Ervin Orlando Mndez Guerra 2011-13790

Mirna Cecilia Hernndez Rosales 2011-14578

Object
Know the meaning of metalworking
Identify the categories in which splits metalworking.
Conclusion
Metalworking in the process of working with metals to create individual parts,
assemblies, or large scale structures.
Forming, cutting and joinig.

Metalworking
Metalworking is the process of working with metals to create individual parts,
assemblies, or large scale structures. The term covers a wide range of work from
large ships and bridges to precise engine parts and delicate jewelry. It therefore
includes a correspondingly wide range of skills, processes, and tools.
Metalworking is a science, art, hobby, industry and trade. Its historical roots span
cultures, civilizations, and millennia. Metalworking has evolved from the discovery
of smelting various ores, producing malleable and ductile metal useful for tools and
adornments. Modern metalworking processes, though diverse and specialized, can
be categorized as forming, cutting, or joining processes. Today's machine shop
includes a number of machine tools capable of creating a precise, useful
workpiece.
Metalworking generally is divided into the following categories, forming, cutting,
and, joining. Each of these categories contain various processes.
Prior to most operations, the metal must be marked out and/or measured,
depending on the desired finished product.

Marking out is the process of transferring a design or pattern to a workpiece and is

the first step in the handcraft of metalworking. It is performed in many industries or
hobbies, although in industry, the repetition eliminates the need to mark out every
individual piece. In the metal trades area, marking out consists of transferring the
engineer's plan to the workpiece in preparation for the next step, machining or
manufacture.
Calipers are hand tools designed to precisely measure the distance between two
points. Most calipers have two sets of flat, parallel edges used for inner or outer
diameter measurements. These calipers can be accurate to within one-thousandth
of an inch (25.4 m). Different types of calipers have different mechanisms for
displaying the distance measured. Where larger objects need to be measured with
less precision, a tape measure is often used.
Cutting processes
Cutting is a collection of processes wherein material is brought to a specified
geometry by removing excess material using various kinds of tooling to leave a
finished part that meets specifications. The net result of cutting is two products, the
waste or excess material, and the finished part. In woodworking, the waste would
be sawdust and excess wood. In cutting metals the waste is chips or swarf and
excess metal.
Cutting processes fall into one of three major categories:

Chip producing processes most commonly known as machining

Burning, a set of processes wherein the metal is cut by oxidizing a kerf to

separate pieces of metal

Miscellaneous specialty process, not falling easily into either of the above
categories

Drilling a hole in a metal part is the most common example of a chip producing
process. Using an oxy-fuel cutting torch to separate a plate of steel into smaller
pieces is an example of burning. Chemical milling is an example of a specialty
process that removes excess material by the use of etching chemicals and
masking chemicals.
There are many technologies available to cut metal, including:

Manual technologies: saw, chisel, shear or snips

Machine technologies: turning, milling, drilling, grinding, sawing

Welding/burning technologies: burning by laser, oxy-fuel burning, and

plasma

Erosion technologies: by water jet, electric discharge, or abrasive flow

machining.

Chemical technologies: Photochemical machining

Milling

Milling is the complex shaping of metal or other materials by removing material to

form the final shape. It is generally done on a milling machine, a power-driven
machine that in its basic form consists of a milling cutter that rotates about the
spindle axis (like a drill), and a worktable that can move in multiple directions
(usually two dimensions [x and y axis] relative to the workpiece). The spindle
usually moves in the z axis. It is possible to raise the table (where the workpiece
rests). Milling machines may be operated manually or under computer numerical
control (CNC), and can perform a vast number of complex operations, such as slot
cutting, planing, drilling and threading, rabbeting, routing, etc. Two common types
of mills are the horizontal mill and vertical mill.

The pieces produced are usually complex 3D objects that are converted into x, y,
and z coordinates that are then fed into the CNC machine and allow it to complete
the tasks required. The milling machine can produce most parts in 3D, but some
require the objects to be rotated around the x, y, or z coordinate axis (depending
on the need). Tolerances are usually in the thousandths of an inch (Unit known as
Thou), depending on the specific machine.
In order to keep both the bit and material cool, a high temperature coolant is used.
In most cases the coolant is sprayed from a hose directly onto the bit and material.
This coolant can either be machine or user controlled, depending on the machine.

