Cutting processes – tolerance and surface roughness

Here’s a useful table of tolerance and surface roughness achievable with cutting and machining process (collectively termed “material removal processes”

This information has been collated personally by myself from a variety of sources. If you have any suggestions of processes to include in this table please leave a comment and they will be added.

 

Tolerance (mm);
Surface roughness (µm)
Process name min max min max
Electro- discharge wire cutting 0.01 0.125 0.1 30
Band sawing 0.8 3 0.8 45
Circular sawing 0.2 3 0.8 45
Cropping/guillotining 0.2 2 0,1 12.5
Sheet metal 0.01 1 0,1 12.5
Sheet metal (non-tooled) 0.01 1 0,1 12.5
Water jet cutting 0.1 0.25 3.2 27
Oxyfuel gas cutting 0.8 2 6.3 71
Plasma arc cutting 0.5 2.54 12 128
Chemical machining 0.004 0.3 0.8 12.5
Chemical polishing 0.0001 1.3
Electro-Chemical Machining 0.013 0.5 0.2 12.5
Electro-Discharge Machining 0.05 0.1 0.1 30
Electron beam machining 0.005 0.05 0.2 6.3
Electropolishing 0.012 1.3
Abrasive jet machining 0.05 0.125 0.1 1.6
Abrasive grinding / polishing 0.0006 0.1 0.025 6.3
Broaching 0.0015 0.02 0.4 6.3
Drilling 02 0.5 0.4 12.5
Honing 0.00055 0.04 0.025 1.6
Lapping 0.00055 0.04 0.012 0.8
Milling (CNC) 0.01 1 0.2 25
Milling (manual) 0.01 1 0.2 25
Planing/shaping 0.02 1 0.4 25
Reaming 0.002 0.07 0.4 6.3
Turning/boring (CNC) 0.003 0.2 0.05 25
Turning/boring (manual) 0.003 0.2 0.05 25
Ultrasonic machining 0.005 0.05 0.2 1.6
Laser beam machining 0.013 0.13 0.2 6.3

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