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

ƒ Machining is a very wasteful process.

ƒ Reduce
R d th costt as much
the h as possible.
ibl

ƒ 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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