IME 144 Lecture
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pziegler24mpaIndustrial & Manufacturing Engineering Department
IME 144
INTRODUCTION TO
DESIGN AND MANUFACTURING
Lecture #07
Abrasive & Non-Traditional Machining Processes
Industrial & Manufacturing Engineering Department
Machining Process Classification
Sawing
Drilling
Conventional Milling
Turning
Broaching
Grinding
Machining
Processes Abrasive Honing
Lapping
Mechanical Energy
Electrical Energy
Non-Traditional
Thermal Energy
Chemical Energy
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Industrial & Manufacturing Engineering Department
Abrasive Machining Processes
• Sometimes the basic machining
processes (sawing, drilling,
milling and turning) cannot
produce the required
___________________
4. mentional accuracy
: or
___________________.
surface finish
• The workpiece may be too hard
or too brittle to process with the
basic machining processes.
• One of the most common
methods for manufacturing these
types of parts is abrasive
machining.
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Industrial & Manufacturing Engineering Department
Abrasive Machining Processes
• An abrasive is a small, hard
particle that contains sharp
edges and an irregular shape.
• Abrasive grains are hard crystals
either found in nature or
manufactured.
• Capable of removing small
amounts of material from a
surface by a cutting process that
produces tiny chips.
• Abrasives also are used to hone,
lap, buff, and polish work pieces.
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Industrial & Manufacturing Engineering Department
Abrasive Machining Processes
• Most commonly used materials:
• Natural – emery, alumina, garnet, zirconia, quartz and even
walnut shells
• Synthetic - Aluminum oxide, silicon carbide, cubic boron
nitride, diamond, zirconia.
• Abrasive products are used in three basic forms by industry:
• ___________
bonded – Formed as a solid shaped tool such as
disks, cylinders, rings, cups, segments, or sticks
• ___________
Coated - backings made of paper or cloth, in the
form of sheets, strips, or belts.
• ___________
Looke - held in some liquid or solid carrier, or
propelled by centrifugal force (air or water pressure).
Industrial & Manufacturing Engineering Department
Abrasive Machining Processes
• A ___________
grit number is used to specify the
size of the abrasive particle.
• Smaller the grain size the larger the number.
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Industrial & Manufacturing Engineering Department
Grinding
• Grinding is an abrasive chip-removal process that
uses a single abrasive grain as the cutting tool to
remove material from the workpiece.
• The selection of a grinding process and machine for
a particular application depends on the workpiece
shape and features, size, ease of fixturing, and
production rate required.
Industrial & Manufacturing Engineering Department
Grinding
• Each abrasive grain typically removes only a very
small amount of material at a time; consequently,
high material-removal rates can only be achieved
if a very large number of these grains act together.
• This is done by using _______________,
bonded abrasives typically in
the form of a _________________,
g rinding wheel in which the
abrasive grains are distributed and oriented randomly.
https://www.youtube.com/watch?v=uqBTmj5vupI
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Industrial & Manufacturing Engineering Department
Grinding Temperature
• Temperature is an important parameter as it can:
• Adversely affect the surface properties by tempering and
softening the workpiece during the grinding process.
• Cause residual stresses on the workpiece.
• Cause distortions due to thermal expansion & contraction
on the workpiece.
• To reduce temperatures small depths of cut < .005”
• Sometimes cutting fluids are utilized.
Industrial & Manufacturing Engineering Department
Dressing & Trueing Grinding Wheels
• A grinding wheel must be __________
dressed-face cleaning
and _________
trued after mounting it on a
spindle. ↑
parallel to part or proper
,
Chape
• Uses an industrial diamond to remove
material from the grinding wheel.
• Dressing - any operation performed on the
face of a grinding wheel that improves
cutting action.
• Truing – a precise dressing operation, i.e.,
the face of the wheel may be made
parallel to the spindle or made into a
radius or special shape.
• Regularly applied for accurate size and
form control of the work, particularly in
automatic grinding.
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Industrial & Manufacturing Engineering Department
Surface Grinding
• Surface grinding generally involves the grinding
of flat surfaces.
• Typically, the workpiece is held on a magnetic
chuck, attached to the worktable of the grinder.
• Nonmagnetic materials are held by vises,
https://www.youtube.com/watch?v=NhmAa0X3oeI
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Industrial & Manufacturing Engineering Department
Cylindrical Grinding
• In cylindrical grinding the external cylindrical
surfaces and shoulders of workpieces are ground.
• Also called center-type grinding
• The rotating grinding wheel travels down the length
of the rotating cylindrical workpiece.
https://www.youtube.com/watch?v=x9tRltQXtjA
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Industrial & Manufacturing Engineering Department
Centerless Grinding
A high-production process for grinding cylindrical
surfaces; the workpiece is supported not by centers
or chucks, but by a blade,
https://www.youtube.com/watch?v=DdB_unEgyK8
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Industrial & Manufacturing Engineering Department
CNC Grinding
• The grinding wheel is trued to the shape of the
feature being ground into the part!
• How solid carbide milling cutters are manufactured.
https://www.youtube.com/watch?v=vtCnoP-mxEw
https://www.youtube.com/watch?v=ROKJhTX_VTQ
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Industrial & Manufacturing Engineering Department
Abrasive Belt Grinding
•Abrasive belts are used in
the machining industry for:
• Deburring
• Removing Stock
• Cleaning up of Metal
Surfaces (castings)
• Grinding welds
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Industrial & Manufacturing Engineering Department
Abrasive Cutting
•Abrasive cut-off wheels can cut
steel, brass, aluminum, ceramics,
plastics, insulating materials, glass
and cemented carbides.
• The traditional metal saw continues
to be the more economical method
for cutting-off large sections of
certain materials.
