Machining techniques: The basics of metalworking

Machining is a technique in which materials are processed precisely. Especially in the area of Metal processing it is an important process that plays a central role. Technology has developed a great deal in recent years. This has also changed the methods used for machining. Machining technology is no longer just about removing material. When you machine metal, you need precision, technological sophistication and efficiency. They bring with them a unique fascination once you look beyond the sight of modern machine components and precision engineering components.

Estimated reading time: 8 minutes

What is machining?

Machining technology is a manufacturing process. Excess material is removed in the form of chips. Hence the name. Tools that work with high precision are used in machining technology. They ensure that the workpiece is given the desired shape. The materials can be turned, milled, drilled or ground. Each of these techniques has its own areas of application and specific characteristics. It is often commonly thought that moulding is done by casting or forging. Unfortunately, this is not the case. Controlled removal is important for the mould to succeed. Machining technology can also be used to produce complex geometries with high dimensional accuracy. This is why machining technology is highly valued in the aerospace and automotive industries.

The diversity of machining techniques

Machining technology can be roughly divided into three main areas. On the one hand, machining processes with geometrically defined cutting edges are used. Another area is the machining process with a geometrically indeterminate cutting edge. The third is non-conventional machining processes. In conventional techniques, the turning and milling of materials is becoming increasingly important. However, they are also being replaced by modern processes. Nowadays, processes such as laser ablation or spark erosion are becoming increasingly important. This is not only a further development of the processes, it also makes it possible to machine more or less any metal workpiece to a precise fit.

Turning - the classic of metalworking

Classically speaking, turning is one of the most widespread and oldest machining techniques. Turning involves rotating the workpiece, which has previously been clamped. The tool is then guided along its surface. This method can be used to machine cylindrical shapes with maximum precision. These can be simple shafts, but complex engine parts can also be manufactured in this way. This is also known as CNC turning. This technology is particularly popular in series production.

Modern lathes enable fully automated machining with minimal waste - an aspect that is also becoming increasingly important in contract manufacturing.

Milling - precision in multiple axes

Milling is slightly different from turning. Here too, the tool rotates. However, the workpiece is moved in several axes. This makes it possible to create complicated geometries. This would not be possible with turning. Milling techniques are used particularly in tool and mould making. But they are also very popular in aerospace engineering. The use of CNC-controlled milling machines enables precise and repeatable production even with the smallest tolerances. However, these machines require trained personnel - an area in which the shortage of skilled labour is increasingly becoming an issue.

Drilling - precise machining

But you don't need to go that far. Machining technology is also used in everyday life. Anyone who has ever drilled at home has used machining technology. Drilling involves attaching a rotating tool to a material. The rotation creates a round opening. However, if you then bring the whole thing back into an industrial context, it is much more than just making a hole. In industry, special drill heads and cooling lubricants are used to drill deep holes in hard metals. The conditions are often extreme. Reaming, countersinking and thread cutting also belong to the extended category of drilling.

Sanding - for the final touch of perfection

Sanding is often the final step in the processing of materials. Sanding can ensure that things fit precisely or that surfaces are refined. The abrasive is rotated and different grit sizes are used depending on the area of application. This is particularly important in the production of precision components. This is used to manufacture hydraulic cylinders or bearing housings. The requirements for accuracy and surface quality are high in this process - and require qualified specialists.

Modern processes: Eroding and laser cutting

In addition to traditional methods, modern processes are becoming increasingly important. Electrical discharge machining (EDM) enables the machining of extremely hard materials without the need for mechanical contact. This process has become indispensable in toolmaking in particular. Laser cutting, in which a focussed beam of light cuts the material with pinpoint accuracy, also offers many advantages - from high cutting speeds to minimal heat input. Both processes open up new possibilities in prototype production and small series production.

Automation and CNC technology

Digitalisation is also on the rise in machining. CNC machines (Computerised Numerical Control) are now part of everyday working life and processes can no longer be imagined without them. They can be used to carry out highly precise automated production. This precise work reduces rejects to a minimum. It can also be used to programme complex machining sequences. The advantage here is that manual intervention does not have to be repeated. 

However, the demand for operating personnel is also increasing as digitalisation progresses. Although the machines perform many work steps fully automatically, CNC specialists are still needed. With this development, more and more temporary employment agencies and personnel service providers are coming into play because suitable specialised personnel are often not available in the companies. 

Shortage of skilled labour in machining - a growing challenge

Machining is very diverse. Employees who work in this field not only need technical knowledge, but also practical experience. However, there are many industrial companies that have a shortage of trained specialists. They are unable to operate CNC machines. Furthermore, they are not trained in the machining of highly complex operations. Small and medium-sized companies in particular have difficulties finding suitable staff. This is where temporary work comes into play - and Eastern European skilled labour is increasingly playing a central role.

Temporary work as a solution to the skills shortage

Temporary work gives many companies the opportunity to react flexibly to production peaks. You can also bridge short-term staff shortages. Especially in the field of machining technology, this can be very important in order to remain competitive. It is important that employees can be trained quickly. Temporary workers from Eastern Europe have proven to be a valuable resource in recent years. Their solid training, technical affinity and high motivation make them sought-after specialists in many manufacturing companies. Personnel service providers that specialise in this area are now an indispensable part of the industrial supply chain.

Recruitment of Eastern European skilled labour - opportunities and challenges

There are now many agencies that specialise in the placement of workers from Eastern Europe. They understand exactly what companies need and can fulfil their requirements by finding suitable employees. This is particularly important in the field of machining technology. Employees need a sound understanding of machines and materials science. Language barriers and cultural differences also play a role - but these hurdles can be overcome through targeted training programmes. The trend is clearly moving in the direction of international teams on the shop floor.