1.

General Design recommendation for Machining

The following are some important, Design recommendation for Machining that should be
followed by the part designers.

1. Avoid machining operations if the surface or the feature required can be produced by casting or
forming.
2. Specify the most liberal surface finish and dimensional tolerances consistent with the function
of the surface to avoid costly grinding, lapping, and other finishing operations

3. Use stock dimensions whenever possible

4. Design the part for ease of fixation and secured clamping during the machining operation.
5. Design parts that are rigid enough to withstand clamping and cutting forces.
6. Avoid tapers and contours that complicates tooling and setups.
7. Avoid the use of hardened or difficult-to-machine materials unless their functional
properties are required.
8. Avoid undercuts because they involve more operations and special ground tools.
9. For thin and flat parts that require machining, allow sufficient stock for rough and finish
operations.
10. Put the machined surfaces in one plane.
11. Provide space for cutters, bushings, and fixture elements.
12. Avoid projections and shoulders, which interfere with the cutter movement.
13. Provide relief space for burr formation and furnish means for easy burr removal.
14. Design parts so that standard cutters can be used
15. . Machined features such as sharp corners, edges, and points should be avoided because
they are difficult to machine, creates burrs and are dangerous to handle, causes stress
concentration.
16. Select materials with good machinability
17. Design machined parts with features that can be produced in a minimum number of
setups.
18. Avoid unusual hole sizes, threads, and features requiring special form tools.
19. Use large tolerances
20. Design the part in such a way that reduces setup, reorientation time thus reducing total
operation time .

21. Minimize the use of different machine for a single part. Use single machine as far as
possible .
II. What are the design recommendations for the Turning :
Designers should follow these recommendations while designing a part for Tuning operations:
A. Stock size and shape
1. The largest diameter of the component should be taken as the diameter of the bar stock
in order to conserve material and save machining time.
2. Standard sizes and shapes of bar stock should be used in preference to special diameters
and shapes.
B. Basic part shape complexity
1. Keep the design of parts as simple as possible to reduce the number of tool stations and
gauging processes required.
2. Use standard tools as much as possible by specifying standard, common sizes of holes,
screw threads, knurls, slots, and so on.
C. Avoiding secondary operations
1. The part should be complete when cut off from the bar material.
2. Secondary operations such as slots and ! ats should be small and performed when the
part is held in the pickoff attachment.
3. Internal surfaces and screw threads should be located at one end so that they can be
performed before cutoff and without the need for rechecking.

.
D. External forms
1. The length of the formed area should not exceed two and half times the minimum
WP
diameter

2. Sidewalls of grooves and other surfaces that are perpendicular to the axis of the WP
should have a slight draft of 1/2° or more to prevent tool marks when the tool is
withdrawn.
 3. When turning from square or hexagonal stock, the turned diameter is the distance
between two opposite ! ats of the stock. It is advisable to design turned parts to be
about 0.25 mm or smaller than the bar stock size.

4 Avoid deep narrow grooves and sharp corners.

E. Undercuts
1. Avoid angular undercuts and use undercuts obtainable with traverse or axial tool
movements.
2. External grooves are machined more economically than internal recesses.
F. Holes
1. The bottom shape of blind holes should be that made by a standard drill point

G. Screw threads
1. Avoid the formations of burrs in threaded parts

H. Knurls
1. Knurled width should be narrow (≤WP diameter).
2. Specify the approximate number of teeth per inch, type of knurl, general size, and
use of Knurl.
I. Sharp corners
1. Avoid sharp corners (external and internal) as they cause weakness or more costly
fabrication of form tools.
2. Provide a commercial corner break of 0.4 mm by 45°.
3. An internal sharp corner can be made by providing an undercut at the corner
 .
J. Spherical ends: 1. Design the radius of the spherical end to be larger than the radius of
the adjoining cylindrical surface.

