A machinist is a tradesperson or trained professional who operates machine tools , and has the ability to set up tools such as milling machines, grinders, lathes, and drilling machines.
92-455: A competent machinist should have a well-developed mechanical aptitude, the ability to correctly use precision measuring instruments and to interpret blueprints, and a working knowledge of the proper parameters required for successfully utilizing the various tools commonly used in machining operations. CNC (computer numerical control) is the modern manufacturing method in which machinist use a form of programming called G-code to make components for
184-412: A BOS process is manufactured in one-twelfth the time. Today, electric arc furnaces (EAF) are a common method of reprocessing scrap metal to create new steel. They can also be used for converting pig iron to steel, but they use a lot of electrical energy (about 440 kWh per metric ton), and are thus generally only economical when there is a plentiful supply of cheap electricity. The steel industry
276-684: A carbon-intermediate steel by the 1st century AD. There is evidence that carbon steel was made in Western Tanzania by the ancestors of the Haya people as early as 2,000 years ago by a complex process of "pre-heating" allowing temperatures inside a furnace to reach 1300 to 1400 °C. Evidence of the earliest production of high carbon steel in South Asia is found in Kodumanal in Tamil Nadu ,
368-444: A change of volume. In this case, expansion occurs. Internal stresses from this expansion generally take the form of compression on the crystals of martensite and tension on the remaining ferrite, with a fair amount of shear on both constituents. If quenching is done improperly, the internal stresses can cause a part to shatter as it cools. At the very least, they cause internal work hardening and other microscopic imperfections. It
460-428: A ferrite BCC crystal form, but at higher carbon content it takes a body-centred tetragonal (BCT) structure. There is no thermal activation energy for the transformation from austenite to martensite. There is no compositional change so the atoms generally retain their same neighbours. Martensite has a lower density (it expands during the cooling) than does austenite, so that the transformation between them results in
552-512: A few. The tools that a machinist is expected to be proficient with fall into broad categories: Machining Machining is a manufacturing process where a desired shape or part is created using the controlled removal of material, most often metal, from a larger piece of raw material by cutting. Machining is a form of subtractive manufacturing , which utilizes machine tools , in contrast to additive manufacturing (e.g. 3D printing ), which uses controlled addition of material. Machining
644-457: A finished product. A finished product would be a workpiece that meets the specifications set out for that workpiece by engineering drawings or blueprints . For example, a workpiece may require a specific outside diameter. A lathe is a machine tool that can create that diameter by rotating a metal workpiece so that a cutting tool can cut metal away, creating a smooth, round surface matching the required diameter and surface finish. A drill can remove
736-445: A hard but brittle martensitic structure. The steel is then tempered, which is just a specialized type of annealing, to reduce brittleness. In this application the annealing (tempering) process transforms some of the martensite into cementite, or spheroidite and hence it reduces the internal stresses and defects. The result is a more ductile and fracture-resistant steel. When iron is smelted from its ore, it contains more carbon than
828-407: A heat-affected zone, as opposed to laser and plasma cutting . With the recent proliferation of additive manufacturing technologies, conventional machining has been retronymously classified, in thought and language, as a subtractive manufacturing method. In narrow contexts, additive and subtractive methods may compete with each other. In the broad context of entire industries, their relationship
920-566: A large variety of shapes, and whose use in the workflow depends on the part to be machined. CNC machines are becoming the standard due to their speed, precision, flexibility, repeatability, and reduced downtime while changing jobs. Production runs consisting of large numbers of parts are more cost effective and commonly referred to as production work in the trade. Conversely, small production runs are sometimes referred to as prototype or jobbing work. Production engineers use blueprints and engineering drawings to produce detailed specifications of
1012-412: A narrow range of concentrations of mixtures of carbon and iron that make steel, several different metallurgical structures, with very different properties can form. Understanding such properties is essential to making quality steel. At room temperature , the most stable form of pure iron is the body-centred cubic (BCC) structure called alpha iron or α-iron. It is a fairly soft metal that can dissolve only
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#17328517783921104-422: A number of ways. In the 18th century, the word machinist meant a person who built or repaired machines . This person's work was primarily done by hand, using processes such as the carving of wood and the writing- forging and hand- filing of metal. At the time, millwrights and builders of new kinds of engines (meaning, more or less, machines of any kind), such as James Watt or John Wilkinson , would fit
