# Title: What is Japanese Machining? A Comprehensive Guide to Machining Mechanisms, Types, Tools, and Applications [Beginner-Friendly]
Japanese machining is a technique that removes unnecessary parts from materials such as metals and resins to shape them into desired forms. It is utilized in a wide range of fields, from automotive parts and precision equipment to artistic crafts.
This article explains the basic mechanisms of machining, representative types of processing, tools used, and actual applications in an easy-to-understand manner. For those interested in crafts and manufacturing, this content serves as an excellent introduction to the world of Japanese machining.
Table of Contents
What is Japanese Machining?
Japanese machining is one method of processing materials by physically removing unnecessary parts to achieve a desired shape. Due to its high versatility in handling various materials such as metals, wood, and plastics, it plays an extremely important role in the manufacturing of precision parts and the finishing processes of industrial products.
Here, we will first organize the definition and basic mechanisms of machining, and explain in detail its characteristics and differences from other processing methods.
Definition and Basic Mechanisms of Machining
Japanese machining is a processing technique that removes portions of material to obtain a desired shape, primarily used for processing metals and plastics. The basic mechanism involves a cutting tool that rotates or moves at high speed while contacting the material, forming the material by generating small chips. Machining is performed using tools such as drills, milling machines, and lathes, each capable of achieving different shapes and precision levels.
Elements such as cutting speed, feed direction, and cutting depth affect the precision of the finish and surface quality. These elements need to be optimized according to the characteristics of the workpiece (the material being processed) and the properties of the tool. Machining plays an important role in manufacturing industries where high precision is required for part molding and size adjustment.
Characteristics, Advantages, and Disadvantages of Machining
Japanese machining is a technique for obtaining a desired shape by removing unnecessary parts from a workpiece. It mainly uses machine tools such as lathes and milling machines, capable of processing various materials including metals and plastics with high precision and smoothness.
Main Characteristics of Machining
- High precision: Dimensional control is possible, yielding consistent quality.
- Flexibility: Various shapes and finishes can be achieved by changing tools.
- Versatility: Accommodates a wide range of materials from metals to resins.
Advantages
- High-precision finishes are possible.
- Can handle everything from prototypes to mass production.
- Surface roughness and dimensional accuracy can be finely controlled.
Disadvantages
- High material waste (chips).
- Increased costs due to tool wear.
- Not suitable for complex internal structures.
Due to these characteristics, machining is used for manufacturing high-precision parts and small-batch production.
Differences from Plastic Processing and Grinding
Japanese machining is a method of finishing materials to a desired shape and dimension by removing parts of the material with tools. It differs from plastic processing and grinding in the following ways:
Differences from Plastic Processing
Plastic processing is a method of changing the shape of a material by applying force, utilizing the material’s plastic deformation (deformation that doesn’t return to its original state) rather than elastic deformation. It has good material yield because it doesn’t produce chips, but it’s not suitable for high-precision dimensional control.
Differences from Grinding
Grinding is a technique that uses a grinding wheel for fine removal of material and is mainly used for surface finishing and fine dimensional adjustments. While machining provides relatively large dimensional accuracy, grinding allows for smoother surface finishes.
These technologies are used differently depending on the application and purpose due to their different characteristics.
Representative Types and Features of Machining
Japanese machining has various processing methods to create a desired shape by removing unnecessary parts from materials. Here, we introduce representative processing methods such as turning, milling, drilling, and boring, and explain the characteristics and distinctions of each.
The Three Types of Machining: Turning, Milling, and Drilling
Japanese machining is a basic processing method to obtain a desired shape by removing unnecessary parts from materials such as metals and resins. Representative processing methods include turning, milling, and drilling.
Turning is a method of cutting material by rotating the material while a fixed tool cuts it, efficiently producing cylindrical parts. On the other hand, milling processes fixed material with a rotating cutting tool, forming planes and grooves. Drilling is the process of making holes in materials using a drill, and if necessary, reamers or boring bars can be used to improve the precision of the hole or expand the inner diameter.
These basic processing methods each have their own unique characteristics and applications, and are essential for the manufacture of precision parts.
What are Precision Cutting and Micro-Machining?
Precision cutting and micro-machining are processing technologies that require very high accuracy and fine finishing. Micro-machining is particularly used for manufacturing microscopic parts required in industries such as electronics, medical devices, and aerospace.
Due to the extremely small tool diameter, very careful control is necessary depending on the material being processed. This technology enables dimensional management at the micron (μm) level, improving product performance and achieving miniaturization.
