Select key parameters of 2-axis precision cutting method

While producing metal bars, tubing, or extrusions with small tolerances and no burrs, precisely cutting to a target of a specific length may sound simple, the task can be extremely challenging. This is because the efficiency of any precision metal cutting method can vary greatly depending on the operation parameters and how well the method matches the job at hand - and the wrong decision can cost you time and money.

For non-burr, 2-axis cutting of metal parts, the top five methods are shear, cold saw, precision abrasive cutting, wire cutting, discharge machining and laser cutting. While there are other ways to separate metals, none of them are ideal for simple 2-axis cutoff (essentially the process of taking long and making it short). Even among the five preferred methods, there are pros and cons, depending on the job.

While metal cutting options vary in terms of characteristics and appropriate applications, the good news is that a clear and thorough understanding of several key parameters will help you successfully evaluate which 2-axis metal cutting method best meets your key requirements.

Choosing the right method should first consider the following parameters:

1. Part type

Consider whether the final component is bar, pipe, or extruded. Not all methods perform well in all part types, and it may be too late to discover until you've already normalized the process.

2. Material type

The efficacy of the first five cutting methods may vary depending on the hardness or softness of the metal being cut - for example, depending on whether you are cutting stainless steel, titanium, black alloy with high nickel content, Nitinol (e.g., Nitinol/NiTi) or tungsten.

3. Part size

In general, metal cut-off capacity is expressed as follows:

The length of the

Very short = less than 0.125" (3.175mm)

Short = 0.125" (3.175mm) to 1" (25.4mm)

Length = 1" (25.4mm) to 1' (304.8mm)

Very long = 1' to 6' (304.8mm to 1828.8mm)

size

Outside diameter from maximum 1" (25 mm) to minimum 0.001" (0.025 mm)

Tubing specific requirements, such as ID and wall thickness required for capillaries

Some methods have real limitations in part length. Imagine considering the consequences of a particular method that excels at one aspect of the specification but fails to produce the required length.

Also, depending on the part you need to produce, you may need to consider OD, ID and wall thickness. For solid components, only considering OD is relevant; However, for thin-walled parts requiring special cleaning, such as capillaries, some 2-axis cutting methods will not work.

4. Tolerances and slotting

Less is more when it comes to tolerances and cuts. Although the 2-axis cutting method is well suited to difficult tolerances, some methods are more effective in certain ranges. Slotting is also a consideration, as it can drive up material costs.

Simply put, the tighter the tolerance, the better, ideally equal to or less than +/- 0.005" (0.127mm). Again, the minimum number of slits is the goal.

5. Capacity, speed and cost

One of the most overlooked considerations in choosing a cutting method is the relationship between volume, speed and cost. By prioritizing properly, you can determine whether the approach is cost-effective for the number of parts required and the schedule/deadline.

Making the best choice is not an impossible task. But it does require a deep understanding of your unique application and its specific parameters, as well as a firm grasp of the different methods used to cut metal.

To learn more about the five most common 2-axis metal cutting methods and how to make the best choice for your specific application,

Please contact us at zhang@pride-cnc.com