K. Slots and Flats

1. Slots are produced with a concave surface at the bottom or end (milling cutter radius)

L. Marking
1. Position impression marking so that roller marking tools can be used

Designers should also follow these additional recommendations:

1. Incorporate standard tool geometry at diameter transitions, exterior shoulders, grooves,
and chamfer areas.
2. Minimize unsupported, delicate, small-diameter work whenever possible to reduce work
deflection. In this regard, short, stubby parts are easier to machine
3. Avoid interrupted cutting actions that may be caused by hole intersections, slant surface
drilling, and hole or slotting operations before turning.
4. Castings and forgings with large shoulders or other areas to be faced should have 2°–3°
from the plane normal to the axis of the part to provide edge relief for the cutting tools.

5.Radii, unless critical for the part function, should be large and conform to standard toolnose
radius specifications

6. Specify a break of sharp corners where sharpness or burs may be hazardous or

disadvantageous
to the function of the part

7. Avoid clamping or locating the part using parting lines, draft angles, and forging flash
III. Design Recommendations for Drilling and Allied Operations

The following are recommended design practices for,

A. Drilling
1. The drill entry surface should be perpendicular to the drill bit to avoid starting problems
and to ensure proper location (Figure 13.20).
2. The exit surface of the drill should be perpendicular to the axis of the drill to avoid
drill breakage when leaving the hole (Figure 13.20).

3. For straightness requirements, avoid interrupted cuts to avoid drill de! ection and
breakage (Figure 13.21).

4. Use standard drill sizes whenever possible.

5. Through holes are preferable than blind holes, as they provide easier clearance for
tools and chips.
6. Blind holes should not have ! at bottoms because they require a secondary machining
operation and cause problems during reaming.
7. Avoid deep holes (over three times diameter) because of chip clearance problems and
the possibility of straightness errors (Figure 13.22).

8. Avoid designing parts with very small holes if they are not truly necessary
(3 mm is the desirable minimum diameter).
9. If large holes are required, it is desirable to have cored holes (casting) in the WP
before drilling.
10. If the part requires several drilled holes, dimension them from the same surface to
Simplify fixturing (Figure 13.23).
11. Rectangular rather than angular coordinates should be used to designate hole locations
(Figure 13.24).

12. Design parts so that all can be drilled from one side or from the fewest number of
sides.
13. Design parts so that there is a room for the drill bushing near the surface where the
drilled hole to be started (Figure 13.25).

14. Standardize the size of holes, fasteners, and screw threads as much as possible.
15. For multiple-drilling operations, the designer should bear in mind that there are
limitations as to how closely two simultaneously drilled holes can be spaced
(for 6 mm diameter or less, spacing should not be less than 19 mm center to center).

B. Reaming :
1. Even when using guide bushing, do not depend on reaming to correct location or alignment
discrepancies unless the discrepancies are very small.
2. Avoid intersecting drilled and reamed holes to prevent tool breakage and burr removal
problems (Figure 13.26).
3. If blind holes require reaming, increase the drilled depth to provide room for chips
(Figure 13.27).

C. Boring
1. During boring, avoid designing holes with interrupted surfaces, as they cause out-of
roundness errors and tool wear.
2. Avoid designing holes with a depth-to-diameter ratio of over 4:1 or 5:1 to avoid
inaccuracies caused by boring-bar de! ection. This ratio becomes 8:1 for carbide boring
bars.
3. For larger depth-to-diameter ratios, consider the use of stepped diameters to limit the
depth of a bored surface (Figure 13.22).

4. Use through holes whenever possible.

5. If the hole must be blind, allow the rough hole to be deeper than the bored hole by 1/4
hole diameter.
6. Use boring only when the accuracy requirements are essential.
7. Do not specify bored-hole tolerances unless necessary.
8. The bored part must be rigid so that deflection or vibrations caused by the cutting
forces are reduced.
The following factors affect the dimensional tolerances of drilling, reaming and
boring operations:
1. The drill sharpness affects the accuracy of the diameter and straightness of drilled holes.
2. The play and lack of rigidity in the drill spindle.
3. Drill bushing reduces the bell mouthing of holes as well as the possible hole oversize.
4. Thermal expansions of the material to be drilled.
5. The location and direction of reamed holes are affected by the previous drilling operation
even when using guide pushing.
6. Temperature changes of the WP caused by heat generated by cutting or from other causes
affect the accuracy of bored holes.
7. WP distortion from clamping.
8. Machine condition and rigidity and boring-bar rigidity are essentially important in jig
boring operations.
III. Design Recommendations for Milling
The following general product design rules apply to other machining and milling operations:
1. Sharp inside and outside corers should be avoided.
2. The part should be easily clamped.
3. Machined surfaces should be accessible.
4. Easily machined material should be specified.
5. Design should be as simple as possible.
Additional recommendations particularly applicable to milling are as follows:

1. The product design should permit the use of standard cutter shapes and sizes rather than
special ones (Figure 13.28).

2. The product design should permit manufacturing preference as much as possible to determine
the radius where two milled surfaces intersect or where profile milling is
involved (Figure 13.29).

