mathematical formulas, after which it performs the work according to the requirements specified by the program.

The program can set parameters such as:

power;
speed of work;
acceleration;
rotation and much more.

The relatively low coefficient of material utilization (during machining it rarely exceeds 70-80%) is compensated by minimal tolerances and high quality of the finishing surface of products.

Manufacturers of numerical control systems place the main emphasis on the expanded technological capabilities of the equipment in question, the use of modern high-resistant tool steels and the elimination of manual operator labor. All preparatory and final operations on such complexes are performed by robotics.

Energy-saving methods of plastic deformation of metals

The technology of metal forming, in addition to the increased utilization of metal, has other significant advantages:

As a result of plastic deformation, the macro- and microstructure of the product improves;
The productivity of stamping equipment is several times higher than that of metal-cutting machines;
After pressure treatment, the strength of the metal increases and its resistance to dynamic and impact loads increases.

Progressive processes of cold and semi-hot stamping - mandrel, precision cutting, extrusion, ultrasonic processing, stamping in a state of superplasticity, liquid stamping. Many of them are implemented on automated equipment equipped with computer monitoring and control systems. The precision of manufacturing stamped products in many cases does not require their subsequent finishing - straightening, grinding, etc.

High-energy methods for forming metals

High-energy metal processing technologies are used in cases where it is impossible to change the shape and dimensions of a metal workpiece using traditional methods.

Four types of energy are used:

Hydraulic - the pressure of a liquid or individual elements driven by it.
Electric, in which all processes of material removal are carried out using a discharge - arc or spark.
Electromagnetic, which implements the process of metal processing when the workpiece is exposed to an electromagnetic field.
Electrophysical, acting on the surface with a directed laser beam.

Combined methods of influencing metal, in which two or more energy sources are used, also exist and are being successfully developed.

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Waterjet machining of metals is based on the surface action of a high-pressure liquid. Such installations are used mainly to improve the quality of the surface, remove micro-irregularities, clean the surface from rust, scale, etc.

In this case, the liquid jet can affect the product both directly and through abrasive components located in the flow. The abrasive contained in the emulsion is constantly renewed to ensure consistency of the results obtained.

Electrical discharge machining of metals is a process of dimensional destruction (erosion) of a metal surface when exposed to a pulse, spark or arc discharge.

The high density of the volumetric thermal power of the source leads to dimensional melting of metal microparticles with their subsequent removal from the processing zone by the flow of the dielectric working medium (oil, emulsion).

Since during metal processing processes of local heating of the surface to very high temperatures simultaneously occur, as a result, the hardness of the part in the processing zone increases significantly.

Magnetic-pulse metal processing involves placing the workpiece in a powerful electromagnetic field, the force lines of which act on the workpiece placed in a dielectric.

In this way, low-plasticity alloys (for example, titanium or beryllium), as well as steel sheets, are formed. Ultrasonic waves generated by magnetostrictive or piezoelectric frequency converters act in a similar way on the surface.

High-frequency vibrations are also used for surface heat treatment of metals.

The most concentrated source of thermal energy is a laser. Laser metal processing is the only way to produce ultra-small holes of increased dimensional accuracy in workpieces. Due to the direction of the thermal action of the laser on the metal, the latter in the adjacent zones is intensively strengthened. The laser beam is capable of producing dimensional firmware of such refractory chemical elements as tungsten or molybdenum.

Electrochemical processing of metal is an example of the combined effect on the surface of chemical reactions that occur when an electric current passes through the workpiece.

As a result, the surface layer is saturated with compounds that can only form at elevated temperatures: carbides, nitrides, sulfides.

Similar technologies can be used to perform surface coating with other metals, which is used for the production of bimetallic parts and assemblies (plates, radiators, etc.).

Modern metal processing technologies are continuously improved, using the latest achievements of science and technology.

Source: http://new-technologi.ru/obrabotka_metalla/

Chemical processing of metals

To achieve certain goals, in particular before painting, metals are subject to various treatments, among which chemical is especially popular (there are also mechanical and thermal). Since almost every metal is capable of rusting, and rust is a real disease of metal products that worsens their properties, it is important to promptly rid their surfaces of signs of rust. This will extend the life of equipment and tools.

Chemical processing of metals is a variety of processes designed to remove a layer of material from a metal surface through a series of chemical processes. reactions, and also create a protective layer.

