Grinding Metal

Grinding Metal

The Process of Metal Working

Metalworking is the process of working with metals to create a diverse range of products, from the hulls of ships to engagement rings.

There are many reasons to practice metalworking.  Metalworking can be used for experimentation, to create works of art, for enjoyment, as its own profession, or as part of a profession. The many specialized fields of modern metalworking can be grouped under the categories of joining, forming, or cutting.

Welding joins two pieces of metal through the use of heat, pressure, or some combination of the two.  Though a third agent is often introduced to the process and melted between the two workpieces to aid in the weld, in order to be a true weld, the two pieces must blend and coalesce.  Brazing and Soldering are also standard metalworking joining processes.  These differ from welding in that only a filler metal is melted between the two workpieces, while the workpieces themselves do not coalesce, and remain unchanged.  Because it occurs at a much higher temperature and with different filler metals, brazed joints are much stronger than soldered.

Forming modifies metal without removing or adding anything to the original workpiece.  This can be done with pressure and/or heat.  Forming processes include casting, the melting and pouring of metal into a mold, as well as many processes performed with the metal at room temperature, such as bending, drawing, rolling, and stamping.

Cutting processes are any of those used in metalworking that results in a separation of the workpiece into two pieces.  Machining uses cutting instruments such as a drill or saw, and produces swarf (chips of metal).  Burning uses a torch, and does not produce swarf.

* Grinding is a metalworking process in which an abrasive, fast spinning disk is used to remove small amounts of the workpiece to smooth edges and create a smooth finish.  Grinding can also be used as a cutting technique.

* Milling shapes metal by cutting away unneeded parts to reveal the final shape.  Milling is able to produce complex three dimensional objects with a high degree of precision.  Milling machines can be completely or partially automated by computer controls.  Almost any metal can be milled, though different metals require different bits and bit speeds, depending on the hardness of the material.  A liquid coolant is required to keep the material and bit from being deformed.  This combines to make milling a costly process that must be factored into the final cost of the product being milled.

* Drilling and tapping produce holes in metal through the use of a drill and drill bit.  This is the fastest way to machine material from a workpiece.  Tapping uses a bit that cuts a female thread into the workpiece, creating a screw thread where a screw can be fastened.

* Filing is the use of a file to grind small bits of material away from the workpiece by hand.  It is commonly used for deburring.

* Turning is the term used to refer to metalworking processes performed on a lathe.  Other processes can be performed on a lathe, such as basic milling, but turning is always performed on a lathe.  Lathes turn blocks or cylinders of metal at high speeds while different tools are applied to the workpiece, shaving away layers to produce the desired shape.  Turning produces symmetrical objects such as table legs.

Different primary cutting processes exist which may or may not be used in conjunction with the above techniques.  These include laser cutting, abrasive water jet cutting, plasma arc cutting, and oxyfuel cutting.

* Laser cutting uses either a gas or solid state laser to produce an extremely precise cutting area with very little heat affected zone.  This method is expensive, and does not always work on material that is thick or highly reflective.

* Abrasive water jet cutting uses a pressurized stream of water with an added abrasive to cut metals with high precision and a low heat affected zone.  While this method is less expensive than laser cutting, it has the disadvantage of being slow, thus reducing output.

* Plasma arc cutting uses a high speed gas simultaneously with an electrical arc between the nozzle and workpiece that combines to form plasma hot enough to cut the metal.  The plasma is instantly blown away by the gas, reducing the size of the heat affected zone.  Plasma cutting is quick, inexpensive, able to cut almost any metal, and capable of cutting very thick pieces and sheets.  It leaves a large heat affected zone and forms dross at the bottom of the cut, making it less precise than laser or abrasive water jet cutting.

* Oxyfuel cutting uses a mixture of oxygen and gas which combined and burned in torch, just as in oxyfuel welding.  Oxyfuel cutting is very low cost, but it is slow, produces a large heat affected zone requiring additional machining, and is less precise than some other methods.

About the Author

Ryan Fyfe is the owner of http://www.metal-welding.info/ - an information resource for all things related to Metal including articles, news, movies and more.

Dremel EZ541GR EZ Lock Grinding Wheel for Metal $12.99 EZ Lock Grinding Wheel for Metal - EZ541GR

Technician Grinding a Piece of Metal Inside a Caproni Hangar $24.99 A. Villani Technician Grinding a Piece of Metal Inside a Caproni Hangar - Photographic Print

Makita 4'' Metal Grinding Wheel 5 pk. $17.95 ? For metal polishing and general flat grinding. Aluminum oxide abrasive grains are evenly distributed to give a smooth surface? 24 git? 5 pack? Tool must be properly guarded? Size: 4'' x 3/16'' x 5/8''? Max. Safe speed: 13,690 RPM

Makita 4-1/2'' Metal Grinding Wheel 5 pk. $40.95 ? For metal polishing and general flat grinding. Aluminum oxide abrasive grains are evenly distributed to give a smooth surface? 24 git? 5 pack? Tool must be properly guarded? Size: 4-1/2'' x 1/4'' x 7/8''? Max. Safe speed: 11,900 RPM