1196-426: A saw cut length of stock or a casting . Producing a part will often require several steps and more than one machine tool. Each machine tool plays a specific role in cutting away excess material. When large numbers of parts are needed, production planning is required to plan the most logical workflow through a series of machines. Computer numerical controlled (CNC) machines are computer-driven tools that can machine
1288-473: A sharp cutting tool to remove material to achieve a desired geometry. Since the advent of new technologies in the post–World War II era, such as electrical discharge machining , electrochemical machining , electron beam machining , photochemical machining , and ultrasonic machining , the retronym "conventional machining" can be used to differentiate those classic technologies from the newer ones. Currently, "machining" without qualification usually implies
1380-599: A significant Material Removal Rate (MRR), to produce a shape close to the desired form but leaving some material on the piece for a subsequent finishing operation. Finishing cuts complete the part and achieve the final dimension, tolerances , and surface finish. In production machining jobs, one or more roughing cuts are usually performed on the work, followed by one or two finishing cuts. Roughing operations are done at high feeds and depths – feeds of 0.4–1.25 mm/rev (0.015–0.050 in/rev) and depths of 2.5–20 mm (0.100–0.750 in) are typical, but actual values depend on
1472-534: A small concentration of carbon, no more than 0.005% at 0 °C (32 °F) and 0.021 wt% at 723 °C (1,333 °F). The inclusion of carbon in alpha iron is called ferrite . At 910 °C, pure iron transforms into a face-centred cubic (FCC) structure, called gamma iron or γ-iron. The inclusion of carbon in gamma iron is called austenite. The more open FCC structure of austenite can dissolve considerably more carbon, as much as 2.1%, (38 times that of ferrite) carbon at 1,148 °C (2,098 °F), which reflects
1564-421: A standalone operation, many businesses maintain internal machine shops or tool rooms that support their specialized needs. Much modern-day machining uses computer numerical control (CNC), in which computers control the movement and operation of mills , lathes , and other cutting machines. The precise meaning of the term machining has changed over the past one and a half centuries as technology has advanced in
1656-448: A steel's final rolling, it is heat treated for strength; however, this is relatively rare. Steel was known in antiquity and was produced in bloomeries and crucibles . The earliest known production of steel is seen in pieces of ironware excavated from an archaeological site in Anatolia ( Kaman-Kalehöyük ) which are nearly 4,000 years old, dating from 1800 BC. Wootz steel
1748-491: A thousandth of an inch – or 0.0025 mm) for specialty operations. A machinist deals with all facets of shaping, cutting and some aspects of forming metal, although forming is typically a separate trade. The operations most commonly performed by machinists are milling , drilling , turning , and grinding . There are other more specialized operations that a machinist will less frequently be called upon to perform such as honing , keyseating , lapping , and polishing , to name
1840-414: A wide variety of industries. CNC programming is a highly skilled position. Programmers are usually machinist as well. A CNC programmer creates programs using software called CAM (computer aided manufacturing). The programmer must be proficient in math, speeds and feeds, machine tooling, work holding, and the different ways various materials react to stress and heat in the machining process. The machine trade
1932-672: Is continuously cast into long slabs, cut and shaped into bars and extrusions and heat treated to produce a final product. Today, approximately 96% of steel is continuously cast, while only 4% is produced as ingots. The ingots are then heated in a soaking pit and hot rolled into slabs, billets , or blooms . Slabs are hot or cold rolled into sheet metal or plates. Billets are hot or cold rolled into bars, rods, and wire. Blooms are hot or cold rolled into structural steel , such as I-beams and rails . In modern steel mills these processes often occur in one assembly line , with ore coming in and finished steel products coming out. Sometimes after
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#17328517783922024-412: Is a major process of the manufacture of many metal products, but it can also be used on other materials such as wood , plastic , ceramic , and composites . A person who specializes in machining is called a machinist . As a commercial venture, machining is generally performed in a machine shop , which consists of one or more workrooms containing primary machine tools. Although a machine shop can be
2116-595: Is an extremely broad field with a wide variety of workplaces, job duties, and types of work. Most machinists work in machine shops and factories where they operate machinery that produce precision component parts. In general, the occupation is exacting, and requires extensive knowledge of the tools and processes in order to achieve the tight tolerances and surface finishes that these parts specify. Many machinists make mass-produced parts using highly automated computer numerical control machines which are common today, but still require such professionals to set up and calibrate