Special solutions promote the formation of oxide and other compounds. As a result, a film appears, the quality of which depends on many factors, including: chemical.

composition of the solution, processing temperature, duration of exposure of the solution to the metal, as well as the degree of pre-processing preparation of the product.

Purpose of chem. processing – increasing strength characteristics + corrosion protection, and thus increasing the service life of equipment/products. It is often used when repairing the technical base of an enterprise.

Main advantages:

– significant productivity due to the efficiency of chemical reactions;

– availability of processing of viscous and hard materials;

– absence of unnecessary influences on the metal (mechanical/temperature).

Methods of chemical processing of metals

There are several of them. You need to choose one that suits best in a particular case. It is worth considering that different methods require different equipment and tools.

Among the main methods are the following:

– spraying (exposure to metal with a jet of solution under low pressure). The best technology option is dead-end/pass-through mechanisms, due to the high level of operating time. At the same time, pass-throughs are characterized by the highest productivity.

Special units can process without interrupting work. Preference is given to one type of conveyor both during preparation and directly when performing the main task.

In order for the result to be of the highest quality, it is permissible to limit the speed of movement of the device;

– immersion (position of the metal in a specially prepared solution for a certain time). Here, for preparation, you will need equipment, the working space of which looks like separate containers arranged in a clear order. It must be equipped with mixers, tubular connections leading to the drying compartment, and a conveyor;

– steam treatment, or steam jetting (exposure to vapor of the required concentration). This method is used, as a rule, for painting large mechanisms and when organizing production areas is not possible.

Here, manual processing takes place using a cleaning barrel and using equipment (mobile or stationary). It is important to thoroughly clean the surface of grease beforehand. A parallel process is amorphous phosphating of the base. Suitable temperature is 140 °C.

During the work, additional use of chemicals is possible. components;

– hydroblasting (using appropriate units).

Particularly in demand at metallurgy, mechanical engineering enterprises, etc. uses the deep etching method (chemical milling) . It is preferable for products with complex surface shapes, made from thin metal, and when many small parts need to be processed.

Other methods: oxidation (forming a protective oxide film), anodizing (electrochemical oxidation of aluminum), bluing (applying an oxide film to steel), galvanizing (making a zinc protective layer), as well as fluoridation, chrome plating, nitriding, etc. At the same time, new, more progressive chemical methods are constantly appearing. metal processing.

Which method is better in a particular situation depends on production standards and areas, the configuration and dimensions of the parts being processed, the individual characteristics of the company’s working departments, etc. Whichever method is chosen, it must be preceded by preparatory work, for example: degreasing, sanding, priming, etching with chromites. They can be carried out using special chemical installations preparation.

Chemistry for metal processing

To accomplish this task, various chemicals may be needed. The main ones are acids, mainly phosphoric, hydrochloric and sulfuric. They effectively clean surfaces and eliminate corrosion. They are used, as a rule, in diluted form and together with a corrosion inhibitor - methenamine . Depending on the size of the surface covered with rust, acids can be applied using a brush or spray.

All chemicals treatments belong to one of two types: rinse-off or leave-on. The first one is quite effective, but has one drawback. After treatment, such products are washed off with water, and because of this, rust can be replaced by corrosion.

To prevent this from happening, immediately after using water the metal must be dried and treated with an anti-corrosion agent.

When using leave-in substances, when there is no need to additionally use water, plus the high efficiency is added convenience, eliminating the waste of additional time, the implementation of auxiliary processes and the cost of post-processing products.

Orthophosphoric acid. A solution of this substance is especially effective for processing metals, and therefore is used most often. Its working concentration is usually 15-30%. It transforms rust on metal into a durable coating.

To improve the effect, orthophosphate acid can be combined with butanol or tartaric acid . The positive effect is realized through the formation of iron orthophosphate on the surface, creating a brown protective coating.

Sulfuric acid and hydrochloric acid , or rather their 5% solutions with water, belong to the group of indelible substances. They are also effective, but their use without methenamine is not recommended. Otherwise, not only the rust will be corroded, but also the metal surface itself. Sulfate acid is particularly effective in removing oxides from steel, zinc and silver.

In addition, lactic acid in combination with petroleum jelly . This mixture works on a very simple principle: rust turns into salt, which is then dissolved by oil. Please note that with this processing method, the surface will need to be wiped when the reaction is complete.

