Technical Note

Main Processing Methods Used by the IMR Machine Shop

Turning

A type of machining process in which a workpiece mounted in a lathe chuck is rotated and brought into contact with a stationary cutting tool called a tool bit. Because the workpiece rotates, this method is particularly well-suited for machining cylindrical parts.

Milling

A type of machining process in which the workpiece is secured to a milling machine using a vise or similar device, and a cutting tool called an end mill is rotated to contact the workpiece.

Grinding

A machining method that precisely removes material from a surface by rotating a grinding wheel at high speed. It is suitable for machining hard materials that are difficult to cut with conventional cutting processes. It requires a longer machining time due to the fine removal of material.

Electrical Discharge Machining (EDM)

A type of electrical discharge machining that processes materials by melting them with heat generated from discharges between the metal material and a shaped electrode. No physical resistance is applied to the material. It enables complex shapes and can process hard materials. Since discharges are required, only electrically conductive materials can be processed, and depending on the material and shape, machining can take a significant amount of time.

Wire-cut EDM

A type of electrical discharge machining that cuts by melting metal materials and the wire using the heat generated by electrical discharge. Since it uses a thin wire for discharge machining, no physical resistance is applied to the material. It enables complex shapes with minimal material loss and can process hard materials. Because discharge is required, only electrically conductive materials can be processed, and depending on the material and shape, machining can take a significant amount of time.

CNC Machining

A machining method that uses computer numerical control (CNC) to automatically control the operation of machine tools and cutting conditions. Based on programmed data, it can cut and machine metals, plastics, and other materials with high precision and at high speeds, enabling the production of parts with complex shapes. Creating the program requires a significant amount of time.

Ultrasonic Machining

By using ultrasonic vibrations to cause the tool to vibrate at a high frequency, it is possible to machine brittle and hard materials such as glass and ceramics. Machining while circulating water mixed with abrasive particles allows the tool to avoid direct contact with the material, but this process is time-consuming. Furthermore, our group’s equipment is not capable of high-precision machining.

CO₂ Laser Processing

CO₂ laser processing using infrared lasers. Excels at cutting and engraving non-metallic materials such as wood and acrylic. Cannot process reflective materials like metals, transparent materials like glass, or heat-resistant materials.

Shielded metal arc welding

This is a type of joining process. It is a welding method in which a welding rod serves as the electrode, and the heat generated by the arc discharge (over 5,000°C) between the tip of the rod and the base metal (the material being welded) melts both the rod and the base metal to join them. It is commonly used in the construction of structures.

TIG Welding

This is a type of joining process. TIG stands for “Tungsten Inert Gas,” and it is a welding method in which an arc discharge from a tungsten electrode is shielded by an inert gas such as argon to prevent oxidation. Although the process takes time, it can be used on a wide variety of shapes and metal materials. Because it produces no sparks, it is suitable for precision components that must remain clean, such as vacuum products and thin-walled parts.

Soldering

A type of joining process. It involves joining components together using a low-melting-point metal called “solder,” which has a melting point below 450°C, without melting the base material (the metal being joined). It is widely used for wiring electronic devices and assembling circuit boards.

Brazing

A type of joining process. It involves joining metals together by pouring molten “brazing filler metal” onto the base metals (the metals being joined) without melting the base metals themselves. Performed at high temperatures above 450°C, it offers greater strength than soldering and is suitable for joining dissimilar metals.

Forging

Forging is a type of plastic working. Here, we are performing free forging, which deforms the shape by striking it with a hammer or similar tool.

Flat Roll Rolling

Flat roll rolling is a type of plastic deformation. It uses a pair of flat rolls. The two rolls rotate in opposite directions. As the sample passes between the flat upper and lower rolls, pressure causes its thickness to decrease and its area to increase.

Caliber rolling

Caliber rolling is one type of rolling process. A pair of rolls with grooves are used in caliber rolling. Two rolls rotate in the opposite direction to each other. As the sample goes through between the upper and lower rolls at the grooves, it decreases in breadth and increases in length. V-shape grooves are used for square samples, and round grooves for round samples.

Swaging

Swaging is a type of plastic forming process. It involves using a die to continuously hammer the outer circumference of a metal workpiece (such as a round bar or pipe) to compress and reduce its outer diameter at room temperature. It is also known as rotary cold forging.

Wire Drawing

Wire Drawing is a type of plastic forming process. It is a method of plastic forming in which metal bars, tubes, or wire are passed through a die and pulled to reduce their diameter and shape their cross-section. It is primarily performed at room temperature.