2208-524: Is any process in which a cutting tool removes material from the workpiece (the workpiece is often called the "work"). Relative motion is required in traditional machining between the device and the work to remove material; non-traditional machining processes use other methods of material removal, such as electric current in EDM (electro-discharge machining). This relative motion is achieved in most machining operations by moving (by lateral rotary or lateral motion) either
2300-403: Is common for quench cracks to form when steel is water quenched, although they may not always be visible. There are many types of heat treating processes available to steel. The most common are annealing , quenching , and tempering . Annealing is the process of heating the steel to a sufficiently high temperature to relieve local internal stresses. It does not create a general softening of
2392-441: Is complementary. Each method has its advantages over the other. While additive manufacturing methods can produce very intricate prototype designs impossible to replicate by machining, strength and material selection may be limited. Steel Steel is an alloy of iron and carbon with improved strength and fracture resistance compared to other forms of iron. Because of its high tensile strength and low cost, steel
2484-403: Is desirable. To become steel, it must be reprocessed to reduce the carbon to the correct amount, at which point other elements can be added. In the past, steel facilities would cast the raw steel product into ingots which would be stored until use in further refinement processes that resulted in the finished product. In modern facilities, the initial product is close to the final composition and
2576-449: Is distinguishable from wrought iron (now largely obsolete), which may contain a small amount of carbon but large amounts of slag . Iron is commonly found in the Earth's crust in the form of an ore , usually an iron oxide, such as magnetite or hematite . Iron is extracted from iron ore by removing the oxygen through its combination with a preferred chemical partner such as carbon which
2668-408: Is heat treated to contain both a ferritic and martensitic microstructure to produce a formable, high strength steel. Transformation Induced Plasticity (TRIP) steel involves special alloying and heat treatments to stabilize amounts of austenite at room temperature in normally austenite-free low-alloy ferritic steels. By applying strain, the austenite undergoes a phase transition to martensite without
2760-535: Is known as stainless steel . Tungsten slows the formation of cementite , keeping carbon in the iron matrix and allowing martensite to preferentially form at slower quench rates, resulting in high-speed steel . The addition of lead and sulphur decrease grain size, thereby making the steel easier to turn , but also more brittle and prone to corrosion. Such alloys are nevertheless frequently used for components such as nuts, bolts, and washers in applications where toughness and corrosion resistance are not paramount. For
2852-452: Is made of a harder material than the work material. The cutting edge serves to separate the chip from the parent work material. Connected to the cutting edge are the two surfaces of the tool: The rake face, which directs the flow of the newly formed chip, is oriented at a certain angle and is called the rake angle "α." It is measured relative to the plane perpendicular to the work surface. The rake angle can be positive or negative. The flank of
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2944-687: Is often considered an indicator of economic progress, because of the critical role played by steel in infrastructural and overall economic development . In 1980, there were more than 500,000 U.S. steelworkers. By 2000, the number of steelworkers had fallen to 224,000. The economic boom in China and India caused a massive increase in the demand for steel. Between 2000 and 2005, world steel demand increased by 6%. Since 2000, several Indian and Chinese steel firms have expanded to meet demand, such as Tata Steel (which bought Corus Group in 2007), Baosteel Group and Shagang Group . As of 2017 , though, ArcelorMittal
3036-507: Is one of the largest manufacturing industries in the world, but also one of the most energy and greenhouse gas emission intense industries, contributing 8% of global emissions. However, steel is also very reusable: it is one of the world's most-recycled materials, with a recycling rate of over 60% globally . The noun steel originates from the Proto-Germanic adjective * * stahliją or * * stakhlijan 'made of steel', which
3128-463: Is one of the most commonly manufactured materials in the world. Steel is used in buildings, as concrete reinforcing rods, in bridges, infrastructure, tools, ships, trains, cars, bicycles, machines, electrical appliances, furniture, and weapons. Iron is always the main element in steel, but many other elements may be present or added. Stainless steels , which are resistant to corrosion and oxidation , typically need an additional 11% chromium . Iron
3220-544: Is one of the world's most-recycled materials, with a recycling rate of over 60% globally; in the United States alone, over 82,000,000 metric tons (81,000,000 long tons; 90,000,000 short tons) were recycled in the year 2008, for an overall recycling rate of 83%. As more steel is produced than is scrapped, the amount of recycled raw materials is about 40% of the total of steel produced - in 2016, 1,628,000,000 tonnes (1.602 × 10 long tons; 1.795 × 10 short tons) of crude steel
