This document provides information on various manufacturing cutting processes including photochemical cutting, laser cutting, electrical discharge machining, punching and blanking, die cutting, water jet cutting, and glass scoring. It describes the introduction, typical applications, related processes, quality considerations, design opportunities, compatible materials, costs, and environmental impacts for each process.

1. IDT 203
MANUFACTURI-
NG PROCESS
(CUTTING
TECHNOLOGY)
GROUP MEMBERS
MOHD ZARAHAN BIN ZAKARIA
MOHD ROZAIME BIN ABDULLAH
MEOR SYUKRI BIN MEOR ARIS

2. PHOTOCHEMIC
AL CUTTING

3. INTRODUCTION
 Unprotected metal is chemically dissolved in
photochemical machining. Masks are design
so that components are cut out and
engraved simultaneously. The results are both
decorative and functional.
 The chemical cutting is used predominantly to
mill and machine thin sheet metals, is also
known as chemical blanking and
photofabrication.
 This process is limited to foils and thin sheet
metal between 0.1mm and 1mm thick.

4. TYPICAL APPLICATION
 The technical aspects of this technology
are utilized in aerospace, automotive and
electronics industries.

5. RELATED PROCESS
 Laser cutting and engraving are used to
produce similar products.
 Abrasive blasting
 CNC machining

6. QUALITY
 This process produces an edge finish free
from burrs, and it is accurate to within 10%
of the material thickness.

7. DESIGN OPPORTUNITIES
 Photochemical machining is used to
score lines, mill holes, remove surface
material and profile entire parts.

8. DESIGN CONSIDERATIONS
 The intricacy of a pattern is restricted by
the thickness of the material: any
configuration can be machined, as long
as the smallest details are large than the
material thickness.

9. COMPATIBLE MATERIALS
 Most metals can be photo etched
including stainless stell, mild steel,
aluminium, copper, brass, nickel, tin and
silver.
 Glass, mirror, porcelain and ceramic are
also suitable for photo etching.

10. COSTS
 Very low tooling cost.
 Moderate to high unit cost.

11. ENVIRONMENT IMPACTS
 Metal that is removed from the workpiece
is dissolved in the chemical etchant.
 The chemical used to etch the metal is
one-third ferric chloride.

12. LASER CUTTING

13. INTRODUCTION
 This is a high precision CNC process that can
be used to cut, etch, engrave and a mark a
variety of sheet materials including metal,
plastic, wood, textiles, glass, ceramic and
leather.
 The two main types of laser used for this
process are CO2 and Nd:YAG.
 Both work by focusing thermal energy on a
spot 0.1mm to 1mm wide to melt or vaporize
the material.

14. TYPICAL APPLICATION
 Application are diverse and include
modelmaking, furniture, consumer
electronics, fashions, signs and trophies,
point of sale, film and televisions sets, and
exhibition pieces.

15. RELATED PROCESS
 CNC maching, water jet cutting and
punching and blanking can all be used to
produce the same effect in certain
materials.

16. QUALITY
 Certain materials, like thermoplastics,
have a very high surface finish when cut
in this way.

17. DESIGN OPPORTUNITIES
 These processes do not stress the
workpiece, like blade cutting, so small
and intricate details can be produced
without reducing strength or distorting the
part.

18. DESIGN CONSIDERATIONS
 These are vector-based cutting systems:
the laser follow a series of lines from point
to point.

19. COMPATIBLE MATERIALS
 These processes can be used to cut a
multitude of materials including timber,
veneers, paper and card, synthetic
marble, flexible magnets, textiles and
fleeces, rubber and certain glasses and
ceramics.

20. COSTS
 There are no tooling costs for this process.
Data is transmitted directly from a CAD
file to the laser cutting machine.

21. ENVIRONMENT IMPACTS
 Careful planning will ensure minimal
waste, but it is impossible to avoid offcuts
that are not suitable for reuse.
 Thermoplastic scrap, paper and metal
can be recycled, but not directly.

22. ELECTRICAL
DISCHARGE
MACHINING

23. INTRODUCTION
 High voltage sparks erode the surface of the
workpiece or cut a profile by vaporizing the
material, making this a precise method of
machining metals. Material is removed from
the workpiece and a texture is applied
simultaneously.
 Electrical discharge machining (EDM) has
revolutionized toolmaking and metal
prototyping.
 There are two versions of the EDM process :
die sink EDM and wire EDM.

24. TYPICAL APPLICATION
EDM equipment is very expensive, so its use
is limited to applications that demand the
very high levels of precision and the ability
to work hardened steels and other metals
that are impractical for CNC machining.

25. RELATED PROCESS
 CNC machining
 Laser cutting
 Water jet cutting

26. QUALITY
 The quality of EDM parts is so high they
can be used to manufacture tooling for
injection molding without any finishing
operations.
 The quality of the finish and resulting
texture are determined by the cutting
speed and voltage.

