Design for Machining
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Introduction
In machining,g, material is removed from
the workpiece until the desired shape
is achieved.
Avoiding machining is impractical.
Methods
M th d like
lik near nett shape
h i becoming
is b i
popular. This method should be
foremost in the designers mind.
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All machine tools provide a means of
• Holding a cutting tool or abrasive
wheel.
• Holding a workpiece.
• Providing relative motion between
them in order to generate the required
surfaces.
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Machining Operations
• Machining
M hi i with
ith single-point
i l i t tools.
t l
• Machining with multiple-point tools.
• Machining with abrasive wheels.
• Non-conventional
Non conventional machining
machining.
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Machining Using Single-Point
Cutting Tools
Lathes
L th are designed
d i d tot rotate
t t the
th
workpiece and feed the cutting tool in
the direction necessary to generate the
required machined surface.
surface
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Five Typical Lathe Operations
• Cylindrical Turning
• Facing
• Boring
• External Threading
• Cut-off
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Cylindrical Turning
• Motion:
– Turning workpiece along an horizontal axis.
– Linear feeding motion of a tool along two other axes
axes.
• Principal surfaces & features:
– Concentric cylindrical outer surfaces & holes.
– Plane surfaces normal to work-piece axis.
– Threaded
Th d d sectionti off b
bolts,
lt screws, ...
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Facing
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Boring
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External Threading
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Parting or Cut-off
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Boring on Horizontal Boring Machine
• Motion:
– Workpiece secured on a stationary horizontal table.
– Turn and feeding motion of a tool on a horizontal
ram.
• Principal surfaces & features:
– Large cylindrical hole
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Facing on Horizontal Boring Machine
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Production of a Flat Surface
• Motion:
– Linear (quick return) motion of large workpiece on
horizontal plane
– Tool with feeding motion perpendicular to the
workpiece motion
• Principal surfaces & features:
– Large plane surface.
surface
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Shaping Operations
• Motion:
– Linear (quick return) motion of tool, horizontal or
vertical.
– Stable workpiece.
workpiece
• Principal surfaces & features:
– Small to medium plane surface. Size is limited due
t the
to th cantilever
til structure
t t off the
th ram.
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Machining Using Multipoint Tools
• Milling
• Drill
• Broaching
g
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Drilling
• M
Motion:
ti
– Turning tool moving vertically
– Stationary work-piece
• Principal surfaces & features:
– Parallel circular holes
• Operation:
– Center Drilling
– Reaming
– Spot-facing
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• Operation:
((a)) Center
C t Drilling
D illi
(b) Reaming
(c) Spot-facing
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Milling
• Motion:
– Turning tool along a horizontal axis.
– Linear feeding motion by work-piece.
• Principal surfaces & features:
– Accurate large plane surface.
– Partial circular surface.
– Special features with special tools
tools.
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Horizontal Milling
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Vertical Milling
• Motion:
– Turning tool moving vertically.
– Linear feeding motion by work-piece.
• Principal surfaces & features:
– Accurate large plane surface.
– Partial circular surface.
– Large cylindrical hole.
– Special
S i l ffeatures
t with
ith special
i l ttools.
l
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Broaching Operations
• Motion:
– Tool reciprocating vertically.
– Linear feeding motion by work-piece.
• Principal surfaces & features:
– Long concave slot on an outer surface.
– Special slots with special tools.
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Grinding with Abrasive Wheels
• Surface grinding with rotating abrasive tools
• Machine types:
– Vertical grinder
– Horizontal grinder
– Horizontal internal grinder
g
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Non- Conventional Machining
• Ultrasonic machining:
– Piezoelectric transducer to g
generate a HF
motion(20 ~ 40 kHz).
– Abrasive slurry between tool and workpiece
to form a cavity.
• Water jet machining:
– Pressurized water thru a nozzle of .07 to .5
mm.
– To
T drill
d ill a h
hole
l or slit
lit a sheet
h t material.
t i l
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• Abrasive-jet machining:
– Eroding action of high-velocity stream of abrasive-
laden gas.
• Electrical-discharge machining:
– Repetitive spark discharge.
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Mechanics of Metal Cutting
Chip Formation & Build-up Edge
• At low cutting speed, the friction between tool
and chip is so great that chip welds itself on the
tool.
• Build-up edge makes the surface rough.
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Heat Generation
Temperature profile during machining mild steel
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Tool
• Tool wear
• Tool material requirement:
– High temperature stability (chemical,
physical)
– Wear resistance.
