What Is Metal Cutting? An Introduction to the World of Metalworking
Everything you need to know about metal cutting processes, cutting tools, CNC machines, and machining parameters, to produce metal parts with precision, efficiency, and competitive cost.
What Is Metal Cutting?
Metal cutting (Metal Cutting / Machining) is a process in which material is removed from a raw workpiece using a cutting tool until the required shape, dimensions, and surface finish are achieved. It is one of the oldest and most central manufacturing processes in the industry, and it continues to evolve with the arrival of new technologies.
Unlike processes such as casting or forging, here material is removed layer by layer, producing chips. Controlling the process — from cutting-tool selection to setting the machining parameters — is what distinguishes a mediocre result from a precise and cost-effective one.
The Main Processes
⚙️ Turning
In turning, the workpiece rotates while the cutting tool moves along its length. The process is mainly suited to producing round and symmetrical parts, and it is performed on CNC lathes.
⚙️ Milling
In milling, the cutting tool itself rotates and removes material from the workpiece. Milling makes it possible to machine complex shapes, pockets, slots, and three-dimensional surfaces. Modern machining centers work on 3 to 5 axes simultaneously.
⚙️ Drilling and Tapping
Drilling creates holes and tapping creates internal threads. It sounds simple, but at high precision levels and in tough materials it requires precise tools and parameters.
Cutting Tools
🔹 Indexable inserts are the component in direct contact with the material. Inserts come in different shapes, coatings, and chipbreakers, and the right selection directly affects tool life, surface finish, and production rate.
🔹 Milling heads, drills, and toolholders complete the system. Choosing the right holder (HSK, BT, Capto, and others) affects stability, runout accuracy, and the ability to achieve better results.
Leading manufacturers in the cutting tool field include Sandvik Coromant, Iscar (an Israeli company!), Kennametal, Seco, Walter, Mitsubishi, and Kyocera. Each manufacturer specializes in different areas, and the right choice depends on the combination of material, process, machine, and quality requirements.
CNC Machines
CNC machines (Computer Numerical Control) are the backbone of every machining shop. They perform cutting movements automatically according to a G-code program, enabling repeatable precision, high speed, and consistency that cannot be achieved in manual machining.
Leading machine manufacturers: DMG Mori (Germany/Japan), Mazak (Japan), Okuma, Haas (USA), Makino, and Doosan. Each manufacturer has different strengths in areas such as speed, thermal stability, control systems, and cost-benefit ratio.
🎯 Optimizing Machining Parameters
Four critical parameters determine the success of the process:
📐 Cutting speed (Vc) — measured in meters per minute, determined by the workpiece material and the tool material.
📐 Feed (f / fz) — the tool's advance rate, in mm per revolution or mm per tooth.
📐 Depth of cut (ap) — how much material is removed in each pass.
📐 Width of cut (ae) — mainly relevant in milling.
Balancing the four parameters is what determines tool life, surface quality, material removal rate, and ultimately the cost per part.
CAM Software
CAM software (Computer Aided Manufacturing) is the bridge between the 3D model and the G-code program that runs on the machine. Good software enables the selection of advanced machining strategies, the definition of precise parameters, and optimal toolpaths that save time and extend tool life.
Leading software in the field: ESPRIT CAM (Hexagon) for 2-5 axis programming with factory-certified post-processors, NCSIMUL for G-code simulation and verification, Robotmaster for industrial robot programming, as well as Mastercam, Siemens NX, hyperMILL, and others.
Today's Challenges
The metal-cutting industry faces several notable challenges: materials that are harder to machine (titanium alloys, Inconel, hardened steels), ever-rising precision requirements, pressure to reduce costs, and a shortage of skilled workforce.
Meeting them requires the right combination of advanced cutting tools, suitable CNC machines, smart CAM software, and above all practical knowledge and experience that enable sound decisions on the shop floor.
🚀 Need Professional Machining Consulting?
At ZF Engineering we bring more than 50 years of experience in machining consulting, cutting-tool selection, CNC programming, and CAM software integration. We don't just sell tools — we are engineers who understand your challenges and deliver tailored solutions.