Zinc sulfate. This substance is the most important participant in a process such as galvanizing. The optimal concentration is 200-300 g/l. Work must be carried out at room temperature.

To improve the structure of the coating, you can additionally use salts such as sodium sulfate (to increase electrical conductivity), aluminum sulfate (to stabilize pH) and other substances.

To further increase protection and presentation after galvanizing, chromate plating is carried out in solutions with chromates and dichromates. Typically, this is sulfuric acid + chromic anhydride . Although the composition of the solution may be different and depends on the electrolyte in which the zinc was deposited. The result of such actions is a passive film on the metal surface.

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Reagents for metal processing

When metalworking you will also need some other reagents. What and why you need, read on.

Zinc chloride. Acid treatment can cause gray stains on the metal. To get rid of them, you need to use a zinc chloride solution. Place the part in it, then take it out, heat it a little until it dries and rinse with water. As a result of such simple manipulations, gray spots will be removed, and the surface will become completely clean.

Nitric acid. Can be used as a supplement when cleaning copper, bronze and brass with concentrated H2SO4. Also useful for making the surface matte. To do this, take a complex of nitric and sulfuric acids, plus table salt and zinc sulfate. The longer the metal remains in such a solution, the more matte its surface will be. After placing the product in it, it must be rinsed well and promptly dried, for example, in sawdust.

Concentrated nitric acid with pine soot in a small volume is an excellent way to rid iron and steel oxides. Here you will need a double immersion in the solution with intermediate rinses.

This acid also removes the copper layer from zinc products.

In addition, when processing metals, various sodium compounds may be needed: sodium benzoate , sodium nitrite , sodium bicarbonate and other reagents.

In order for the chemical processing of metals to lead to the desired results, it is important to have a good understanding of the specifics of working with certain materials. Chemicals and reagents must not only be suitable, but also of high quality. Therefore, it is best to purchase from reliable companies.

If you need any of the above chemicals or need other chemical components. processing of metal surfaces, please contact us! Our specialists will provide all the necessary information about the product and organize fast delivery to any region of Ukraine!

Source: https://www.systopt.com.ua/ru/hymycheskaya-obrabotka-metallov/

Metal processing

Metals and their alloys have long been used by humans to make tools and weapons, jewelry and ritual objects, household utensils and machine parts.

To turn metal ingots into a part or product, they need to be processed, or their shape, size and physical and chemical properties must be changed. Over several millennia, many methods of metal processing have been developed and fine-tuned.

Metal processing

Features of metal processing

Numerous types of metalworking can be classified into one of the large groups:

mechanical (cutting);
casting;
thermal;
pressure;
welding;
electric;
chemical

Casting is one of the most ancient methods. It consists of melting metal and pouring it into a prepared mold that repeats the configuration of the future product. This method produces durable castings of various sizes and shapes.

Other types of processing will be discussed below.

Welding

Welding has also been known to man since ancient times, but most of the methods were developed in the last century. The essence of welding is to connect the edges of two parts heated to the plasticity temperature or to the melting temperature into a single integral whole.

Depending on the method of heating the metal, several groups of welding technologies are distinguished:

Chemical. The metal is heated by the heat released during the chemical reaction. Thermite welding is widely used in hard-to-reach places where it is impossible to supply electricity or haul gas cylinders, including under water.
Gas. The metal in the welding zone is heated by the flame of a gas burner. By changing the shape of the torch, you can carry out not only welding, but also cutting of metals.
Electric welding. The most common way:
- Arc welding uses the heat of an electric arc to heat and melt the work area. Special welding machines are used to ignite and maintain the arc. Welding is carried out using spatter electrodes or special welding wire in an atmosphere of inert gases.
- In resistance welding, heating is carried out by a strong electric current passing through the point of contact of the workpieces being joined. There are spot welding, in which parts are connected at individual points, and roller welding, in which a conductive roller rolls along the surface of the parts and connects them with a continuous seam.

Arc welding

Welding is used to connect machine parts, building structures, pipelines, ship and car hulls, and much more. Welding goes well with other types of metal processing.

Electrical processing

The method is based on the partial destruction of metal parts under the influence of high-intensity electrical discharges.

It is used for burning holes in thin sheet metal, when sharpening tools and processing workpieces made of hard alloys. It also helps to remove a broken or stuck tip of a drill or threaded tap from a hole.