3M Green Corps 7'' Grinding Disc (Grade 24) $14.95 ? All purpose grinding discs for door skinning, grinding MIG welds or any kind of metal grinding? High-performance grinding discs? Long-lasting and fast-cutting? Grade: 24? Size: 7''x 7/8''

Gw27M701 - Grinding Wheel7 inch For Metal $4.42 [8884272] UPC: 000346325966 1.15L x 7.1W x 7.1H 1.06 LB 0.03 Cubes

326390 - 4.5X3/32 Grinding Wheel Metal $2.04 [1172048] UPC: 000346326390 0.1L x 4.5W x 4.5H 0.12 LB 0 Cubes

24463 - 4X1/4X5/8 Metal Grinding Wheel $10.13 [6343743] UPC: 000899244639 7.86L x 4.26W x 4.22H 0.27 LB 0.08 Cubes

Cg27M400 - 4X3/32 Grinding Wheel Metal $1.97 [1038199] UPC: 000346326383 0.3L x 4W x 4H 0.1 LB 0 Cubes

Kawasaki 10 Piece 4?'' Grinding Wheel Set $9.95 The 10 Piece 4?" Grinding Wheel Set is ideal for many metal and/or masonry cutting or grinding jobs.   Features: v Max speed: 13, 300 RPM   Includes: v Metal cut-off wheel: 4-1/2" x 1/16" x 7/8" v Masonry cut-off wheel: 4-1/2" x 3/32" x 7/8" v Metal grinding wheel: 4-1/2" x 1/4" x 7/8" v Masonry grinding wheel: 4-1/2" x 1/4" x 7/8"  

Black & Decker dwlt Black & Decker dwlt 5 in Metal Grinding Wheel DW4618 $2.09 5? metal grinding wheel For use on angle grinders Industrial grade, aluminum oxide grinding wheel for heavy-duty cutting, grinding, and material removal applications. double reinforced for increased life and faster cuts Ideal for low angle and vertical grinding A24R grit Bulk 5? x 1/8? arbor, 12,200 RPM, Available Only At Waco Brand #: Black & Decker/DWLT DW4618 UPC: 028874046184 Keywords: metal grinding wheel

Black & Decker dwlt Black & Decker dwlt 5 in Metal Grinding Wheel DW4619 $2.37 5? metal grinding wheel For use on angle grinders Industrial grade, aluminum oxide grinding wheel for heavy-duty cutting, grinding, and material removal applications. double reinforced for increased life and faster cuts Ideal for low angle and vertical grinding A24R grit Bulk 5? x 1/4?, 7/8? arbor, 12,200 RPM, Available Only At Waco Brand #: Black & Decker/DWLT DW4619 UPC: 028874046191 Keywords: metal grinding wheel

Black & Decker dwlt Black & Decker dwlt 7 in Metal Grinding Wheel DW4719 $3.26 7? metal grinding wheel For use on angle grinders Industrial grade, aluminum oxide grinding wheel for heavy-duty cutting, grinding, and material removal applications. double reinforced for increased life and faster cuts Ideal for low angle and vertical grinding A24R grit Bulk 7? x 1/4?, 5/8? arbor, 8500 RPM, hub style Brand #: Black & Decker/DWLT DW4719 UPC: 028874047198 Keywords: metal grinding wheel

Makita Power Tools 4 Inch Metal Grinding Wheel 5 Pk. $19.05 For metal polishing and general flat grinding. Aluminum oxide abrasive grains are evenly distributed to give a smooth surface 24 git 5 pack Tool must be properly guarded Size: 4 inch x 3/16 inch x 5/8 inch Max. Safe speed: 13,690 RPM

Makita MAK7414028 4Inch Metal Grinding Wheel 5 Pack $28.99 For metal polishing and general flat grinding. Aluminum oxide abrasive grains are evenly distributed to give a smooth surface. 24 git. 5 pack. Tool must be properly guarded. Size: 4 x 3/16 x 5/8. Max. Safe speed: 13 690 RPM.

Makita Power Tools MAK7414028 4Metal Grinding Wheel 5 pk. $28.99 For metal polishing and general flat grinding. Aluminum oxide abrasive grains are evenly distributed to give a smooth surface. 24 git. 5 pack. Tool must be properly guarded. Size: 4 x 3/16 x 5/8 . Max. Safe speed: 13 690 RPM

The World Market for Metal Gear Cutting, Grinding, or Finishing Machines $325 This report was created for strategic planners, international executives and import/export managers who are concerned with the market for numerically controlled metal tool sharpening or cutter grinding machines. With the globalization of this market, managers can no longer be contented with a local view. Nor can managers be contented with out-of-date statistics that appear several years after the fact. I have developed a methodology, based on macroeconomic and trade models, to estimate the market for numerically controlled metal tool sharpening or cutter grinding machines for those countries serving the world market via exports or supplying from various countries via imports. I do so for the current year based on a variety of key historical indicators and econometric models.

