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DESIGN CONSIDERATIONS IN
MACHINING
1. Machinability
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Machinability
Depends on
work material
type of machining operation,
tooling
cutting conditions
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Machinability Criteria in
Production
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Machinability Rating
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Machinability Rating
Inconel 0.30
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
ECONOMIC AND PRODUCT
DESIGN CONSIDERATIONS IN
MACHINING
1. Machinability
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Tolerances and Surface Finish
Tolerances
Machining can provide high accuracy, but
Closer tolerances usually mean higher costs
Surface roughness
Machining can provide surface finish, but
Low roughness usually mean higher costs
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Surface Finish
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Geometric Factors
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Geometric Factors Affecting
Surface Finish
Effect of (a) nose radius, (b) feed, and (c) ECEA
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Ideal Surface Roughness
Ri = f2
32NR
where Ri = theoretical
arithmetic average
surface roughness; f =
feed; and NR = nose
radius
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Ideal Surface Roughness
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Work Material Factors
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Actual Surface Roughness
Ra = rai x Ri
Workpiece material
Cutting speed
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Vibration and Machine Tool
Factors
Deflections of fixtures
1. Machinability
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Selection of Cutting Conditions
1. Depth of cut
2. Feed
3. Cutting speed
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Selecting Depth of Cut
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Determining Feed
Roughing / finishing
In roughing, 0.5 – 1.25 mm/rev
In finishing, 0.125 – 0.4 mm/rev
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Determining Feed
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Optimizing Cutting Speed
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Maximum Production Rate
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Cycle Time vs. Cutting Speed
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Minimizing Cost per Unit
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Unit Cost vs. Cutting Speed
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
ECONOMIC AND PRODUCT
DESIGN CONSIDERATIONS IN
MACHINING
1. Machinability
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines
Design rule:
Machined features
such as sharp
corners, edges,
and points should
be avoided
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines
Design rule:
Machined parts
should be
designed with
features that can
be achieved with
standard cutting
tools
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines
Design rule:
Design parts that need no machining
Use net shape processes such as precision
casting, closed die forging, or plastic molding
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines
Design rule:
Avoid undercuts as
in (a)
Additional setups,
operations, and
often special tooling
are required for
undercuts as in (b)
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014
Product Design Guidelines
Design rule:
©2013 Wiley, M P Groover, Principles of Modern Manufacturing 5/e – modified by G Dini 2014