A graphite or brass electrode, to which high voltage is applied, is brought to the processing site. A spark jumps, the metal partially melts and spatters. To trap metal particles, the gap between the electrode and the part is filled with special oil.

Ultrasonic metal processing

Electrical methods of metal processing also include ultrasonic. High intensity vibrations with a frequency of over 20 kHz are excited in the part. They cause local resonance and point destruction of the surface layer; the method is used for processing durable alloys, stainless steel and jewelry.

Artistic types of metal processing include casting, forging and embossing. In the middle of the 20th century, welding was added to them. Each method requires its own tools and devices. With their help, the master either creates a separate work of art, or additionally decorates a utilitarian product, giving it aesthetic content.

Artistic embossing

Embossing is the creation of a relief image on the surface of a metal sheet or the finished product itself, for example, a jug. Embossing is also done on heated metal.

Methods of mechanical processing of metals

A large group of methods for machining metals have one thing in common: each of them uses a sharp and hard tool in relation to the workpiece, to which mechanical force is applied. As a result of the interaction, a layer of metal is separated from the part, and its shape changes. The workpiece exceeds the dimensions of the final product by an amount called “allowance”

There are such types of mechanical processing of metals as:

Turning. The workpiece is fixed in a rotating tooling, and a cutter is brought to it, removing a layer of metal until the dimensions specified by the designer are reached. Used for the production of parts shaped like a body of revolution.
Drilling. A drill is immersed into a stationary part, which quickly rotates around its axis and is slowly fed towards the workpiece in the longitudinal direction. Used for making round holes.
Milling. Unlike drilling, where processing is carried out only with the front end of the drill, the side surface of the cutter is also working, and in addition to the vertical direction, the rotating cutter moves both right and left and back and forth. This allows you to create parts of almost any desired shape.
Planing. The cutter moves back and forth relative to the stationary part, each time removing a longitudinal strip of metal. In some machine models, the cutter is fixed and the part moves. Used to create longitudinal grooves.
Grinding. The processing is carried out by rotating or performing longitudinal reciprocating movements with an abrasive material that removes thin layers from the surface of the metal. It is used for treating surfaces and preparing them for coating.

Metal grinding

Each operation requires its own special equipment. In the technological process of manufacturing a part, these operations are grouped, alternated and combined to achieve optimal productivity and reduce intra-shop costs.

Pressure treatment

Metal forming is used to change the shape of a part without compromising its integrity. The following types exist:

Before forging, the workpiece is heated, supported on a hard surface, and a series of blows are applied with a heavy hammer so that the workpiece takes the desired shape.

Historically, forging was done by hand; the blacksmith heated the piece in the flame of a forge, grabbed it with tongs and placed it on an anvil, and then hit it with a smith's hammer until a sword or horseshoe was made.

A modern blacksmith acts on a workpiece with a hammer from a forging press with a force of up to several thousand tons. Billets up to tens of meters long are heated in gas or induction furnaces and fed to the forging plate by transport systems.

Instead of a hand hammer, forging dies made of high-strength steel are used.

Forging

For stamping, two forms are required that are mirrored in relation to each other - a matrix and a punch. A thin sheet of metal is placed between them, and then moved with great force. The metal, bending, takes the form of a matrix. For large sheet thicknesses, the metal is heated to the point of plasticity. This process is called hot stamping.

During stamping, operations such as:

flexible;
pulling;
settling;
and others.

Stamping is used to produce a wide range of products - from household appliance housings to wheel rims and gas tanks.

Processing by cutting

The metal is supplied to the enterprise in the form of rolled products - sheets or profiles of standard sizes and thicknesses. To separate a sheet or profile into products or blanks of the required size, cutting processing is used.

For profiles, cutting with an abrasive wheel or circular saw is most often used.

Several types of cutting are used for cutting metal sheets:

Manual. A gas welder with a gas torch cuts out pieces of metal of the required size and shape. It is used in small workshops and pilot production.
Gas. The gas cutting installation cuts with the flame of an automated gas burner and allows you not only to quickly cut sheets, but also to arrange the cut pieces into containers for delivery to assembly areas
Laser. Cuts metal with a laser beam. It features high accuracy and low waste ratio. In addition to cutting, it can perform welding and engraving operations - applying permanent inscriptions to metal.
Plasma. Cuts metal with a torch of highly ionized gas - plasma. Used for cutting sheets of hard and special alloys.