3312-529: Is one who is called on to fix a problem with a part or to create a new one using metals, plastics, or rarely, wood. Depending on the company, a machinist can be any or all of the titles listed above. Other related fields include Millwrights , quality assurance , and mechanical engineers . In Australia, a related profession is a fitter and turner . A fitter and turner is the tradesperson who fits, assembles, grinds and shapes metal parts and subassemblies to fabricate production machines and other equipment. Under
3404-510: Is possible only by reducing iron's ductility. Steel was produced in bloomery furnaces for thousands of years, but its large-scale, industrial use began only after more efficient production methods were devised in the 17th century, with the introduction of the blast furnace and production of crucible steel . This was followed by the Bessemer process in England in the mid-19th century, and then by
3496-434: Is possible to make very high-carbon (and other alloy material) steels, but such are not common. Cast iron is not malleable even when hot, but it can be formed by casting as it has a lower melting point than steel and good castability properties. Certain compositions of cast iron, while retaining the economies of melting and casting, can be heat treated after casting to make malleable iron or ductile iron objects. Steel
3588-400: Is quite ductile , or soft and easily formed. In steel, small amounts of carbon, other elements, and inclusions within the iron act as hardening agents that prevent the movement of dislocations . The carbon in typical steel alloys may contribute up to 2.14% of its weight. Varying the amount of carbon and many other alloying elements, as well as controlling their chemical and physical makeup in
3680-457: Is related to * * stahlaz or * * stahliją 'standing firm'. The carbon content of steel is between 0.02% and 2.14% by weight for plain carbon steel ( iron - carbon alloys ). Too little carbon content leaves (pure) iron quite soft, ductile, and weak. Carbon contents higher than those of steel make a brittle alloy commonly called pig iron . Alloy steel is steel to which other alloying elements have been intentionally added to modify
3772-409: Is required between the tool and work to perform a machining operation. The primary action is at a specific cutting speed . In addition, the device must be moved laterally across the work. This is a much slower motion called the feed. The remaining dimension of the cut is the penetration of the cutting tool below the original work surface, reaching the cut's depth. Speed, feed, and depth of cut are called
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3864-441: Is the base metal of steel. Depending on the temperature, it can take two crystalline forms (allotropic forms): body-centred cubic and face-centred cubic . The interaction of the allotropes of iron with the alloying elements, primarily carbon, gives steel and cast iron their range of unique properties. In pure iron, the crystal structure has relatively little resistance to the iron atoms slipping past one another, and so pure iron
3956-416: Is the problem of achieving the right finish or surface smoothness on the workpiece. The inferior finish found on the machined surface of a workpiece may be caused by incorrect clamping , a dull tool, or inappropriate presentation of a device. Frequently, this poor surface finish, known as chatter, is evident by an undulating or regular finish of waves on the machined surfaces of the workpiece. Relative motion
4048-529: Is the world's largest steel producer . In 2005, the British Geological Survey stated China was the top steel producer with about one-third of the world share; Japan , Russia , and the United States were second, third, and fourth, respectively, according to the survey. The large production capacity of steel results also in a significant amount of carbon dioxide emissions inherent related to
4140-498: Is then lost to the atmosphere as carbon dioxide. This process, known as smelting , was first applied to metals with lower melting points, such as tin , which melts at about 250 °C (482 °F), and copper , which melts at about 1,100 °C (2,010 °F), and the combination, bronze, which has a melting point lower than 1,083 °C (1,981 °F). In comparison, cast iron melts at about 1,375 °C (2,507 °F). Small quantities of iron were smelted in ancient times, in
4232-631: The Golconda area in Andhra Pradesh and Karnataka , regions of India , as well as in Samanalawewa and Dehigaha Alakanda, regions of Sri Lanka . This came to be known as wootz steel , produced in South India by about the sixth century BC and exported globally. The steel technology existed prior to 326 BC in the region as they are mentioned in literature of Sangam Tamil , Arabic, and Latin as
4324-586: The cementation process was described in a treatise published in Prague in 1574 and was in use in Nuremberg from 1601. A similar process for case hardening armour and files was described in a book published in Naples in 1589. The process was introduced to England in about 1614 and used to produce such steel by Sir Basil Brooke at Coalbrookdale during the 1610s. The raw material for this process were bars of iron. During
