114.6.2 - Total Manufacturing

Types of Subtractive Manufacturing

Overview of Subtractive Manufacturing Types

Chipmaking Processes

Drilling

Uses a rotating drill bit to cut cylindrical holes into material.
Material is removed in the form of chips along the bit’s flutes.

Boring

Enlarges or finishes an existing hole with a single-point cutting tool.
Often performed on a lathe, mill, or boring machine for improved size, alignment, and roundness.

Tapping

Cuts internal threads into pre-drilled holes using a tap.
Produces small chips as the tool shears material to form thread geometry.

Turning

Workpiece rotates on a lathe while a stationary tool removes material.
Creates cylindrical shapes, bores, and contours.

Milling

Rotating multi-point cutter removes material as the workpiece moves against it.
Produces flat, contoured, or complex 3D surfaces.

Shaping

Tool moves linearly against a stationary workpiece.
Similar to planing but with the cutting motion in the tool, not the workpiece.

Broaching

A multi-tooth tool (broach) is pushed or pulled through material.
Each tooth removes a small layer, producing precise shapes (keyways, splines, etc.).

Sawing

Continuous or reciprocating blade with teeth cuts material into sections.
Common for cutting stock to length.

Filing

Hand or machine-driven abrasive teeth tool removes small amounts of material.
Used for finishing, deburring, and fine adjustments.

Hobbing

A rotating hob tool progressively cuts gear teeth into a blank.
Continuous cutting action creates accurate gear profiles.

Skiving

Uses a specially angled cutting tool to slice material in a shearing action, often with simultaneous rolling or feed motion.
Commonly used for producing gears, splines, and cylindrical surfaces with high accuracy and surface finish.

Non-chipmaking Subtractive Processes

Chemical Machining (CHM)

Uses chemical etchants to dissolve selected areas of material through masks/resists.
Common for thin parts, aerospace components, and decorative/precision patterns.

Electrochemical Machining (ECM)

Material is removed by anodic dissolution in an electrolytic cell, with the workpiece as the anode.
Ideal for hard-to-machine metals; produces smooth, burr-free surfaces without tool wear.

Electrical Discharge Machining (EDM)

Material is eroded by rapid, controlled electrical sparks between an electrode and workpiece.
Works on conductive materials; capable of cutting complex shapes with high precision.

Electrochemical Grinding (ECG)

Combines electrochemical dissolution with abrasive grinding.
Removes hard materials with minimal heat and tool wear, leaving smooth surfaces.

Laser Beam Machining (LBM / LGM)

Focused laser beam melts, vaporizes, or ablates material.
Provides high precision and is useful for micro-holes and intricate shapes.

Abrasive Jet Machining (AJM)

High-velocity stream of gas with abrasive particles erodes material.
Best for brittle materials, fine cutting, deburring, and cleaning.

Water Jet Machining (WJM)

High-pressure water jet erodes material; can be combined with abrasives (AWJM).
Cuts without heat, making it suitable for metals, composites, glass, and plastics.

Ultrasonic Machining (USM)

High-frequency vibrations drive abrasive slurry against the workpiece.
Effective for hard, brittle materials like ceramics and glass.

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