Laser cutting

In conditions of industrial production and medium or large series, the concept of metal utilization rate comes to the fore. It is increased both due to a denser arrangement of parts over the area and due to advanced cutting technologies that produce less waste

Chemical processing of metals to increase the protective properties of the material

Chemical treatment of metal is the action of special substances on it in order to cause a controlled chemical reaction.

They are performed both as preparatory operations to clean the surface before welding or painting, and as finishing operations to improve the appearance of the product and protect it from corrosion.

Metal galvanizing

Protective coatings are applied using electrochemical treatment using the galvanic method.

Thermal types of metal processing

Heat treatment of metals is used to improve their physical and mechanical properties. This includes operations such as:

annealing;
hardening;
vacation;
aging;
normalization.

Heat treatment of steel

Heat treatment involves heating a part to a certain temperature and then cooling it according to a special program.

Annealing

The workpiece is heated to the plasticity temperature and slowly cooled directly in the furnace.

Annealing reduces the hardness of steel, but significantly increases ductility and malleability.

Annealing

Used before stamping or rolling. During annealing, internal stresses that arise during casting or machining are relieved.

Hardening

When hardening, the workpiece is heated to the plasticity temperature and kept in this state for a certain time, during which the internal structures of the metal are stabilized. Next, the product is quickly cooled in a large amount of water or oil. Hardening significantly increases the hardness of the material and reduces its impact strength, thereby increasing brittleness. Used for structural elements subject to large static and small dynamic loads.

Vacation

Carried out after hardening. The sample is heated to a temperature slightly lower than the quenching temperature and cooled slowly. This allows you to compensate for the excessive fragility that appears after hardening. Used in tool production

Aging

Artificial aging involves stimulating phase transformations in the metal mass. It is carried out with moderate heating to give the material properties that arise during natural aging over a long time.

Normalization

Normalization is carried out to increase ductility without a noticeable decrease in hardness due to the steel acquiring a fine-grained structure.

It is used before hardening and to increase machinability by cutting. It is carried out in the same way as annealing, but the workpiece is cooled in the open air.

Source: https://stankiexpert.ru/tehnologii/obrabotka-metalla.html

What is metalworking

To create various parts, structures and assemblies, the metal must undergo a processing process. We can say that this is a rather complex technological process, which includes a number of nuances and features.

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All this is called in one simple word - metalworking. The concept includes all complexes of work with this material: from volumetric parts for ships to elements for jewelry.

Metalworking

A service such as custom metalworking is quite popular today. Various industrial enterprises, mechanical engineering companies and construction organizations turn to it.

There are several main types of this direction, namely:

mechanical. This processing involves the use of various technological methods and methods to finish the material;
turning. The main purpose of this type is to remove the technological layer for further work with metal;
milling view. Using this method, you can give the material the desired shape;
grinding. This is a technological operation that is used for finishing metal with various qualities and properties.

There is a separate type called stamping. In this case, we are talking about plastic deformation, which includes a change in the shape and size of the product.

Basically, two main types of stamping are used: sheet and volumetric. In the first case, work with the material occurs under high pressure, which is performed exclusively in a cold state.

The second option involves a process with simple volumetric blanks. These elements are transformed into more complex ones for use in industrial work.

Benefits of metalworking

Custom metalworking has many advantages, which is why it is in high demand. This process can be performed by a company that supplies metal, or by specialized enterprises working in this area.

Purchasing ready-made parts is not always profitable, as the cost can be very high. In this case, you can turn to the processing option.

There are also parts that cannot be purchased in a store. There are many cases when some important element has to be made to order.

If you need goods in large quantities (for example, for work), then with the help of modern equipment everything will be done in a short time.
Small parts can also be ordered from metalworking companies. One of the metalworking lessons is shown in the video:

Source: http://postroyka.org/chto-takoe-metalloobrabotka/

Methods and types of mechanical processing of metals

[Metal machining] is a necessary process before a metal part can be used.

There are different ways to work with different types of metals - they all have their pros and cons and can be used in different situations depending on your goals.

From the article you will learn what mechanical processing of metals is, and what types of it exist, and you will be able to choose which procedure for working with metal is required for you.