27. DESIGN OPPORTUNITIES
 EDM produce accurate textures, which
are determined by the machine settings,
eliminating the need for further finishing
operations.
 Die sink EDM can be used to produce
internal geometries on parts that are not
possible with conventional machining.
 Wire EDM can be used in much the same
way as hot wire cutting polymer foam.

28. DESIGN CONSIDERATIONS
 These processes can be produce internal
radii as small as 30 microns.
 These do not need to be any larger than
500 microns in most applications.
 The thickness of the material that can be
cut by wire EDM ranges from 0.1mm up to
200mm but depends on the capabilities
of the equipment.

29. COMPATIBLE MATERIALS
 Metals can be shaped by EDM
techniques.
 Metals including stainless steel, tool steel,
aluminium, titanium, brass and cooper are
commonly shaped in this way.

30. COSTS
 Low tooling costs for EDM: no tooling costs
for wire EDM: very high equipment costs.
 Moderate to high unit costs.

31. ENVIRONMENTAL IMPACTS
 This process requires a great deal of
energy to vaporize the metal workpiece.
 It does eliminate the need for any further
processing.
 The metal electrodes are also suitable for
recycling.

32. PUNCHING
AND
BLANKING

33. INTRODUCTION
 Punching refers to cutting an internal
shape.
 Blanking is cutting an external shape in a
single operation.
 Circular , square and profiled hole can be
cut from sheet.

34. TYPICAL APPICATIONS
 Use in :
 Automotive and transportation
 Consumer electronics and appliances
 kitchenware

35. RELATED PROCESSES
 This process can only used for thin sheet
matrials up to 5mm.
 Related processes
 CNC machining
 Laser cutting
 Water jet cutting

36. QUALITY
 High quality and precise but adges
require
de-burring.

37. DESIGN OPPORTUNITIES
 Specialized tooling is required for 3D parts,
which will increase investment cost.
 Selective material will reduce weight but
may not reduce strength too much.

38. DESIGN CONSIDERATION
 The width of material being removed or
left behind.
 Punch diameter or width should be not
smaller than material thickness.

39. COMPATIBLE MATERIALS
 Almost all metals can be processed in this
way.
 Commonly used to cut carbon
steel,stainless steel and aluminium and
copper alloys.

40. COST
 Low to moderate tooling cost
 Low to moderate unit costs

41. ENVIRONMENTAL IMPACTS
 Any scrap is collected and separated for
recycling, so there is very little wasted
material.

42. DIE
CUTTING

43. INTRODUCTION
 Is a rotary operation
 Most cost effective way to cut complex
net shapes from most non-metallic sheet
materials.

44. TYPICAL APPLICATION
 Use in :
 Packaging
 Promotional material
 Stationery and labels

45. RELATED PROCESSES
 Laser cutting
 Punching
 Water jet cutting

46. QUALITY
 High quality edge finish

47. DESIGN OPPORTUNITIES
 A multitude of materials can be die cut.
 Means that an entire packaging system
can be shaped in this way.

48. DESIGN CONSIDERATIONS
 The type of material will determine the
thickness that can be cut
 Nesting parts is essential to reduce cycle
time , scrap material and cost in general

49. COMPATABLE MATERIALS
 Many materials can be cut by die casting
, including plastic sheet, plastic film,
cardboard, board, foam, rubber, leather,
textile, very thin matels, flexible magnets
and cork.

50. COST
 Low tooling costs
 Low unit costs

51. ENVIRONMENTAL IMPACTS
 Die cutting does produce offcuts
 Scrap can be minimized by nesting the
scrap together on a sheet and can be
recycle.

52. WATER
JET
CUTTING

53. INTRODUCTION
 A high-pressure jet of water, which is
typically mixed with abrasive, produce
the cutting action.
 This is a versatile process for cold cutting
sheet materials.

54. TYPICAL APPLICATIONS
 Use in :
 Aerospace components
 Automotive
 Scientific apparatus

55. RELATED PROCESSES
 Die cutting
 Laser cutting
 Punching and blanking

56. QUALITY
 Good quality

57. DESIGN OPPORTUNITIES
 This process cuts most sheet materials
between 0.5mm and 100mm thick.
 The hardness of the material will be
determine the maximum thickness.

58. DESIGN CONSIDERATIONS
 Reducing cycle time reduce the cost of
water jet process.
 Sharp corners slow down the process; the
water jet cutter will slow down to avoid
drag.

59. COMPATIBLE MATERIALS
 Mild steel, steanless steel and tool steel
can all be cut with high accuracy.
 Titanium, aliminium, copper and brass are
suitable for complex profiles and can be
cut rapidly with this process.

60. COST
 No tooling cost
 Moderate unit cost

61. ENVIRONMENTAL IMPACT
 Offcuts in most materials can be cycled
of re-used
 The water is usually tapped from the
mains and is cleaned and recycled for
continous use.

62. GLASS SCORING
INYRODUCTION
-most widely use.
- there is the technique for cutting out
the stained glass design

63. RELATED PROCESSES
 Laser cutting
 Water jet cutting

64. QUALITY
 Good quality cut edge,but with some
lateral cracking.

65. COST
 No tooling cost
 Low unit cost.