• Many materials and shapes can be
cut with much greater speed and
economy by the abrasive wheel
method.
• Dependent on hardness and cross
sectional thickness, shape & size.
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Industrial & Manufacturing Engineering Department
Honing
• A rotating tool carrying ________
abrasive
removes metal from the surface
of a workpiece’s bore.
• It is classified as a finishing
process used to finish the surface
to a particular geometric and
dimensional accuracy as well as
surface requirements, such as
roughness, lay pattern, and
surface integrity.
• Most commonly performed on
internal cylinder walls using a
combined rotating and
reciprocating motion.
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Industrial & Manufacturing Engineering Department
Honing
• Provides final sizing and creates the desired finish pattern on
the interior of tubing or cylinder bores.
• Expanding abrasive stones of abrade against the
workpiece’s surface removing material.
• The stones are rotated and reciprocated in the part with
hone abrasive under controlled pressure.
• Combining rotation and reciprocation produces a cross-
hatch pattern in the surface of the part being honed.
https://www.youtube.com/
watch?v=0WDzcoeneBc
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Industrial & Manufacturing Engineering Department
Honing
• The process is used to:
• Eliminate inaccuracies resulting
from previous machining
operations by generating a true
cylindrical form with respect to
roundness and straightness
• Achieve final dimensional size
accuracy for tight tolerance bores.
• Generate surface finishes of a
specified degree of surface
smoothness with high surface
quality.
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Industrial & Manufacturing Engineering Department
Honing
• Ball Hone
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Industrial & Manufacturing Engineering Department
Abrasive Flow Machining (AFM)
• Abrasive media flows through the
workpiece, effectively performing
erosion.
• Abrasive particles in the media
contact raised positive features on
the surface of the workpiece and
remove them.
• A hydraulic ram forces the media
through the workpiece, becoming a
flexible file or slug that molds itself
precisely to the shape of the
workpiece.
https://www.youtube.com/watch?v=XCFKV_qRr54
https://www.youtube.com/watch?v=meXz_Ph5N50
21 Silly Putty and sand
at High Pressure
Industrial & Manufacturing Engineering Department
Lapping
• Lapping is the removal of material to
produce a accurate smooth, matte
surface.
• Dependent on type of lap used.
• Used for finishing flat, cylindrical, or
curved surfaces.
• Abrasive Particles are Mixed with a
Water-Base or Oil Base Liquid.
• Combined abrasive and liquid are called
a “slurry”, this is a
• Liquid cutting tool
• Slurry is placed on a rotating motorized
platform called a “Lap Plate”
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Industrial & Manufacturing Engineering Department
Lapping
• Produces __________
extreme
dimensional accuracy
and surface finish.
• Principle process is to
produce flat smooth
surfaces however
curved surfaces are
lapped as well.
• Two distinct ways in
which lapping is done:
• Automatic lapping https://www.youtube.com/watch?v=X0-_OwjQBgI
• Hand lapping.
https://www.youtube.com/watch?v=ybkh5SiT5fo
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Industrial & Manufacturing Engineering Department
Hand Lapping
• Lapping can be performed by hand using a lap plate.
• A flat cast iron lapping plate has grooves that allow the
lapping compound to get into that area.
• Add lapping compound on one half of the plate and make a
figure 8 movement with the metal piece that needs to be
lapped.
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Industrial & Manufacturing Engineering Department
Hand Lapping
• Used when surface plates drift
out of tolerance and need to be
adjusted to maintain accuracy.
• Removing material until the entire
surface is flat within the limits of the
grade to which it was made.
• Entire lapping plate is placed
upside down on the surface plate.
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Industrial & Manufacturing Engineering Department
Non Traditional Machining Processes
• “Traditional Machining Processes”
mechanical energy to shear a chip
off the work piece.
• Non-traditional machining processes
cover the processes that do not use
___________
shear stress as their primary
source of energy to remove material.
• Generally have higher energy requirements and
slower throughputs than the traditional machining
processes we have learned about in lecture and
lab.
• Developed and used in manufacturing
applications where traditional machining methods
were impractical, incapable, or uneconomical.
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Industrial & Manufacturing Engineering Department
Non Traditional Machining Processes
• The non-traditional machining methods are typically
divided into four distinct categories:
• ___________
mechanical
• ___________
Electrical
• ___________
Thermal
• ___________
Chemical
• There are about 20 different non-traditional
machining processes available however we are
going to only discuss some of the most popular
processes in this course.
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Industrial & Manufacturing Engineering Department
Heat Affected Zone
• What is it?
• Why is it important in design & manufacturing?
o
Heat
affected
zone
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Industrial & Manufacturing Engineering Department
Heat Affected Zone
• Be-Aware - Some Non-Traditional Processes
Produce Heat Affected Zones on Materials!
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Industrial & Manufacturing Engineering Department
Chemical Machining / Milling
• Components are produced by
the etching technique using a
wide array of metals and alloys.
• This technique avoids burrs, no
mechanical stresses or
_______________________
heat affected Lond
are built into the parts and the
properties of the metal are not
affected.
=
• Hardened and tempered metals are
machined as easily as regular metals.
• The technique is ideal for machining thin
metals and foils.
• Parts with very precise and intricate
designs can be produced without difficulty.
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Industrial & Manufacturing Engineering Department
Chemical Milling
• The chemical machining/milling processes can
precisely etch lines and spaces on all types of metals
with detailed accuracies.
• There are two main chemical milling systems based on how
the acid resist is applied to the part:
• Wet Dip or Spray Application – ____________________
Chemical
hilling
• Photochemical Application – ______________________
Photochemical milling
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Industrial & Manufacturing Engineering Department
Chemical Milling
• Allows engineers to design
and manufacture intricate
metal components with
close tolerances that are
impossible to duplicate by
other production methods.