4416-592: The open-hearth furnace . With the invention of the Bessemer process, a new era of mass-produced steel began. Mild steel replaced wrought iron . The German states were the major steel producers in Europe in the 19th century. American steel production was centred in Pittsburgh , Bethlehem, Pennsylvania , and Cleveland until the late 20th century. Currently, world steel production is centered in China, which produced 54% of
4508-445: The 17th century, it was realized that the best steel came from oregrounds iron of a region north of Stockholm , Sweden. This was still the usual raw material source in the 19th century, almost as long as the process was used. Crucible steel is steel that has been melted in a crucible rather than having been forged , with the result that it is more homogeneous. Most previous furnaces could not reach high enough temperatures to melt
4600-470: The 17th century, the first step in European steel production has been the smelting of iron ore into pig iron in a blast furnace . Originally employing charcoal, modern methods use coke , which has proven more economical. In these processes, pig iron made from raw iron ore was refined (fined) in a finery forge to produce bar iron , which was then used in steel-making. The production of steel by
4692-600: The Arabs from Persia, who took it from India. It was originally created from several different materials including various trace elements , apparently ultimately from the writings of Zosimos of Panopolis . In 327 BC, Alexander the Great was rewarded by the defeated King Porus , not with gold or silver but with 30 pounds of steel. A recent study has speculated that carbon nanotubes were included in its structure, which might explain some of its legendary qualities, though, given
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#17328517783924784-463: The Linz-Donawitz process of basic oxygen steelmaking (BOS), developed in 1952, and other oxygen steel making methods. Basic oxygen steelmaking is superior to previous steelmaking methods because the oxygen pumped into the furnace limited impurities, primarily nitrogen, that previously had entered from the air used, and because, with respect to the open hearth process, the same quantity of steel from
4876-436: The austenite grain boundaries until the percentage of carbon in the grains has decreased to the eutectoid composition (0.8% carbon), at which point the pearlite structure forms. For steels that have less than 0.8% carbon (hypoeutectoid), ferrite will first form within the grains until the remaining composition rises to 0.8% of carbon, at which point the pearlite structure will form. No large inclusions of cementite will form at
4968-471: The austenite is for it to precipitate out of solution as cementite , leaving behind a surrounding phase of BCC iron called ferrite with a small percentage of carbon in solution. The two, cementite and ferrite, precipitate simultaneously producing a layered structure called pearlite , named for its resemblance to mother of pearl . In a hypereutectoid composition (greater than 0.8% carbon), the carbon will first precipitate out as large inclusions of cementite at
5060-494: The boundaries in hypoeutectoid steel. The above assumes that the cooling process is very slow, allowing enough time for the carbon to migrate. As the rate of cooling is increased the carbon will have less time to migrate to form carbide at the grain boundaries but will have increasingly large amounts of pearlite of a finer and finer structure within the grains; hence the carbide is more widely dispersed and acts to prevent slip of defects within those grains, resulting in hardening of
5152-521: The characteristics of steel. Common alloying elements include: manganese , nickel , chromium , molybdenum , boron , titanium , vanadium , tungsten , cobalt , and niobium . Additional elements, most frequently considered undesirable, are also important in steel: phosphorus , sulphur , silicon , and traces of oxygen , nitrogen , and copper . Plain carbon-iron alloys with a higher than 2.1% carbon content are known as cast iron . With modern steelmaking techniques such as powder metal forming, it
5244-433: The cutting conditions. They form the three dimensions of the machining process, and for certain operations, their product can be used to obtain the material removal rate for the process: where Machining operations usually divide into two categories, distinguished by purpose and cutting conditions : Roughing cuts are used to remove a large amount of material from the starting work part as rapidly as possible, i.e., with
5336-730: The definition. The noun machine tool and the verb to machine ( machined, machining ) did not yet exist. Around the middle of the 20th century, the latter words were coined as the concepts they described evolved into widespread existence. Therefore, during the Machine Age , machining referred to (what we today might call) the "traditional" machining processes, such as turning , boring , drilling , milling , broaching , sawing , shaping , planing , abrasive cutting , reaming , and tapping . In these "traditional" or "conventional" machining processes, machine tools , such as lathes , milling machines , drill presses , or others, are used with
5428-422: The desired properties. Nickel and manganese in steel add to its tensile strength and make the austenite form of the iron-carbon solution more stable, chromium increases hardness and melting temperature, and vanadium also increases hardness while making it less prone to metal fatigue . To inhibit corrosion, at least 11% chromium can be added to steel so that a hard oxide forms on the metal surface; this