Turning

Turning is a metal cutting process for producing a cylindrical surface with a single
point tool. The workpiece is rotated on a spindle and the cutting tool is fed into it
radially, axially or both. Producing surfaces perpendicular to the workpiece axis is
called facing. Producing surfaces using both radial and axial feeds is called
profiling.

A lathe is a machine tool which spins a block or cylinder of material so that when
abrasive, cutting, or deformation tools are applied to the workpiece, it can be
shaped to produce an object which has rotational symmetry about an axis of
rotation. Examples of objects that can be produced on a lathe include candlestick
holders, crankshafts, camshafts, and bearing mounts.

Threading
There are many threading processes including: cutting threads with a tap or die,
thread milling, single-point thread cutting, thread rolling and forming, and thread
grinding. A tap is used to cut a female thread on the inside surface of a pre-drilled
hole, while a die cuts a male thread on a preformed cylindrical rod.

Grinding
Grinding uses an abrasive process to remove material from the workpiece. A
grinding machine is a machine tool used for producing very fine finishes, making
very light cuts, or high precision forms using an abrasive wheel as the cutting
device. This wheel can be made up of various sizes and types of stones, diamonds
or inorganic materials.
The simplest grinder is a bench grinder or a hand-held angle grinder, for deburring
parts or cutting metal with a zip-disc.
Grinders have increased in size and complexity with advances in time and
technology. From the old days of a manual toolroom grinder sharpening endmills
for a production shop, to today's 30000 RPM CNC auto-loading manufacturing cell
producing jet turbines, grinding processes vary greatly.
Grinders need to be very rigid machines to produce the required finish. Some
grinders are even used to produce glass scales for positioning CNC machine axis.
The common rule is the machines used to produce scales be 10 times more
accurate than the machines the parts are produced for.

In the past grinders were used for finishing operations only because of limitations
of tooling. Modern grinding wheel materials and the use of industrial diamonds or
other man-made coatings (cubic boron nitride) on wheel forms have allowed
grinders to achieve excellent results in production environments instead of being
relegated to the back of the shop.
Modern technology has advanced grinding operations to include CNC controls,
high material removal rates with high precision, lending itself well to aerospace
applications and high volume production runs of precision components.
Filing

Filing is combination of grinding and saw tooth cutting using a file. Prior to the
development of modern machining equipment it provided a relatively accurate
means for the production of small parts, especially those with flat surfaces. The
skilled use of a file allowed a machinist to work to fine tolerances and was the
hallmark of the craft. Today filing is rarely used as a production technique in
industry, though it remains as a common method of deburring.

Joining processes

 Welding
Welding is a fabrication process that joins materials, usually metals or
thermoplastics, by causing coalescence. This is often done by melting the
workpieces and adding a filler material to form a pool of molten material that cools
to become a strong joint, but sometimes pressure is used in conjunction with heat,
or by itself, to produce the weld.
Many different energy sources can be used for welding, including a gas flame, an
electric arc, a laser, an electron beam, friction, and ultrasound. While often an
industrial process, welding can be done in many different environments, including
open air, underwater and in space. Regardless of location, however, welding
remains dangerous, and precautions must be taken to avoid burns, electric shock,
poisonous fumes, and overexposure to ultraviolet light.
Brazing
Brazing is a joining process in which a filler metal is melted and drawn into a
capillary formed by the assembly of two or more work pieces. The filler metal
reacts metallurgically with the workpiece(s) and solidifies in the capillary, forming a
strong joint. Unlike welding, the work piece is not melted. Brazing is similar to
soldering, but occurs at temperatures in excess of 450 C (842 F). Brazing has
the advantage of producing less thermal stresses than welding, and brazed
assemblies tend to be more ductile than weldments because alloying elements can
not segregate and precipitate.
Brazing techniques include, flame brazing, resistance brazing, furnace brazing,
diffusion brazing, inductive brazing and vacuum brazing.
Soldering

Soldering is a joining process that occurs at temperatures below 450 C (842 F). It
is similar to brazing in the way that a filler is melted and drawn into a capillary to
form a join, although at a lower temperature. Because of this lower temperature

and different alloys used as fillers, the metallurgical reaction between filler and
work piece is minimal, resulting in a weaker joint.
Riveting
Riveting is one of the most ancient metalwork joining processes. Its use has
declined markedly during the second half of the 20th century, but it still retains
important uses in industry and construction, and in artisan crafts such as jewellery,
medieval armouring and Metal Couture into the 21st century. The earlier use of
rivets is being superseded by improvements in welding and component fabrication
techniques.
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