• There are four major
process steps:
• Pre-process - cleaning
• Masking
• Etching
• Post Process
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Industrial & Manufacturing Engineering Department
Chemical Milling
• Shallow cavities can be produced on large plates
sheets forgings or extrusions. – Aerospace Parts
• The acid resist is either ________
dipped or sprayed on.
• Larger parts & features use.
https://www.youtube.com/watch?v=OFYAUAOwrzY
https://www.youtube.com/watch?v=C9wPOSsMCTQ
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Industrial & Manufacturing Engineering Department
Photochemical Milling Applications
• Photoresist is laminated on a
cleaned piece of sheet metal.
• A photo tool blocks the UV light
from exposing some areas of the
photoresist.
• The sheet is developed and
washes away the unexposed https://www.youtube.com/
photoresist leaving a very precise watch?v=xTFqHstQ42s
mask of hardened photoresist
behind. https://www.youtube.com/
• The patterned sheet is then watch?v=2O1TyJGXuWY
exposed to concentrated
etchants which dissolve any
exposed material.
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Industrial & Manufacturing Engineering Department
Electrical Discharge Machining (EDM)
• The EDM process uses
electrical pulses to produce
tiny, highly focused sparks
that erode metal smoothly
and precisely.
• The rate of sparking may
range from a few thousand
sparks per second to one-
half million or more.
• The electrode and workpiece
and oil are submerged in a
bath of dielectric oil.
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Industrial & Manufacturing Engineering Department
EDM Process Principles
• Uses spark discharges to create
___________
Thermal energy that
erodes electrically conductive
materials.
• Electrode – positive or negative
charge
• Workpiece – negative or positive
charge
• Non-contact – No cutting forces
generated
• The electrode is maintained
between 0.0005” to 0.030” from
the work piece surface.
• Material removal is independent
of work piece hardness.
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Industrial & Manufacturing Engineering Department
EDM Process
1. DC pulse creates electrical field
2. Suspended particles concentrate at
strongest point in the field
3. High conductivity bridge forms
across the gap
4. As voltage increases temperature of
bridge increases
5. Spark channel develops when
dielectric & particles vaporize
6. High temperature spark melts
vaporizing workpiece & electrode
material.
7. Electrical pulse terminates causing
spark channel to collapse
8. Explosive expulsion of molten metal
from inrush of dielectric resulting in
small crater.
This can happen up to 1 million times
per second in the EDM process!
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Industrial & Manufacturing Engineering Department
Electrical Discharge Machining
• There are two types of EDM Machining Systems:
Linker die
• ___________ • ___________
wire
https://www.youtube.com/ https://www.youtube.com
watch?v=k646HE6MxE4 /watch?v=pBueWfzb7P0
38 I
need an electrode
the shape of the
Part
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Industrial & Manufacturing Engineering Department
Sinker Die Process Recast Layer
• Recast is created on steel
workpieces, where sparking occurs.
• Molten metal draws out carbon atoms
• Forms very thin, hard, brittle surface
called the recast layer - Heat-affected
zone (HAZ)
• Beneath the recast layer in steel,
there is martensite that has been
hardened by heating and cooling
sequences.
• Martensite is hard and has different
rates of expansion compared to the
parent metal.
• Stresses may cause surface cracks.
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Industrial & Manufacturing Engineering Department
Wire EDM Heat Affected Zones
• Deionized water is used as the
dielectric fluid.
• Carbon is extracted from the recast
layer, rather than added to it.
• Sometimes wire cut surfaces are softer
than the parent material.
• Higher amperage with shorter on
times compared to sinker
machines.
• HAZ can be held below 1 micron.
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Industrial & Manufacturing Engineering Department
EDM Advantages
• No cutting forces
• High aspect ratios
• Intricate cavities
• Unaffected by material hardness
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Industrial & Manufacturing Engineering Department
EDM Disadvantages
• Electrically conductive
workpiece required
• Low MRR
• Recast & HAZ
• Consumable electrode
• High capital cost
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Industrial & Manufacturing Engineering Department
Laser Beam Machining / Cutting
• The source of energy is a laser
which focuses ___________
Optical
energy converted to ___________
thermal
energy on the surface of the
workpiece.
• The highly focused, high-density
energy source melts and
evaporates portions of the
workpiece in a controlled manner.
• This process, which does not
require a vacuum, is used to
machine a variety of metallic and
nonmetallic materials.
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Industrial & Manufacturing Engineering Department
Laser Cutting
• Laser cutting is the process of
vaporizing material in a very small,
well-defined area. The laser itself is
a single point cutting source with a
very small point, (0.001" to 0.020)
allowing for very small cut widths.
https://www.youtube.com/watch?v=_zMGqVuhxrE
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Industrial & Manufacturing Engineering Department
Laser Beam Machining / Cutting
• Within the manufacturing world, lasers are used to
___________,
cut materials mark surfaces, weld, & heat in exact
locations!
https://www.youtube.com/watch?v=wYQpnn0heOs
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Industrial & Manufacturing Engineering Department
Laser Cutting Advantages
• Due to the narrowness and intensity of
the beam, laser cutting has a small
heat-affected zone (HAZ) as compared
with other thermal cutting methods.
• Almost no limit to the cutting path.
• The process is forceless allowing very
fragile or flimsy parts to be laser cut
with no support.
https://www.youtube.com/
• The laser beam is always “_________”
Sharp watch?v=jOsPY8L3eIY
and can cut very hard, abrasive, or
https://www.youtube.com/
sticky materials. watch?v=9XojF1jxJ6g
• Lasers cut at high speeds. https://www.youtube.com/
• The speed is limited only by the power watch?v=U66ij5R9kJY
available from the laser.