Pressure Treatment Options

There are only two options for finishing metal parts: this can be done by pressure or by cutting.

Most often it is used when it is necessary to give a metal sheet a shape, or in the process of creating parts from long rolled metal.

This method of influence includes the following types of work: bending, stamping, upsetting, etc. Below we will consider various methods of influencing metal using pressure in more detail.

Manual hot forging is often used to process non-ferrous metals.

To carry it out, the material is preheated to a temperature exceeding its recrystallization, and then it is given the desired shape.

To do this, use the simplest tools: a hand hammer or hammer. The degree of heating of a material depends on its properties: how much carbon it contains.

The lower this value, the higher the operating temperature should be.

Such mechanical finishing of different types of metals is considered quite effective, since it makes it possible to create solid parts of high strength without losing the natural properties of the material.

There is also a more advanced method - a mechanical method of hot processing.

In this case, the material is also heated to the desired temperature, but the effect is carried out using a special device.

Mechanical forging can be free or done using a forging die.

In the first case, the impact on the metal coating occurs with the help of an anvil and a hammer, which is used to act on the metal.

Another option is when the metal is exposed to a special press, which gives it the desired shape.

Both the hammer and the press are mechanical devices, but the first gives the workpieces the desired shape by blows, and the second uses pressure.

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The hammer device can be steam, steam-air, falling with a friction disk or spring.

The press can be hydraulic, steam-hydraulic, screw, friction, eccentric, crank or spring.

Hammering is used less frequently because it is very noisy and less efficient and is used only in large industries.

In addition to hot impact, there is also cold impact - it is used more often because it is capable of giving workpieces made of non-ferrous and ferrous metals the desired shape without affecting its physical characteristics.

Unlike hot exposure, with the cold method there is no need to heat the surface - all work is done at room temperature.

The cold method of influence is called stamping, it is divided into different types. Stamping can be single or multi-operational, depending on the functions of a particular device.

Work with the material can be carried out either while maintaining a continuous coating or with its division - this also depends on the type of device with which the workpiece is given the desired shape.

The most popular types of cold pressing are the following: impact by bending, stretching, crimping, molding, buckling or beading.

Bending allows you to change the axial shape of a part; it is done using a special vice that is installed on bending dies and presses.

Using extrusion, you can make parts of complex shapes. For this type of work, a pressing machine is required.

With the help of crimping, the cross-section of a hollow part is reduced, and molding allows you to turn the workpiece into a part that has a spatial shape.

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This type of processing requires drawing dies or special forming dies.

When bulging, the workpiece also takes on the appearance of a spatial shape, and when beading, sides and other additional elements are created on the part.

Casting

The essence of the method is that molten metal is poured into pre-prepared molds. The resulting part is called a casting.

The casting production process consists of the following basic steps:

Preparation of mixtures.
Production of casting molds and cores.
Assembly and pouring.
Removing castings from molds and subsequent processing.

Casting is used to produce a wide range of parts - equipment frames, cylinder blocks, heating radiators and others.

For the manufacture of castings, cast iron, steel, and non-ferrous metals are used. Most often from the above list, cast iron casting alloy is used. This is the cheapest material and has a low melting point.

The mold for making the casting is assembled from molding earth or using a flask made of metal or wood.

The development of foundry is constantly evolving and the number of technologies is growing, in particular, methods such as pressure casting, chill casting, and lost wax molds are widely used. This makes it possible to obtain castings that do not require further processing, and this leads to a reduction in the cost of the finished product.

Mechanical restoration

The main importance of this work is to obtain by drawing the shape, dimensions and surface cleanliness of the part. During the processing process, several layers of metal (allowance) are removed from the part. Forgings, castings, etc. act as blanks.

Machining in the form of cutting is the most common type of mechanical processing of metals in the manufacture of parts. Processing is performed during the movement of the working tool and the part during which chips are removed from the surface of the part.

Metal-cutting equipment is divided into classes determined by the processing method. Use the following types of machines in the production of products:

Lathe-screw-cutting machines, designed for work related to the processing of parts of rotating bodies (cylinders, cones), making and boring holes, and producing threads. Such machines operate almost the entire range of manufactured tools, for example, boring cutters.
Drilling, they are used to produce holes of different diameters in products, processing edges, and cutting threads.
Milling, they are used for processing surfaces to obtain complex shapes, etc.