– High fracture toughness.
• Tool material:
– High speed steel
(tungsten/chromium/steel)
– Case alloy
(cobalt/tungsten/chromium/carbon)
– Cemented carbide
(tungsten/carbon/cobalt/titanium)
– Ceramic (aluminum oxide/boron/…)
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Machinability
• Surface integrity:
– Surface finish: Roughness,
g , waviness,,
flaws.
– Surface metallurgy: plastic
deformation, recrystallization, residual
stress.
• Tool life.
• Power and force requirement.
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Cutting Fluid
• As a coolant:
– Increased tool life via temperature
reduction.
reduction
– Easier handling of finished workpiece.
– Reduced thermal distortion of
workpiece.
workpiece
• As a lubricant:
– Reduced tool wear
wear.
– Reducead power consumption.
– Improved surface finish by reducing
build-up
build up edge.
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Cost Factors
• Direct material cost
• Tooling/Fixture cost
• Manufacturing
M f t i timeti
• Direct labor cost
• Factory overhead
Machining is a very wasteful process.
Reduce
R d th costt as much
the h as possible.
ibl
Goal of design for machining is to
reduce them
them.
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Goal of Design for Machining
• Reduce material cost
• Reduce tool/fixture cost
• Reduce machining cost
• Reduce direct labour cost
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Reduce Material Cost
• Use less expensive material
• Use
U standard
d d stock
k material:
i l
– Plates
– Sheets
– Bars: Round, square, rectangular
– Tubings
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Standard Stocks
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Reduce Tool/Fixture Cost
• Standard tools for machining
• Universal fixture for easy set-up
• No or simple inspection tools
• More machinable materials
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Reduce Machining Cost
• Use near net-shape
p material
• Standard or relaxed tolerance
• Standard processes
• Fewer
F tool
t l changes
h and
d set-ups
t
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Reduce Direct Labor Cost
• Less
L material
t i l handling
h dli
p
• Easier and fewer set-ups
• Fewer number of machines to work
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In General, Designer Should Know
• Capability of the shop
• Raw
R material
t i l shape
h
• Overall p
process sequence
q
• Which machines and tools to use
• How to hold the workpiece
• Final
Fi l assembly
bl off products
d t
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Summary of Design Guidelines
• Standardization:
– Use standard commercial component
– Use traditional machining processes
and features
• Raw material:
– Choose raw material that will result in
the minimum total cost.
– Use a standard stock or standard
preformed stock that is the most near-
shape to the component.
– Use a preshaped workpieces whenever
possible.
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Summary of Design Guidelines….
• Component design - overall:
– Complete machining by one machine tool.
– Complete machining by one set
set-up.
up.
– Complete machining with minimum number of tools.
– No machining on unexposed surface.
surface
– No machining of non-principal surfaces of features.
– All holes
h l either
ith parallel
ll l or normall tto principal
i i l
surfaces.
– All holes circular and with reasonable L/D ratios.
– No dogleg or other features impossible to machining
– Verify that tools, tool
tool-holders,
holders, workpieces do not
interfere with each other during machining
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Summary of Design Guidelines….
• Component
C t design
d i - rotational
t ti l part:
t
– Ensure that all major surfaces are principal
surfaces.
f
– Ensure that diameters of external/internal
features increases/decreases from the
exposed surfaces.
– Specify radii of internal corners equal to the
radius of the rounded tool corner.
– Avoid long internal features.
– Avoid components with very large or small L/D
ratios.
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Summary of Design Guidelines….
• Component design - non-rotational part:
– Provide a base for work-piece holding and
reference, and ensure that the base is one the
principal plane.
– Ensure that exposed surfaces are principal planes
or normal to them.
– Ensure that all bores are normal to the principal
surfaces and their diameters decrease from the
exposed surface.
– Ensure that internal corners of a machined pocket
have as large a radius as possible.
– Avoid machining of long surfaces by using a work-
work
piece preformed to the required cross section.
– Avoid cylindrical bores in a very long component
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Summary of Design Guidelines….
• Assembly
A bl considerations:
id ti
– Ensure that assembly is possible.
– Ensure all mating surfaces are compatible.
– Ensure all mating corners are compatible.
• Tolerance and surface finish:
– Specify the widest tolerance and roughest
surface that are acceptable.
– Ensure that all surfaces to be ground are
raised and never intersect to form internal
corners.
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END
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