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Industrial & Manufacturing Engineering Department
Electrochemical Machining
• Uses ___________
electrical energy to remove material.
• As opposed to chemical milling, electrolytic etching
dissolves material electro-chemically by applying
DC current to an anodic workpiece.
• Principle of anodic metal dissolution by electrical energy
https://www.youtube.com/watch?v=ARa983c0XTs
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uses redox to manufacture
Industrial & Manufacturing Engineering Department
Electrochemical Machining
• An electrolytic cell is created in an
electrolyte where the tool is the __________
Cathode
and the workpiece is the __________.
mode
• Workpiece must be conductive like EDM!
• A high amperage, low voltage current is
passed through the cell, dissolving away
the material to be removed.
• A electrolyte solution transfers charge in
the gap between the tool and workpiece,
• Electron transfer removing material from anode.
• Most common electrolytes are sodium nitrate
and sodium chloride.
• Solution flows at a high velocity between the
cathode and anode gap.
https://www.youtube.com/watch?v=12-IOyuPJZo
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Industrial & Manufacturing Engineering Department
Electrochemical Machining
• Produces distortion-free, burr-free
parts with excellent surface finish.
• The shape of the cathode (tool)
determines the final shape of the
workpiece.
• The speed of material removal is dictated by
the DC current applied.
• The amount of material removed is defined
by Faraday’s Laws.
• The material removed during the process
must be filtered out of the electrolyte stream.
• The separation distance between the
cathode and the workpiece is key to
regulating the material removal process.
https://www.youtube.com/watch?v=Be3sWAw7oG8
https://www.youtube.com/watch?v=zLD9FxEhzRw
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Industrial & Manufacturing Engineering Department
Electrochemical Machining
• Unlike traditional cutting methods, workpiece
hardness is not a factor – suitable for difficult-to-
machine materials.
https://www.youtube.com/watch?v=zLD9FxEhzRw
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Industrial & Manufacturing Engineering Department
ECM Advantages
• Speed of machining does not depend on
the hardness of the workpiece material.
• The tool does not wear during process.
• Soft materials such as copper may be used.
• No stresses or heat affected zones are
produced on the workpiece surface.
• Burr-free machining operation.
• High surface quality may be achieved.
• High accuracy of the machining
operation.
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Industrial & Manufacturing Engineering Department
ECM Disadvantages
• Higher cost compared to other
machining processes.
• Electrolyte can cause corrosion
of the equipment.
• Process takes up a lot of floor
space.
• Only electrically conductive
materials may be machined.
• Not an environmentally friendly
machining process.
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Industrial & Manufacturing Engineering Department
Ultrasonic Machining (USM)
• A ___________
mechanical material removal
process used to machine holes and
cavities in hard or brittle
workpieces by using shaped tools,
high frequency mechanical motion,
and an abrasive slurry to erode
away the workpiece.
• Designed to machine hard brittle
workpieces such as Glass, Sapphire,
Alumina, Ferrite, PCD, Piezoceramics,
Quartz, CVD Silicon Carbide, Ceramic
Matrix Composites, Technical Ceramics
• Shaped tool creates a mirrored image
in the workpiece.
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Industrial & Manufacturing Engineering Department
Ultrasonic Machining
• Able to effectively machine all
materials harder than HRc 45,
whether or not the workpiece is
an electrical conductor or an
insulator.
• Material is removed by micro-
chipping or erosion between the
abrasive particles and the tool.
• Tool vibrates between 20-100 kHz.
https://www.youtube.com/watch?ti
me_continue=20&v=uXYU5r58n4c
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Industrial & Manufacturing Engineering Department
Rotary Ultrasonic Machining (RUM)
• In RUM, a rotating cutting tool with metal-bonded diamond
abrasive particles is ultrasonically vibrated in the axial
direction while the tool spindle is fed toward the workpiece
at a constant feedrate to remove material.
https://www.youtube.com/watch?v=lWdu9Uo4g-0
https://www.youtube.com/watch?v=TMJosHcfInQ
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Industrial & Manufacturing Engineering Department
Ultrasonic Machining Advantages
• This machining method is capable of
machining brittle and hard material
with high precision.
• Can machine conductive and non-
conductive materials.
• Does not leave a heat-affected-zone.
• The machined parts produced require
fewer finishing process because of
absence of burrs in the process.
• Good surface finishes are achieved
by the process.
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Industrial & Manufacturing Engineering Department
Ultrasonic Machining Disadvantages
• The metal removal is slow due to
micro chipping or erosion mechanism.
• Only workpieces that have a Rockwell
hardness value > 45 HRc can be
machined.
• Abrasive slurry cannot be reused.
• Fast tool wear due to abrasive slurry.
• Uneconomical for small lot sizes
make process due to tooling design.
• Difficult to drill deep holes because of
slurry delivery.
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Industrial & Manufacturing Engineering Department
Waterjet Machining
• A ___________
mechanical material
removal process capable of
slicing into metal or other
materials using a jet of water
at high velocity and pressure.
• The cutter is connected to a
high-pressure water pump
where the water is pressurized
and then fed through a small
jewel orifice where it mixes
with an abrasive garnet and
then ejected out of the nozzle.
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Industrial & Manufacturing Engineering Department
Waterjet Machining
• The workpiece gets cut by the
stream of high-speed water
and abrasive grains.
• Can be used to cut materials
as diverse as bread to titanium
• Metals, wood, rubber, stone, tile, paper
and food (no abrasives in food).
Material vs Cutting Speed
https://www.youtube.com/watch?v=PCsoC3i7JYc
https://www.youtube.com/watch?v=ch_dutN26VU
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Industrial & Manufacturing Engineering Department
Waterjet Machining
• Some parts have __________
placed on them so they do not
fall in between the slats and
into the water and slurry
collection tub.