5520-413: The final steel (either as solute elements, or as precipitated phases), impedes the movement of the dislocations that make pure iron ductile, and thus controls and enhances its qualities. These qualities include the hardness , quenching behaviour , need for annealing , tempering behaviour , yield strength , and tensile strength of the resulting steel. The increase in steel's strength compared to pure iron
5612-625: The finest steel in the world exported to the Roman, Egyptian, Chinese and Arab worlds at that time – what they called Seric Iron . A 200 BC Tamil trade guild in Tissamaharama , in the South East of Sri Lanka, brought with them some of the oldest iron and steel artifacts and production processes to the island from the classical period . The Chinese and locals in Anuradhapura , Sri Lanka had also adopted
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#17328517783925704-503: The form of charcoal) in a crucible, was produced in Merv by the 9th to 10th century AD. In the 11th century, there is evidence of the production of steel in Song China using two techniques: a "berganesque" method that produced inferior, inhomogeneous steel, and a precursor to the modern Bessemer process that used partial decarburization via repeated forging under a cold blast . Since
5796-599: The hardenability of thick sections. High strength low alloy steel has small additions (usually < 2% by weight) of other elements, typically 1.5% manganese, to provide additional strength for a modest price increase. Recent corporate average fuel economy (CAFE) regulations have given rise to a new variety of steel known as Advanced High Strength Steel (AHSS). This material is both strong and ductile so that vehicle structures can maintain their current safety levels while using less material. There are several commercially available grades of AHSS, such as dual-phase steel , which
5888-677: The machines. Other more specialised machinists produce custom-made parts for prototyping, repair, or research. A machinist may work on manufacturing something relatively simple like a bracket, or a shaft, or something extraordinarily complex, such as aerospace components accurate to 5 micrometres. Good machinists are highly sought after and respected skilled trades persons and are generally well-paid. In utility, medical, and military use companies, experienced machinists can earn over $ 100 000 per year. Some titles reflect further development of machinist skills such as tool and die maker , patternmaker , mold maker , programmer , and operator . A machinist
5980-596: The machinist title are other specialty titles that refer to specific skills that may be more highly developed to meet the needs of a particular job position, such as fitter (assembles parts), turning hand , mill hand , and grinder . A machinist is usually called upon when a part needs to be produced from a stock material by cutting. Such a part may be unique or may be needed in the thousands. The part could be anything made from metal or plastic, though machined parts are usually ones that require high precision and cannot be produced by other means. Machinists generally start with
6072-439: The main production route. At the end of 2008, the steel industry faced a sharp downturn that led to many cut-backs. In 2021, it was estimated that around 7% of the global greenhouse gas emissions resulted from the steel industry. Reduction of these emissions are expected to come from a shift in the main production route using cokes, more recycling of steel and the application of carbon capture and storage technology. Steel
6164-699: The meaning of the term suggests the need for specialized handling and/or tooling to machine them effectively. While the foregoing were primarily the materials that a machinist would be cutting, the cutters that the machinist uses must be harder and tougher than the materials to be cut. The materials in the cutters a machinist uses are most commonly high-speed steel , tungsten carbide , ceramics , Borazon , and diamond . Machinists usually work to very small tolerances , usually within 0.010" or 0.25 mm (more commonly expressed as ±0.005" (Plus or minus five thousandths of an inch) or ±0.13 mm), and sometimes at tolerances as low as +/-0.0001" (plus or minus one tenth of
6256-401: The metal in the shape of a cylindrical hole. Other tools that may be used for metal removal are milling machines, saws, and grinding machines . Many of these same techniques are used in woodworking . Machining requires attention to many details for a workpiece to meet the specifications in the engineering drawings or blueprints. Besides the obvious problems related to correct dimensions, there
6348-575: The most common materials. Materials that machinists work with occasionally are plastics , rubber , glass , and wood products. Rarely, machinists also work with exotic and refractory metals . The term exotic metals is a general term describing out of the ordinary, rare or special purpose metals. A synonym might be space-age. A list of exotic metals might include, but is not limited to, titanium , beryllium , vanadium, chromium , molybdenum and tungsten , as well as special high-temperature metal alloys like Inconel or Hastelloy ( superalloys ). Very often