3. When small flat surface is required, the product design should permit the use of spot facing,
which is quicker than face milling (Figure 13.30).
4. When spot faces are speci ed for casting, provide a low boss for the surface to be machined
(Figure 13.31).

5. When the outside surfaces intersect and a sharp corner is not desirable, the product design
should allow a bevel or chamfer rather than rounding (Figure 13.32).

6. When form-milling or machining rails, do not blend the formed surface to an existing
milled surface (Figure 13.33).

7. Keyway design should permit the keyway cutter to travel parallel to the center axis of the
shaft and form its own radius at the end (Figure 13.34).
8. A design that requires the milling of surfaces adjacent to a shoulder should provide
clearance to the cutter path (Figure 13.35).

9. A product design that avoids the necessity of milling at parting lines, ! ash areas, and
weldments
will generally extend the cutter life.

10 The most economical designs are those that require the minimum number of operations.

11. For more economical machining, the product design should allow staking so that a
milled surface can be incorporated into a number of parts in one gang milling operation
(Figure 13.36).

12. The product design should provide clearance to allow the use of larger-size cutters rather
than small-size ones to permit high removal rates.

13. In end-milling slots, the depth should not exceed the diameter of the cutter (Figure
13.37).
IV Design Recommendations for SHAPING, PLANING, AND SLOTTING
The following are rules that should be adhered to either for economy of operation or for
dimensional
control:
1. Design parts so that they can be easily clamped to the worktable and are rigid enough
to withstand deflection during machining (Figure 13.38).

2. It is preferable to put machined surfaces in the same plane to reduce the number of
operations required.
3. Avoid multiple surfaces that are not parallel to the direction of tool reciprocation, which
would need additional setups.
4. Avoid contoured surfaces unless a tracer attachment is available and then specify gentle
contours and generous radii as much as possible.
5. With shapers and slotters, it is possible to cut to within 6 mm of an obstruction or the end of
a blind hole (Figure 13.39). If possible, allow a relived portion at the end of the
machined surface.

6. For thin, flat WPs that require surface machining, allow suf cient stock for a stress-
relieving operation between rough and  nish machining or, if possible, rough machine equal
amounts from both sides to allow 0.4 mm for  nish machining on both sides.
7. The minimum size of hole in which a keyway or a slot can be machined with a slotter or a
 shaper is about 25.54 mm (Figure 13.40).
8. Because of the lack of rigidity of long cutting tool extensions, it is not feasible to machine
a slot longer than four times the hole diameter (Figure 13.40).

V. Design Recommendations THREAD CUTTING

Designers should follow these recommendations:

1. Provide a space (1.5–19 mm) for the thread cutting tool (Figure 13.56).

2. Allow chip clearance space when cutting internal threads (through holes are best)
(Figure 13.57).

3. Consider the use of a reduced height thread form, which machines more easily (Figure
13.58).

4. Keep the thread as short as possible, which machines quicker and provides longer tool life.
5. Include a chamfer at the top and the end of external threads and a countersink at the top and the
end of internal threads.
6. The surface of the starting thread must be flat and perpendicular to the thread’s center axis.
7. Avoid slots, cross holes, and flats that intersect with the cut threads.
8. When cross holes are unavoidable, consider countersinking of such cross holes.
9. Do not specify closer tolerances than required .
10. Ground threads should be provided with corners of 0.25 mm at the root.
11. The length of centerless ground threads should be larger than the thread diameter.
12. Coarse threads are more economical to produce and assemble faster than fine threads.
13. Tubular parts must have a wall thickness that withstands the cutting forces.