• Also keeps the nozzle from
running into parts that may stick
up after getting removed from the
sheet of material.
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Industrial & Manufacturing Engineering Department
Waterjet Machining Advantages
• Able to cut almost any type of material.
• Limitations include materials that are highly
brittle - tempered glass and some ceramics.
• No hazardous waste produced.
• Does not leave a heat-affected-zone.
• Can cut through thicker materials and
materials that do not melt when
compared to laser or plasma cutting.
• Parts are typically cut from sheetmetal
or plate material and require no special
clamps, fixtures or tool changes.
https://www.youtube.com/watch?v=s-SZbqfVuVA
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Industrial & Manufacturing Engineering Department
Waterjet Machining Disadvantages
• Cannot create blind cuts or features.
• Sometimes small indentations occur
in the part where the waterjet stream
begins and ends.
• Parts will have a slight taper along
the cut line due to the waterjet
cutting stream spreading out as it
gets farther from the nozzle.
• Typical _____ width is between .02”-
.04” which limits intricate features.
• Abrasive garnet is a consumable and
is not reusable – has to be removed
from the machine.
https://www.youtube.com/watch?v=ZzAEBpiphh4
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Industrial & Manufacturing Engineering Department
Machining Process vs. Surface Finish
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Industrial & Manufacturing Engineering Department
Tolerance vs. Cost
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Industrial & Manufacturing Engineering Department
Questions?
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IME 144 Lecture
Industrial & Manufacturing Engineering Department
IME 144
INTRODUCTION TO
DESIGN AND MANUFACTURING
Lecture #05
Documenting the Manufacturing Process, Broaching,
Design Project #2 Calculations, & Midterm Exam
Review
Industrial & Manufacturing Engineering Department
Production Planning
• Viewed as the nervous system of the manufacturing
operation (ERP Systems).
• It comprises of: planning, ___________,
routing scheduling,
dispatching, & follow up in the production process.
1
Industrial & Manufacturing Engineering Department
Production Planning
• The highest efficiency in production is obtained by
manufacturing the required quantity of the product in
the required amount of time, with the least amount of
defects, all while using the best & ________
cheapest method.
was called
mipe
·
Now Called
ERP
forecasts of future
Hr
ousiness
Industrial & Manufacturing Engineering Department
Production Planning
• It may be defined as the
technique of foreseeing
every step in a long series
of separate operations,
each step to be taken at
the right time & in the right
place & each operations
to be performed in
maximum efficiency.
• It helps producers to work out the
quantity of material, man power,
machine & money required for
producing predetermined level of
output in given period of time.
2
Industrial & Manufacturing Engineering Department
Production Planning
https://www.youtube.com/w
atch?v=KHU9UOD8utY
Industrial & Manufacturing Engineering Department
Production Planning
https://www.youtube.com/w
atch?v=kLtnsTgQdgk
3
Industrial & Manufacturing Engineering Department
Job Flow Planning / Routings
• Manufacturing engineers create ___________
routings to
establish, the manufacturing operations, their path,
and most efficient sequence.
• To perform these operations the proper type
of machine tools and personnel required are also
determined.
• The main aim of routing is to determine the best
and cheapest sequence of operations and to
ensure that this sequence is strictly followed.
routing-everested in order to manufacture
a Part
Industrial & Manufacturing Engineering Department
Job Flow Planning / Routings
• A routing step is usually defined by workholding!
Standard >
- linear
overlapped fore
8 Parallel- of into
next
[they] -
> the rest
solit > must do
- one of these
4
Industrial & Manufacturing Engineering Department
Job Flow Planning / Routings
Engineering drawings are used to create routings!
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Industrial & Manufacturing Engineering Department
Job Flow Planning / Routings
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5
Industrial & Manufacturing Engineering Department
Operation Sheets
• Assignment of specific operations to machinery.
• Operation sheets give __________________
detailed instruction on
how to perform a specific manufacturing step.
• Safest Way to Perform Operation
• Step by Step Instructions on Setup & Mfg Operation
• Operation Sheets Should Include:
routing
• Personal Protection Equipment (PPE) 10 -> 00
• Engineering Drawing Reference sheet
20-
•
•
Pertinent Dimensions & Tolerances
Fixtures / Workholding
30- ↓
• Tooling / Feeds & Speeds
• Setup Figure or Drawing
11
Industrial & Manufacturing Engineering Department
Operation Sheets
12
6
Industrial & Manufacturing Engineering Department
Broaching
• Broaching is performed on a
-broaching machine or an
___________
Arbor press and the cutting
tool is called the broach.
• It can produce complex
shapes with internal sharp
corners.
13
Industrial & Manufacturing Engineering Department
Broaching
• Originally developed for machining ___________
Internal Kernas but
quickly developed into complex irregular surfaces.
• Used in production to finish an entire surface in a
single pass producing special shaped holes, splines,
flat surfaces, and complex shapes not achievable by
milling or turning processes.
14
7
Industrial & Manufacturing Engineering Department
Broaching
• The machined surface
is always the inverse of
the broach’s profile
where the frontal
contour of the teeth
determines the shape of
the machined surface.
https://www.youtube.com/watch?v=vSmxi2224dc
15
Industrial & Manufacturing Engineering Department
Broaching
• Contains a series of teeth where each tooth stands
slightly higher than the last (in/tooth) creating the
___________.
Chipload Broaches are very expensive
• The pull end of a broach is first fed through the part
then attached to the broaching machine where it
gets pulled through the part usually by a hydraulic
ram.