DEWALT DW4514B5 4-1/2-in x 1/4-in A24R High Performance Metal Grinding Abrasives (5 pk) $9.99 4-1/2" x 1/4" A24R-Grit High Performance Metal Grinding Abrasives (5 pk) - DW4514B5

Bosch CG27M451 4-1/2 x 3/32 x 5/8 -11 Type 27 Grinding & Cutting A24R-BF for Metal $4.99 4-1/2 x 3/32 x 5/8 -11 Type 27 Grinding & Cutting A24R-BF for Metal - CG27M451

Vermont American 4in. .63in. Arbor Metal Grinding Wheel 17453 $22.23 Use for weld grinding surfacing notching and cutting. Depressed center. 15 300 maximum RPM.63 arbor. 4 diameter.25 blade thickness. Carded. Length: 4.3. Width: 4.3. Height: 4.3

Vermont American .75in. Round Ball Grinding Point 16708 $22.91 Round ball grinding point. For grinding intricate shapes. Aluminum oxide for fast metal removal. Recommended for grinding and shaping metal. Constructed of aluminum oxide for fast removal of all types of metal.25 shank fits die grinders and all drills.75 thickness.75 usable length. Carded. Length: 6. Width: 2.4. Height: 2

Grinding Stone $8.99 Grinding Stone

Ali Ind. Ali Ind. 8 in 80g Grinding Wheel 6000 $12.91 8? 80g grinding wheel Aluminum oxide grinding wheel For metal, steel, aluminum, hand, and cutting tools 1? arbor Includes 5/8? bushing 8? x 1? x 1? Fine, 80 grit Brand #: Ali Ind. 6000 UPC: 082354060008 Keywords: grinding wheel aluminum oxide gatorgrit bench

Ali Ind. Ali Ind. 8 in 60g Grinding Wheel 6001 $12.91 8? 60g grinding wheel Aluminum oxide grinding wheel For metal, steel, aluminum, hand, and cutting tools 1? arbor Includes 5/8? bushing 8? x 1? x 1? Medium, 60 grit Brand #: Ali Ind. 6001 UPC: 082354060015 Keywords: grinding wheel aluminum oxide gatorgrit bench

Ali Ind. Ali Ind. 8 in 36g Grinding Wheel 6002 $12.91 8? 36g grinding wheel Aluminum oxide grinding wheel For metal, steel, aluminum, hand, and cutting tools 1? arbor Includes 5/8? bushing 8? x 1? x 1? Coarse, 36 grit Brand #: Ali Ind. 6002 UPC: 082354060022 Keywords: grinding wheel aluminum oxide gatorgrit bench

3M Green Corps 7'' Grinding Discs (Grade 36) $7.97 Used for grinding door skins, MIG welds or any kind of metal or fiberglass grinding. Other applications include paint, rust, and weld removal and metal work. Grade 36 Size: 7" x 7/8" Ideal for body work Pack of 2 discs

Gw27M400 - Grinding Wheel 4 inch For Metal $1.64 [8911646] UPC: 000346325874 0.25L x 4W x 4H 0.25 LB 0 Cubes

Gw27M451 - Grinding Wheel 4.5 inch For Metal $2.78 [3876117] UPC: 000346325935 0.8L x 0.84W x 4.6H 0.49 LB 0 Cubes

Vermont American Cylinder Grinding Point .75in. x 1.25in. 16710 $22.82 For grinding and shaping metal. Aluminum oxide for fast metal removal.25 shank fits die grinder and all drills.75 x 1.25 . Carded. Length: 2.4. Width: 6. Height: 2

Vermont American Pointed Tree Grinding Point 1.06in. x 1.25in. 16702 $22.91 For grinding and shaping metal. Aluminum oxide for fast metal removal.25 shank fits die grinder and all drills. 11/16 x 1.25 . Carded. Length: 2.3. Width: 6. Height: 2

Vermont American Cylinder Grinding Point 1.06in. x .88in. 16703 $22.91 Pointed cylinder. For grinding and shaping metal. Aluminum oxide for fast metal removal.25 shank fits die grinder and all drills. 11/16 x .88 . Carded. Length: 5.9. Width: 2. Height: 1.5

Vermont American Pointed Edge Grinding Point 1.25in. x .25in. 16706 $22.91 For grinding and shaping metal. Aluminum oxide for fast metal removal.25 shank fits die grinder and all drills. 1.25 x .25 . Carded. Length: 6.4. Width: 6.5. Height: 1.5

Grinding Tool $24.99 Grinding Tool - Premium Poster

Grinding the Rice $39.99 Grinding the Rice - Giclee Print

Grinding Corn $49.99 Grinding Corn - Giclee Print

Dewalt Tools DWTDW4419 4in. x .25in. x .63in. High Performance Metal Grinding Wheel $18.49 A24R grit; maximum RPM: 15 200; application: metal grinding. High performance aluminum oxide grain for long life and high material removal. High grain concentration for aggressive grinding action and smoother running wheels. Proprietary material mix ensures durable long life wheels. 3 full sheets of fiberglass for durability and safety. Dimension: 4 diameter; 1/4 thickness; 5/8 arbor size. Dimensions: 4 L x 3.9 W x 0.6 H.