6440-450: The most part, however, p-block elements such as sulphur, nitrogen , phosphorus , and lead are considered contaminants that make steel more brittle and are therefore removed from steel during the melting processing. The density of steel varies based on the alloying constituents but usually ranges between 7,750 and 8,050 kg/m (484 and 503 lb/cu ft), or 7.75 and 8.05 g/cm (4.48 and 4.65 oz/cu in). Even in
6532-436: The oxidation rate of iron increases rapidly beyond 800 °C (1,470 °F), it is important that smelting take place in a low-oxygen environment. Smelting, using carbon to reduce iron oxides, results in an alloy ( pig iron ) that retains too much carbon to be called steel. The excess carbon and other impurities are removed in a subsequent step. Other materials are often added to the iron/carbon mixture to produce steel with
6624-470: The part, especially its geometry (shape), then decide on a strategy to make it. Machine tools are then configured by the machinist and production commences. The machinist works with the quality department to ensure the specifications are maintained in the finished product. Large commercial organizations often staff machinists on site in a maintenance mode to ensure continuing operations of the production machinery. Such machinists can often make replacement parts
6716-449: The product but only locally relieves strains and stresses locked up within the material. Annealing goes through three phases: recovery , recrystallization , and grain growth . The temperature required to anneal a particular steel depends on the type of annealing to be achieved and the alloying constituents. Quenching involves heating the steel to create the austenite phase then quenching it in water or oil . This rapid cooling results in
6808-741: The production methods of creating wootz steel from the Chera Dynasty Tamils of South India by the 5th century AD. In Sri Lanka, this early steel-making method employed a unique wind furnace, driven by the monsoon winds, capable of producing high-carbon steel. Since the technology was acquired from the Tamilians from South India, the origin of steel technology in India can be conservatively estimated at 400–500 BC. The manufacture of wootz steel and Damascus steel , famous for its durability and ability to hold an edge, may have been taken by
6900-408: The proper cutting fluid is usually included within the scope of the cutting condition. Today other forms of metal cutting are becoming increasingly popular. An example of this is water jet cutting. Water jet cutting involves pressurized water over 620 MPa (90 000 psi) and can cut metal and have a finished product. This process is called cold cutting, which eliminates the damage caused by
6992-872: The same day. Because of this, the labor cost for this role are significantly lower than costs involved with production shutdowns. Additive machining means 3D printing to create industrial components, prototypes, tooling, and end-use production parts. Additive machining comes into its own in the manufacturing of very small intricate parts, which could not be produced through any other manufacturing process. There are several processes in additive manufacturing which include direct metal deposition: electron beam melting, fused filament fabrication, select laser sintering, and variations of them. The most common materials that machinists make parts from are steel , aluminium , brass , copper , and various alloys of these materials. Other less common materials such as vanadium , zinc , lead , or manganese are often used as alloying elements for
7084-471: The solid-state, by heating the ore in a charcoal fire and then welding the clumps together with a hammer and in the process squeezing out the impurities. With care, the carbon content could be controlled by moving it around in the fire. Unlike copper and tin, liquid or solid iron dissolves carbon quite readily. All of these temperatures could be reached with ancient methods used since the Bronze Age . Since
7176-401: The steel. At the very high cooling rates produced by quenching, the carbon has no time to migrate but is locked within the face-centred austenite and forms martensite . Martensite is a highly strained and stressed, supersaturated form of carbon and iron and is exceedingly hard but brittle. Depending on the carbon content, the martensitic phase takes different forms. Below 0.2% carbon, it takes on
7268-556: The steel. The early modern crucible steel industry resulted from the invention of Benjamin Huntsman in the 1740s. Blister steel (made as above) was melted in a crucible or in a furnace, and cast (usually) into ingots. The modern era in steelmaking began with the introduction of Henry Bessemer 's process in 1855, the raw material for which was pig iron. His method let him produce steel in large quantities cheaply, thus mild steel came to be used for most purposes for which wrought iron
7360-555: The technology of that time, such qualities were produced by chance rather than by design. Natural wind was used where the soil containing iron was heated by the use of wood. The ancient Sinhalese managed to extract a ton of steel for every 2 tons of soil, a remarkable feat at the time. One such furnace was found in Samanalawewa and archaeologists were able to produce steel as the ancients did. Crucible steel , formed by slowly heating and cooling pure iron and carbon (typically in