16
8
Industrial & Manufacturing Engineering Department
Broaching B roach makes
different shape
a hole into a
• In internal broaching, a ___________
hole must exist in
the work piece into which the broach can enter.
https://www.youtube.com/watch?v=8QHthaoBU40
17
Industrial & Manufacturing Engineering Department
Machining Process Classification
Sawing
Drilling
Conventional Milling
Turning
Broaching
Grinding
Machining
Processes Abrasive Honing
Lapping
Mechanical Energy
Electrical Energy
Non-Traditional
Thermal Energy
Chemical Energy
18
9
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Objective:
• Design a shaft assembly with standard purchased parts
from another vendor using: design constraints and
criteria; allowance and clearance calculations; vendor
specified part tolerances; and engineering drawings.
19
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Design Constraints & Criteria:
• Stock Size: Ø1.00 X 4.10 L.O.C. 6061-T6
Aluminum Round
• Overall Shaft Length 4.00 ± .01
• Largest Shaft OD = .925 ± .005
• L1 - Allowance = .002 & Clearance = .042
between Shaft and Washer Shoulders
• Ø1 - Allowance = .005 & Clearance = .035
between Busing ID & Shaft OD
• L2 - Allowance = 2 Threads Visible &
Clearance = 3 Threads Visible
• Ø2 - 5/8-11 UNC 2A Thread
• L3 - Allowance = -.020 & Clearance = 0
between Washer and Shaft Shoulder
• Ø3 Thread Relief Must Be .015 - .025
Smaller Than Thread Minor Diameter
20
10
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Project Deliverable
• Design Calculations to Figure our L1-3 & Ø1-3
21
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Vendor Part = McMaster-Carr Part # 94639A891
• Determine the Busing Design Variables
• Bushing Length MMC · 165
• Bushing Length LMC · 135
• Bushing ID MMC 105
• Bushing ID LMC ·
165
22
11
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Vendor Part = McMaster-Carr Part # 92141A035
• Determine the Washer Variables
• Washer Thickness MMC .
085
• Washer Thickness LMC .
or
23
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Vendor Part = McMaster-Carr Part # 95462A533
• Determine the Hex Nut Variables
• Hex Nut Thickness MMC · 554
• Hex Nut Thickness LMC · 535
24
12
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Determine the Thread Variables
• 5/8-11 UNC 2A Major Ø MMC · 6234
• 5/8-11 UNC 2A Major Ø LMC ·
6113
• 5/8-11 UNC 2A Minor Ø ·
S11 &
• 5/8-11 UNC 2A Pitch 1/16
25
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Determine the Thread Variables
26
13
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Determine the Chamfer Variables
• Largest Chamfer 6 .
080
• Smallest Chamfer 6 . 018
27
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate Ø1’s Maximum Material Condition
• (MMC Bushing ID) - (Ø1 Allowance)= (Ø1 MMC)
· 115- - 005 . 110
28
14
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate Ø1’s Least Material Condition
• (LMC Bushing ID) - (Ø1 Clearance)= (Ø1 LMC)
%
65 -
. 035 =. 730
29
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate Ø1’s Nominal Dimension
• (MMC Ø1 +LMC Ø1)/2= (Ø1 Nominal Dimension)
. _ St
0
.
30
15
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate Ø2’s Maximum Material Condition
• (MMC Thread Major Ø) = (Ø2 MMC)
·
6231 =. 6234
31
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate Ø2’s Least Material Condition
• (LMC Thread Major Ø) = (Ø2 LMC)
6112 =. 6113
32
16
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate Ø2’s Nominal Dimension
• (MMC Ø2 +LMC Ø2)/2= (Ø2 Nominal Dimension)
↓ +xXX
·
6231 - 61137615
33
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate Ø3’s Maximum Material Condition
• (Thread Minor Ø) – (.015) = (Ø3 MMC)
· 9118- 019 =. 1964
-
34
17
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate Ø3’s Least Material Condition
• (Thread Minor Ø) – (.025) = (Ø3 LMC)
·
(119- - 025 = :
1869
35
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate Ø3’s Nominal Dimension
• (MMC Ø3 +LMC Ø3)/2= (Ø3 Nominal Dimension)
+++X
- 1964 + 1864.
,y
=. 401
36
18
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate L1’s material condition at MMC
• (L1 Allowance)+ (MMC Bushing Length) = (MMC L1)
.
00 2 + 165 =. 16.
37
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate L1’s material condition at LMC.
• (L1 Clearance)+ ( LMC Bushing Length) = (LMC L1)
044 + .
139 =. 4)
0 .
38
19
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate L1’s Nominal Dimension
• (MMC L1 + LMC L1)/2 = (L1 Nominal Dimension)
·1 1.0
39
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate L2’s Maximum Material Condition.
• (MMC Washer Thickness) + (MMC Nut Thickness) +
(Largest Chamfer ) + (L2 Allowance) = (MMC L2)
0 . 085 +. 554 +. 080 + ↑ =
06
40
20
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate L2’s Least Material Condition.
• (LMC Washer Thickness) + (LMC Nut Thickness) +
(Smallest Chamfer ) + (L2 Clearance) = (LMC L2)
0 .
011 + East .
%0 + 37 . 949
41
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate L2’s Nominal Dimension
• (MMC L2 + LMC L2)/2 = (L2 Nominal Dimension)
.40 Peo
42
21
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate L3’s Maximum Material Condition.
• (MMC Washer Thickness) + (L3 Allowance) = (MMC L3)
085- 02 .
65 =
43
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate L3’s Least Material Condition.
• (LMC Washer Length) + (L3 Clearance) = (LMC L3)
11 =.
44
22
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Calculate L3’s Nominal Dimension
• (MMC L3 + LMC L3)/2 = (L3 Nominal Dimension)
·. =. 0681 to
45
Industrial & Manufacturing Engineering Department
Lathe Design Project #2
• Project Deliverable - Create an Engineering Drawing!