In addition to the above types of equipment, planing, grinding and many other types are also used.

Nowadays, both manual and fully automatic machines are used, which operate under numerical control. Recently, a lot of equipment has been produced that allows you to perform both turning of rotating bodies and milling in one installation of the workpiece.

Electrical treatment

Metals are processed using electricity. There are two main methods - electric spark and ultrasonic.

The first one is used for making holes of different shapes, sizes and complexity in the body of the part. This technology is used for the production of tools, in particular, molds and dies.

The second method is used when working with high-alloy steels, hard alloys, etc. In particular, its use allows you to clean the surface of the part from traces of corrosion, oils, etc.

Each metal processing method has many varieties and requires the use of appropriate equipment, tools and equipment.

Source: https://prompriem.ru/metalloobrabotka/vidy.html

Types of metal processing

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Metalworking methods differ in the technologies and equipment used. The main types of processing methods include:

mechanical method - processing by pressure and cutting;
thermal;
art;
welding;
electric;
turning;
casting.

Metal forming – plastic changes in the dimensions and shape of a product using the deformation process. With this method the following changes occur:

the structure of the material improves;
the physical and mechanical properties of the workpiece are increased;
chemical heterogeneity of the alloy is eliminated;
shrinkage porosity is reduced;
the material becomes durable and elastic.

The metal is processed depending on the technology used. The main methods of pressure treatment are presented in the table:

Metal cutting

Machining of workpieces by cutting is a technological process for the production of various equipment parts using cutting tools. After cutting off the top layer of material, a workpiece of a given accuracy, geometric shape, and roughness is obtained. Metal-cutting machines are used to remove layers. The material for the workpieces is rolled sections of non-ferrous and ferrous metals.

Metal processing using various methods is used to produce parts and blanks used in mechanical engineering, automotive, aviation and other industries.

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Metal processing: 5 basic methods

People used some relatively simple methods of metal processing back in ancient times. It was metal and all the new methods of processing it that became the key to technical progress. Now we know so many different methods that it is very easy to get confused. Let's try to briefly and clearly break everything down.

The main metalworking methods include:

Casting;
Heat treatment;
Pressure treatment;
Welding;
Electrical processing.

The metalworking process is unique for each method. Moreover, each method has its own variations.

Heat treatment

This method is aimed at changing the internal structure of the metal, which is achieved by heating the metal, followed by aging and cooling. To give the metal the desired properties, the heat treatment parameters can be different. Heating temperature, holding the metal in a heated state and cooling rate - all these parameters affect the final properties of the metal.

There are 3 types of heat treatment:

Heat treatment - there are three main types: annealing, hardening and tempering;
Chemical-thermal treatment of metal - used to saturate the metal surface with other elements (for example, carbon). With this method, the highest heating temperatures of metals and significant holding periods are observed to give the alloy homogeneity;
Thermo-mechanical treatment - this method allows you to achieve better mechanical properties of the metal than classical heat treatment.

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What technologies are used in metal processing

Man has been working with different types of metals for a long time. Most often, these are durable materials that require a special approach when changing shape and size. Metal processing is carried out on different machines and using different techniques.

Basic processing methods

The basics of metalworking are necessary for any novice craftsman and foundry worker to know. Knowing how certain metals behave under different processing methods, you can avoid mistakes when carrying out the technological process.

Modern metalworking includes several main areas of processing:

Electric. Using this method, you can make holes in metal sheets for sharpening tools and working with hard types of steel.
Mechanical. An extensive group of methods for processing metal workpieces. They are processed using special equipment.
Chemical. Creating an artificial chemical reaction using acids, alkalis and other components.
Working with pressure. In order not to violate the integrity of the workpiece and change its shape, equipment is used that creates powerful pressure. To change the shape of a workpiece made of hard steel, the material is initially heated.
Thermal. To improve the technical characteristics of the material, various methods of temperature processing of workpieces are used.

Metalworking technology is developing and improving every year. New equipment and options for working with metals are emerging.

What determines the type of processing?

Types of metalworking involve different ways of working with metals. Each method is selected depending on the hardness of the material and its other characteristics. This is also influenced by what needs to be done with the workpiece. For example, heat treatment is used to change the technical characteristics of a material. To change the shape of the workpiece, a mechanical method or injection pressure equipment can be used.