7452-406: The term machining . The two terms are effectively synonymous , although the long-established usage of the term machining continues. This is comparable to the idea that the verb sense of contact evolved because of the proliferation of ways to contact someone (telephone, email, IM, SMS, and so on) but did not entirely replace the earlier terms such as call , talk to , or write to . Machining
7544-406: The tool provides a clearance between the tool and the newly formed work surface, thus protecting the surface from abrasion, which would degrade the finish. This angle between the work and flank surfaces is called the relief angle. There are two basic types of cutting tools: A single-point tool has one cutting edge for turning, boring, and planing. During machining, the device's point penetrates below
7636-604: The tool, or the workpiece. The shape of the tool, the relative motion, and its penetration into the work, produce the desired shape of the resulting work surface. Machining operations can be broken down into traditional, and non-traditional operations. Within the traditional operations, there are two categories of machining based on the shape they machine; being circular shapes that includes; turning, boring, drilling, reaming, threading and more, and various/straight shapes that includes; milling, broaching, sawing, grinding and shaping. A cutting tool has one or more sharp cutting edges and
7728-415: The traditional machining processes. In the decades of the 2000s and 2010s, as additive manufacturing (AM) evolved beyond its earlier laboratory and rapid prototyping contexts and began to become standard throughout all phases of manufacturing, the term subtractive manufacturing became common retronymously in logical contrast with AM, covering essentially any removal processes also previously covered by
7820-522: The upper carbon content of steel, beyond which is cast iron. When carbon moves out of solution with iron, it forms a very hard, but brittle material called cementite (Fe 3 C). When steels with exactly 0.8% carbon (known as a eutectoid steel), are cooled, the austenitic phase (FCC) of the mixture attempts to revert to the ferrite phase (BCC). The carbon no longer fits within the FCC austenite structure, resulting in an excess of carbon. One way for carbon to leave
7912-519: The work part's original work surface. The fact is sometimes rounded to a certain radius, called the nose radius. Multiple cutting-edge tools have more than one cutting edge and usually achieve their motion relative to the work part by rotating. Drilling and milling use turning multiple-cutting-edge tools. Although the shapes of these tools are different from a single-point device, many elements of tool geometry are similar. An unfinished workpiece requiring machining must have some material cut away to create
8004-450: The workpiece materials. Finishing operations are carried out at low feeds and depths – dinners of 0.0125–0.04 mm/rev (0.0005–0.0015 in/rev) and depths of 0.75–2.0 mm (0.030–0.075 in) are typical. Cutting speeds are lower in roughing than in finishing. A cutting fluid is often applied to the machining operation to cool and lubricate the cutting tool. Determining whether a cutting fluid should be used and, if so, choosing
8096-428: The world's steel in 2023. Further refinements in the process, such as basic oxygen steelmaking (BOS), largely replaced earlier methods by further lowering the cost of production and increasing the quality of the final product. Today more than 1.6 billion tons of steel is produced annually. Modern steel is generally identified by various grades defined by assorted standards organizations . The modern steel industry
8188-697: Was developed in Southern India and Sri Lanka in the 1st millennium BCE. Metal production sites in Sri Lanka employed wind furnaces driven by the monsoon winds, capable of producing high-carbon steel. Large-scale wootz steel production in India using crucibles occurred by the sixth century BC, the pioneering precursor to modern steel production and metallurgy. High-carbon steel was produced in Britain at Broxmouth Hillfort from 490–375 BC, and ultrahigh-carbon steel
8280-502: Was formerly used. The Gilchrist-Thomas process (or basic Bessemer process ) was an improvement to the Bessemer process, made by lining the converter with a basic material to remove phosphorus. Another 19th-century steelmaking process was the Siemens-Martin process , which complemented the Bessemer process. It consisted of co-melting bar iron (or steel scrap) with pig iron. These methods of steel production were rendered obsolete by
8372-438: Was produced globally, with 630,000,000 tonnes (620,000,000 long tons; 690,000,000 short tons) recycled. Modern steels are made with varying combinations of alloy metals to fulfil many purposes. Carbon steel , composed simply of iron and carbon, accounts for 90% of steel production. Low alloy steel is alloyed with other elements, usually molybdenum , manganese, chromium, or nickel, in amounts of up to 10% by weight to improve
8464-729: Was produced in the Netherlands from the 2nd-4th centuries AD. The Roman author Horace identifies steel weapons such as the falcata in the Iberian Peninsula , while Noric steel was used by the Roman military . The Chinese of the Warring States period (403–221 BC) had quench-hardened steel, while Chinese of the Han dynasty (202 BC—AD 220) created steel by melting together wrought iron with cast iron, thus producing
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