46
23
Industrial & Manufacturing Engineering Department
Mill Design Project #2
• Objective:
• Use allowance and clearance
calculations, engineering drawings,
design criteria, and constraints to
design and manufacture a part to
fit within an assembly of parts.
47
Industrial & Manufacturing Engineering Department
Mill Design Project #2
• Design Constraints & Criteria:
• Stock Size: .375” & 2.0” X 2.6 L.O.C. 6061-T6 Aluminum
• Overall Part Height including Key .350”
• Tightest Fit between Key & Slot = .004”
• Loosest Fit between Key & Slot = .020”
• All Sides of the Part Must Be Machined
48
24
Industrial & Manufacturing Engineering Department
Mill Design Project #2
• Project Deliverable
• Design Calculations
49
Industrial & Manufacturing Engineering Department
Mill Design Project #2
• Project Deliverable
• Model Part and Create Engineering Drawing in SolidWorks!
50
25
Industrial & Manufacturing Engineering Department
Midterm Exam Review
Who: IME 144 Lecture Students
What: IME 144 Midterm Exam
Where: Virtual (By Yourself) On Zoom – Need
Video ON For Password
When: 10-29-2024 9:10 – 11:00 AM
Why: To assess student’s understanding
of the lecture and lab material
presented in the course thus far.
How: Multiple Choice, Drawing
Interpretation, Shaft Design,
Threads, & GD&T
Positional Tolerances
51
Industrial & Manufacturing Engineering Department
Midterm Exam Review
52
26
Industrial & Manufacturing Engineering Department
Midterm Exam Review
53
Industrial & Manufacturing Engineering Department
Midterm Exam Review
54
27
Industrial & Manufacturing Engineering Department
Midterm Exam Review
55
Industrial & Manufacturing Engineering Department
Midterm Exam Review
56
28
Industrial & Manufacturing Engineering Department
Questions?
57
29
Industrial & Manufacturing Engineering Department
IME 144
INTRODUCTION TO
DESIGN AND MANUFACTURING
Lecture #04
Tolerances, Fits, Datums, &
Geometric Dimensioning & Tolerancing (GD&T)
Industrial & Manufacturing Engineering Department
Tolerancing / Interchangeability
• Tolerancing is dimensioning for _________________
Interchability
and insures fitment between mating parts in an
assembly.
• What is interchangeability?
• An interchangeable part is simply a mass produced part.
• Mass produced parts are interchangeable with one
another and tolerances establish dimensional limits for the
part features .
• Makes it possible to manufacture parts at different times,
or in different places that still assemble properly.
1
Industrial & Manufacturing Engineering Department
Tolerancing / Interchangeability
• How is a feature on an interchangeable part
dimensioned?
• The feature is not dimensioned using a single value, but a
range of values.
2.005
2.000 →
1.994
Industrial & Manufacturing Engineering Department
Tolerancing / Interchangeability
• A tolerance is the amount of _________
Variation permitted.
• You can choose a tolerance that specifies a large or
small variation.
2.005
Size limits =
1.994
Tolerance = 2.005 - 1.994 = .011
2
Industrial & Manufacturing Engineering Department
Tolerancing / Interchangeability
• Why do we want a part’s size to be controlled by
two limits?
• It is necessary because it is impossible to
manufacture parts without some variation.
• The stated limits are a form of quality control.
Industrial & Manufacturing Engineering Department
Tolerancing / Interchangeability
• Choosing a tolerance for your design.
• Specify a tolerance with whatever degree of accuracy
that is ______________________________________!
required for the design to work
• Choose a tolerance that is not _________________
too accurate or
_________________.
not accurate enough
3
Industrial & Manufacturing Engineering Department
Tolerancing / Interchangeability
• Choosing the correct tolerance for a particular
application depends on:
• The Design Intent (end use) of the Part
• _________________
cost
• How it is Manufactured
• Experience
Industrial & Manufacturing Engineering Department
Types of Fits
• There are three major types of fits.
• _________________
Interference Fit Press fit
-
• _________________
Transition Fit Some friction USA Parts
-
• _________________
Clearance Fit Ther hole , free
sliding
-
4
Industrial & Manufacturing Engineering Department
Interference Fit
• Two mating parts must be pressed or forced together.
• At any produced size within the stated tolerance, the
shaft is larger than the hole.
• “Press-Fit”
Industrial & Manufacturing Engineering Department
Clearance Fit
• Part 1 will always fit into Part 2 with a clearance
between the two parts no matter what the actual
size of each part is when produced within the given
tolerances.
5
Industrial & Manufacturing Engineering Department
Transition Fit
• What is a transition fit?
Depending on the sizes
of the shaft and hole
there could be a space
or no space.
Industrial & Manufacturing Engineering Department
Inch Tolerances Definitions Review
• Limits: the maximum and minimum size the part
is allowed to be. [
%00n
,
• Basic Size or Target Dimension: the size from
which limits are calculated. -
2 .
000
• Tolerance: the total amount a specific dimension
is permitted to vary. # .
Gos
6
Industrial & Manufacturing Engineering Department
Tolerance Types Review
• The there are three main tolerance methods utilized
on engineering drawings:
• Limit dimensions between
• Plus or minus tolerances #
• Block tolerances
• No matter what type of tolerance is used, the number
of decimal places in the basic dimension should
match the number of decimal places in the tolerance.
Industrial & Manufacturing Engineering Department
Limit Dimension Review First Prea -
• Limits are the maximum and minimum sizes that a
part can obtain and still pass inspection.
• External dimensions:
• The larger dimension is first or on top and the smaller dimension
is on the bottom.
• Internal dimensions:
• The smaller dimension is first and the larger dimension is last.