Additionally, by utilizing high-performance CNC (Computer Numerical Control) machines and the latest CAD/CAM technologies, it is possible to balance accuracy and efficiency, promoting innovative product development.
Advanced Machining with Multi-Axis and Compound Machine Tools
Multi-axis and compound machine tools play an important role as advanced machining technologies in modern manufacturing. Multi-axis machine tools have rotational axes (A, B, C, etc.) in addition to the conventional three axes (X, Y, Z), allowing the tool and workpiece to move in multiple directions. This enables complex parts to be machined with a single fixation, reducing machining time and improving precision.
On the other hand, compound machine tools can perform different machining methods such as turning, milling, and drilling on a single machine, enabling process integration. This reduces the need for re-fixation and setup changes, improving machining precision and production efficiency. It also contributes to factory space-saving and management cost reduction by reducing the number of machines.
These technologies are also utilized in manufacturing parts that require complex shapes and high precision, such as aerospace, automotive, and medical devices.
Tools Used in Machining and How to Choose Materials
In Japanese machining, the proper selection of tools and workpiece materials significantly affects quality, efficiency, and safety. Tools need to be chosen according to the material and processing purpose; incorrect choices lead to decreased finishing precision and shortened tool life.
Understanding the characteristics of materials and setting optimal cutting conditions also leads to cost reduction and improved product reliability. Here, we organize basic knowledge for correct selection by explaining the types of basic cutting tools, differences between tool materials, and characteristics of workpiece materials.
Basic Tools: Bits, End Mills, Drills, etc.
In Japanese machining, the selection of appropriate tools and materials directly impacts processing quality and efficiency. Basic cutting tools include bits, end mills, and drills. Bits are used for external and internal diameter machining on lathes, while end mills are suitable for surface machining and concave-convex machining on milling machines and machining centers. Drills are used for making holes in materials, and in cases requiring precision, auxiliary tools such as reamers, center drills, and drill guides are used in conjunction.
When selecting tools, it’s important to choose appropriate material tools according to the hardness and viscosity of the workpiece. High-speed steel (HSS) is versatile and widely used for general cutting operations. Carbide alloys excel in hardness and wear resistance, suitable for high-speed machining and cutting high-hardness materials. Cermets combine heat resistance and wear resistance, making them suitable for finishing processes. Ceramics, CBN (Cubic Boron Nitride), and diamond tools are used for high-precision machining of super-hard materials and non-ferrous metals. Optimal cutting performance can be achieved by selecting according to the purpose and conditions of the machining.
Differences Between Carbide, High-Speed Steel, and Diamond Tools
The selection of tools and materials in Japanese machining greatly affects processing precision and cost efficiency. In particular, carbide, high-speed steel, and diamond tools each have different characteristics.
Carbide Tools
Carbide tools are alloys mainly composed of tungsten carbide (WC) and cobalt (Co), with high hardness, wear resistance, and heat resistance, suitable for high-speed cutting and machining hard materials. However, they have low toughness, requiring caution in interrupted cutting and impact machining.
High-Speed Steel (HSS) Tools
High-speed steel tools are alloys with chrome, tungsten, and other elements added to steel, featuring high toughness and suitability for interrupted cutting and complex shape machining. They are relatively low-cost and easy to resharpen.
Diamond Tools
Diamond tools have extremely high hardness, making them ideal for ultra-precision machining of non-ferrous metals and composite materials. However, their heat resistance temperature is relatively low at about 600°C, and they react chemically with iron, making them unsuitable for machining iron and steel materials.
Additionally, diamond tools include “Monocrystalline Diamond (MCD) tools” and “Polycrystalline Diamond (PCD) tools,” which are used differently depending on the application.
Characteristics of Target Materials (Metal, Resin, Ceramic, etc.)
In Japanese machining, selecting appropriate tools and materials is very important. Understanding the characteristics of the target materials greatly improves processing quality and efficiency.
Metals
With high hardness and ductility, tools require high wear resistance. Carbide tools and cermet tools are suitable for machining carbon steel and alloy steel, while TiAlN-coated carbide tools are recommended for stainless steel machining.
Resins
Flexible with low cutting resistance, sharpness is important for tools. When machining POM (polyacetal), appropriate machining speed and feed rate adjustments are necessary, and tool selection should be made accordingly.
Ceramics
Extremely hard and brittle, requiring tools that maintain high-strength and stable cutting conditions. Diamond-coated tools are suitable for alumina-based ceramics machining, and tools with excellent heat resistance and wear resistance are recommended for silicon nitride-based ceramics machining.
Selecting appropriate tools for each material extends tool life and improves product finishing.
