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1.design For Machining
1.design For Machining
1.design For Machining
Machining processes are material removal processes which are a family of shaping operation
in which excess or undesired material is removed from the work piece finally remaining with
the desired geometry. The design of machining considers the conventional machining
processes. In conventional machining a sharp cutting tool is used to mechanically cut the
material to achieve the desired geometry. Three major machining processes are turning,
drilling and milling. There are other machining operation include shaping, planning,
broaching etc. Figure M3.1.1 shows the cross-sectional view of machining process.
Machining can be applied to a variety of work material. Virtually all solid metals can
be machined.
It is possible to achieve very good surface finishes (roughness value less than 0.4
microns)
Wastage of material in the form of chips ( though chips can usually be recycled)
Very time consuming operation when compared to other alternative processes like
casting or forging.
Process
Sand-mould casting
Maximum
area
3 3 m
Die casting
0.6 m2
size,
flat Deviation
from flatness
4.2 mm/m
Surface finish
1225 m
1.1 mm/m
0.81.6 m
Planer
and
shaper Planer to 14 m
machining
Milling-machine machining Planer type to 14 m
0.4 mm/m
1.612.5 m
0.4 mm/m
0.86.3 m
Surface grinding
1.2 6 m
0.08 mm/m
0.11.6 m
1.8 3 m
1.3 mm/m
0.83.2 m
2.4 3.6 m
5.2 mm/m
12.525 m
1.2 3.6 m
0.8 mm/m
0.8 m
None
Improves
Ductility
Improves
Improves
Improves
Strain hardenability
Improves
Improves
Improves
Coefficient of friction
Improves
Improves
Improves
Heat conductivity
None
None
Reduces
Heat capacity
None
None
Reduces
Chemical reactivity
None
Improves
Improves
Grain size
Improves
Improves
Reduces
Abrasive insoluble
Improves
Improves
Improves
Decreases
Decreases
Design recommendations
Design recommendations for machined parts are listed below
1. It is always recommended to avoid machining operations if possible. It is always less
costlier to produce a surface or feature by processes like casting or forming.(Refer
Figure M3.1.2)
Figure M3.1.2: Avoid tolerances that involve machining without affecting the parts
function.
2. The prime operations are to be simplified by considering the most liberal surface
finish and dimensional tolerances consistent with the function of the surface, so that
the costly secondary machining operation like grinding, reaming lapping etc. can be
avoided. (Refer Figure M3.1.2)
3. Parts should be designed in such a way that it will be easy for fixturing and secure
holding during machining operation. (Refer Figure M3.1.3)
Figure M3.1.3: Design planer and shaper machined parts to withstand cutting-tool
forces and to be solidly clamped.
4. Since sharp corners and sharp point in cutting tool are more prone to breakage, in the
design these features should be avoided.
5. Use stock dimension whenever possible. This will eliminate machining operation or
the need for machining additional surface (Refer Figure M3.1.4).
Not These
These
Not these
These
Figure M3.1.5: Design the part to be rigid to withstand cutting and clamping forces
8. If possible rectangular shapes are preferred because of simple tooling and setup than
the use of tapers and contours.
9. It is recommended to reduce the number and the size of the shoulders as these usually
require extra operational steps and additional material.
10. Avoid undercuts to avoid separate operation of specially ground tools as shown in
Figure M3.1.6.
Not these
These
15. It is required to provide access room for cutters bushing and fixture element.
16. Work piece is to be designed in such a way that standard cutters can be used. (Refer
Figure M3.1.8)
Not these
These
Figure M3.1.8: Design parts so that standard cutting tools can be used.
17. It is recommended to avoid parting lines or draft surfaces for clamping or locating
surfaces.
18. It is required to provide relief space for burr removal.