MACHINING SECTION 1 Page 1 of 8 TABLE OF CONTENTS CONTENTS PAGE NO, ACHING, WC GENERAL, une LATHE TURNING (CUT-OFF REMOVAL ‘SCREW MACHINE PARTS Design Considerations oaNOING LN Leminated Materia REAMNG AUOAMENT OF HOLES CCOUNTERBORNG & SPOTFACING SURFACE FISH (Roughness)MACHINING MACHINING IN GENERAL The machining processes include ming lethe turing, reaming, broaching, ling, threading, counterborig, knuring, ond surface folshing, Whenever posse, parts should be designed so that stendord fosing con be uilizes auc A part designed to be miled should heve no excessively thin or weak sections which Gould break during the operation. The ort should ago be easy to. 5g ond machine without damage Some surfeces which can be miled include recesses, slots, Keywaye and fats Miling A Recess Spottacing of roised surfaces or bosses ae often used to avoid coelly miling operations. ‘spor Face Z SECTION 1 Page 2 of 8 Wherever possible, the design should utiize Htondard mlling cutters, c= when milng Slots for Keyseats. "oy cues Miling A Keynay There ore times when the lathe con replace the miling machine to accerplish a iven task as shown below. corte 4 Va LaTHe TooMACHINING SECTION 1 Page 3 of 8 {LATHE TURNING Numerous operations are performed on @ lathe suen ae turning, boring, ling threading end tapping. re Some products made on a lathe ere shafts, color, bushings, seeves, geor blonks ete XS OF WORK Toot, Revs Not only is this process economical but it reduces parts of high dimensions Seeuracy and surface finish The ae cand material from stenderd stock sizes, whenever possible, Preferred Cutolt Teal carioer eaves Application of the preferred cutoff Too! ig shown below hen using © canventionel lathe turning operation, cutoff und burrs are awaye C present os lustrated below ima T CUTOFF TOOL Vv Stet 0 aR g m Conventions Lethe Turning If these cutoffs and burrs are to be minimized, the designe” should incieate Where these ere to be removed, The Femovel process could include grinding, fing ex tumiing, Another method used for keeping cutofle tnd burrs to”0 minimum is By using @ futotf tool ground at a sight angle ond Felieved in the center os shown in the following ilustration iOMACHINING SECTION 1 Page 4 of 8 ‘SCREW MACHINE PARTS. ‘Among the most commen types of fabricated parts ofe those mode by screw machines, These machines are Used where turning, threading, forming, focing. or ering ere repeated on large quantities of parts The types of products produced on screw machines include bushings, bearings, Bearing ports, pins, nuts, bolts, studs, pirion shetts, Istument perts ete. In dion, screw machining is to be used to put the finishing touches on perts which have been semi~completed by some other process. Die costings, and tubing ere ten used to save material costs and rmachining tine In eeélit'on, tolerances should not be specified thet are closer then needed, and e surface fish that ie finer than necessary should be avoiged because it adde to the expent of @ screw machine por. As indicated previously, o drawing should specity whether or not the eut off burrs fre to be removed [rms 1 considerable saving con be realized if burre do not have {o be removed, Should eburring be necessary, this operation should be done by tumbling er some lor method, if posse DESIGN CONSIDERATIONS Whon designing parts to be produced by screw machines, « few design points must be kept in mind The example below shows the correct method of indicating specifications for Fea, corners, charters, and. countersinks When @ sharp comer is required, it should be 20 specified on the drawing, However, sharp corners are not desirable because they increase the cost of manufecturng ane henaing, Whenever possible, © chamfer shoulé be called for rather thon @-radus which Usually requires. creful lending of two intersecting surfaces and results in higher coats ‘iso note thot finite on breaking comers are clearly shown on 9 drawingMACHINING BROACHING Broaching Is the process of removing metel by drawing rod shoped, multiple tooth cutter over or through the material being worked. Srocehing is used for cutting shapes euch as internal gears, eyways, ond splined or slotted holes, Also, broaching Ts superior to reeming when finishing round holes beccuse in a single stroke, all excess material can be removed ‘© 6® ale Keyway Although costly, broaching tools can be re~shorpened after becoming dull. This, however, hes the disadvantage of being Aime consuming Moterials which eon be successfully broached include steels, cast iron, bronze, brass, magnesium and aluminum. Surface broeching is often substituted for milling when large quantities of @ part are to be produced to close tolerances and fine finish. SECTION 1 Page 5 of 8 GRINDING Grinding is done by means of @ bonded ‘abrasive wheel rotating ot high speed. Practically any type of material con be ‘successfully ground, although some soft ‘materials, such as aluminum ond bress ‘may load the grinding wheel Rough machining usucly precedes grinding Leaving on excess of material for grincing wil reduce production efficiency ‘As shown below, ports can be finished to very precise dimensions by grinding Notes: 1. Diameters A-B-C must be concentric te within .002 TR, when mounted on centers or equivalent 2, Herden and Grind Parts tht are to be ground must be firmly secured to avoid distortion. Also, slots, holes and flats in the surface of parts should be avoided. Flat ond cireuler surfaces can be ground ‘on stenderd machines. Irregular shapes usually require grinding by hand or, where ‘accuracy is important, by use of @ special setup.MACHINING DLL though simple, the dling operation ‘cannot be cantralle with eny high degree of eecuraey. The rotation of the tool or \rort, causes lines on the ined wall of the hole. This hele may not be perfectly Found but eliptical because of © bend in the sil or because the angle of the ail (Gt its point) may be slghly of ‘The design of holes should not require the use of extra long eri nor be located 20 8 to hinder the accessbilty of the t00 When « dell passes through sold metal, f clocner, straighter hole results. It is hot advisable to dril through @ iscontinuty of mete eae Pose Practice Design holes away from filets ond curved surfaces, Dring through filets is not Gesirable since the ail more likely te break and domage the part ye SECTION 1 Page 6 of 8 The designer should ovoid locating holes on curved surfaces, Flot eurfoces ore 2 Holes should only be placed at right angles to the laminctions. If this ie not posse, only ¢ cloth bese laminate should be sea, ‘BEAMING hen holes have been previously punched or eile, reaming Is often used as & precise firishing operation as ip the cose CF holes to be uses for mounting Bearings oF Uopered holes Tor pine mere the ciameters of two or more holes ‘re to be concentric and ere close {ogether, multisdiemeter reamers wil provide excelent results. Eger aMACHINING EAMING (cont'd) In order to prevent damage to © reamer becouse of the accumulation of chipe in a hole, the hole should be designed deeper than necessary. Through oles are always preferred ALIGNMENT OF HOLES Alignment of three or more holes ie difficult and should be kept to @ minimum, When it is necessary, however, @ jg and pilot bushings wil be requiced, os shown, aaa me) v a IN [7 ener NI fe A SPACER PILOT BUSHING SECTION 1 Page 7 of 8 COUNTERBORING AND SPOTEACING These operations are used to provide flat surfaces on which to rest weshers, bolt heads, spacers, bushings ete. When counterbores are used to provide cleorance for bolt heads, fractional dimensions with adequate clecrance ie acceptable, CCOUNTERBOF LAW a LB THREADING AND TAPPING The formetion of threads in « part can be achieved by means of taps, dies, miling cutters, grinding wheels or rolers. Part design is usuclly dependent on the process used to form the threed. Stondord hardware such as bolts. ond serews use threcds which are rolled Diecut threads wil accept all commen threaded fasteners ane are ereatee either by hand or semi-automatic machines, though milled threads are more dificult te mate, they ean have closer tolerances tnd wil have @ better surface finish than die cut thresds. High precision threads are usually groundMACHINING ‘SURFACE FINISH (Roughness) Surface finish je both a mecsurable dimension and © tolerance. Generally, the finer the finish, the higher the cost, Therefore, the designer should not specify @ finish Finer then te oetuclly required The value given to establish surface finish is an amount equal to the average deviation, in mieroinehee, which is measured normal to the center line. [A mieroineh ie one millionth of an inch (000001). The mieroinch finish Is shown fon drawings in terme of RMS (arithmetica! means) units In the following exemple, @ rating of 63 mieroinches is shown. This value is Understooe to apply to all surfaces defined by thet dimension oy When @ definite range of roughness is required, itis usually indicated with the meximur rating always appearing shove the minimum rating 53 BY When the finish symbol ig specified with "As Cast", "As Forged’, "As Punched”, ete. Its interpreted to mean that edditional machining operations are not required and that the finish should be achieved by the process incicated, Os cast SECTION 1 Page 8 of 8 As previously stated, surface finish is beth a messureble dimension and tolerance, The following table liste the approximate reletionship between finish end tolerance, ‘SBO «GRADE ~—=CTOLERANCE oF Pius ox EnNisHt ‘MINUS 8 Super 0005" Finn 16 Extra 001" Fine 2 Very 002" Fine 63 Fine 003" Tool 125 Semi 008" Fine Tool 250 Medium 07" Tool 500 ‘Semi 1s" Rough W Rough 025" ‘Also, it must be remembered that in otder to achieve a porticular finish, cereful consideration must be given to the method of production to ensure that the desired fnish is possible using « perticular procest