Applications and Industrial Fields of Machining
Japanese machining is an indispensable technology in many industrial fields, including metal processing. This method, using lathes and milling machines, realizes precise shapes with high accuracy, greatly contributing to product quality improvement.
Especially in fields such as aerospace, automotive, and medical devices where both strength and precision are required, machining technology continues to evolve. Furthermore, with the spread of CNC (Computer Numerical Control) machines, efficient mass production of complex parts has become possible.
From here, we will introduce application examples of machining in various industries, as well as its relationship with traditional crafts and integration with the latest digital technologies.
Application Examples in Aerospace, Automotive, Medical Devices, etc.
Japanese machining plays an important role in a wide range of industrial fields.
Aerospace Industry
For the manufacture of jet engine turbine blades and turbine discs, heat-resistant alloys such as Inconel and Waspaloy are used, and high-precision machining using 5-axis machining centers, ceramic, and carbide tools is essential.
Automotive Industry
In addition to manufacturing conventional engine parts and transmission parts, the shift to EVs has increased demand for motor, battery, and reducer parts. The manufacture of these parts requires precision machining.
Medical Device Manufacturing
For the manufacture of implants and surgical instruments, difficult-to-cut materials such as titanium alloys and stainless steel are used, requiring high-precision machining.
In these industrial fields, advanced machining technology and processing precision greatly affect product performance and safety.
Machining Technology in Metal Crafts, Sword Making, and Crafts
Japanese machining plays an important role in the following traditional crafts and artistic fields to achieve precise shapes and beautiful finishes.
Metal Crafts
Metal crafts require intricate craftsmanship that balances decoration and functionality. Particularly in the production of copper, brass, and silver products, fine pattern engraving and three-dimensional pattern application are performed, which utilize high-precision machining technology. NC lathes and small milling machines are introduced to reproduce fine details and achieve uniform processing that would be difficult by hand.
Sword Making
While traditional processes such as forging, polishing, and heat treatment are the main components in Japanese sword production, machining is also used in some processes today. In particular, high-precision cutting tools are used for decorative “carvings” applied to the blade and the “hi” (groove) dug along the blade. This produces swords that balance aesthetics and functionality, promoting the fusion of traditional and modern techniques.
General Crafts (Woodworking, Precious Metals)
Machining is also important in the manufacture of crafts using wood and precious metals. For example, in woodworking, CNC routers are used for wood carving and three-dimensional processing, enabling the reproduction of precise patterns and curves. In jewelry production, ultra-precision machining technology using diamond tools is utilized for micro-machining required for precious metals such as gold and platinum. This enables the production of highly decorative one-of-a-kind pieces and products with complex structures.
Technological innovation in these fields enables the creation of more advanced and diverse products through the fusion of traditional craftsmanship and the latest mechanical technology.
Hybrid Utilization with 3D Printers
In recent years, there has been increasing attention to “hybrid manufacturing” combining 3D printer technology. This is a manufacturing method that integrates additive manufacturing by 3D printer and subtractive manufacturing by machining. This simultaneously achieves efficiency in the product manufacturing process and advancement in shape and function.
For example, it is possible to dramatically improve finishing precision by creating parts with complex internal structures with a 3D printer and then applying machining to the surface or critical dimensional parts. This process enables the manufacture of parts that balance functionality and design by achieving free shape design that was traditionally difficult while ensuring precision through mechanical processing.
Additionally, the introduction of hybrid manufacturing has consolidated multiple processing steps that were traditionally necessary, leading to reduced manufacturing time and costs. This has created a structure that maintains high competitiveness even in fields requiring small-lot production of various products. In practice, hybrid metal 3D printers like the “LUMEX” series, which integrate layered manufacturing and high-precision cutting, are being used for medical implants and complex mold production.
Thus, the fusion of Japanese machining and 3D printer technology is expected to be applied in even broader fields as an important technological innovation that improves design freedom, quality, and production efficiency in manufacturing.
Summary
Japanese machining is a representative subtractive manufacturing technology that achieves desired shapes and dimensions by cutting materials. With characteristics that enable high processing precision and beautiful surface finishes, it has the flexibility to handle diverse materials such as metals, resins, and ceramics.
Japanese machining plays an important role not only in manufacturing sophisticated industrial products such as automobiles, aircraft, and medical devices but also in fields of traditional crafts and art crafts. In metal crafts, woodworking, and sword making, machining technology is utilized to improve the precision of detailed modeling and decoration, and the fusion with modern CNC technology makes manufacturing possible that balances tradition and innovation.
Thus, Japanese machining is widely applied from industrial products to crafts, and further development is expected due to its technological evolution and ability to respond to diverse needs.