7
Industrial & Manufacturing Engineering Department
Plus or Minus Tolerances Review
• Bilateral Tolerance
• Permitted to vary in both the + and – directions from the
specified dimension.
• Equal Bilateral Tolerance
• The variation from the specified dimension is the same in
both directions.
• Unequal Bilateral Tolerance
• The variation from the specified dimension is not the same in
both directions.
• Unilateral Tolerance
• Permitted to increase or decrease in only one direction
from the specified dimension.
Industrial & Manufacturing Engineering Department
Title Block Tolerances Review
• A title block tolerance is actually a general note that
applies to all dimensions not covered by some other
tolerancing type directly on the feature.
• Block tolerances are usually found in the title block or
in the notes section on the drawing.
fond in bottom
drawing
of
8
Industrial & Manufacturing Engineering Department
Material Conditions & Tolerances
• Maximum Material Condition (MMC): The MMC is
the size of the part when it consists of the most
material. add material to part, more weight
-
• Least Material Condition (LMC): The LMC is the
size of the part when it consists of the least
material. remove material
-
less
weight
Industrial & Manufacturing Engineering Department
Tolerance
• What is the tolerance for the shaft and the hole?
• Shaft: mmzLmc
Dshaft – dshaft =
• Hole: muc-Luc
Dhole – dhole =
9
Industrial & Manufacturing Engineering Department
Material Conditions
• What are the limits of the shaft and the hole?
Oshaft
• MMC Shaft: _________________
• MMC Hole: _________________
shaft
• LMC Shaft: _________________
I hole
• LMC Hole: _________________
Dhole
0993-943 as =
= ·
0948 + LMC
Industrial & Manufacturing Engineering Department
Allowance
• The minimum clearance (positive value) or
maximum interference (_______________)
negative between
mating parts. fightest it say be
-
• The tightest possible fit between parts.
• Allowance is calculated at MMC.
dhole – Dshaft =
Allowance = MMChole – MMCshaft
3010-Ushaft
10
Industrial & Manufacturing Engineering Department
Clearance
• The maximum clearance (positive value) or
minimum interference (______________)
Negative between
mating parts. host loose
• The loosest possible fit between mating parts.
• Clearance is calculated at LMC.
Dhole – dshaft =
Onde shaft
Clearance = LMChole – LMCshaft
Industrial & Manufacturing Engineering Department
Limits & Tolerance
Shaft Hole
Limits · Sl - 4) ·
14-090
Tolerance 1 . 00
11
Industrial & Manufacturing Engineering Department
MMC & LMC
Hole
MMC 6 51 . 0 . 44
LMC 0 - 4) ·
So
Industrial & Manufacturing Engineering Department
Allowance & Clearance Calcs
Allowance · 44- .
[= -
- 02
Clearance · 50-047 = 03
12
ess
a
transitive cemet
Industrial & Manufacturing Engineering Department
Identifying Type of Fit
• What does a negative allowance mean?
material is in the was means
Allowance
Clearance
Industrial & Manufacturing Engineering Department
Type of Fits
13
Industrial & Manufacturing Engineering Department
Machining Process, Tolerance, & Cost
Industrial & Manufacturing Engineering Department
Extreme Form Variation
• The limits of size of a feature
control the ________
Variation of the part.
• The limits of size refers to the
boundaries formed by MMC and
LMC.
• The form of the feature may vary
between these limits.
• Extreme form variation
14
Industrial & Manufacturing Engineering Department
GD&T & Extreme Form Variation
• _________________________________________
60 ant controls extreme variation
Industrial & Manufacturing Engineering Department
Dimensioning & Tolerancing
• GD&T is necessary to control specific geometric
form and location.
• Major features of the part should be used to establish
the basic coordinate system.
• Establish datums related to the function of a part, and
relate datum features in order of precedence as a basis
for CAM.
15
Industrial & Manufacturing Engineering Department
Geometric Characteristics
• Symbols used in geometric dimensioning and
tolerancing to provide specific controls related to:
• The ______________
form of an object
• The ______________
orientation of features
Profile
• The outlines of features (______________)
• The relationship of features to an axis (______________)
runout -
how
Straight
• ______________
locative of features a part is
Industrial & Manufacturing Engineering Department
Geometric Dimensioning & Tolerancing
16
Industrial & Manufacturing Engineering Department
Geometric Dimensioning & Tolerancing
• Feature Control Frame: -
limit dimension
• The means by which a
geometric tolerance is
specified for an individual
feature.
• The frame is divided into
compartments containing, in
order from the left, the
geometric characteristic
symbol followed by the
tolerance.
• Where applicable, the
tolerance is preceded by the
diameter symbol and/or
followed by an appropriate
material condition symbol.
Industrial & Manufacturing Engineering Department
Datum Features & Targets
• ______________
Datum are considered
theoretically perfect surfaces,
planes, points, or axes.
• In GD&T, datums are identified
with a datum feature or target
symbol .
• You can identify a datum using any
letter of the alphabet except for I, O,
or Q.
• Each datum on a part must have
its own unique identification letter.
No 1,0 , as must have
ony one
17
Industrial & Manufacturing Engineering Department
Datums
• As the engineer you will establish the part datums!
• There are many concepts to keep in mind when
establishing datums:
• Part Function
• Manufacturing Processes
• Inspection Methods
• Part Shape
• Relationship to other Features
• Assembly Considerations
• Design Requirements
Industrial & Manufacturing Engineering Department
Datum Feature Symbols
• Placed in the drawing to identify the
features of the object that are
specified as datums.
• The Datum symbol may be placed on
the following places on a drawing:
• The view where the surface appears as
an edge.
• Off extension lines projecting from the
edge view of a surface.
• In connection with a diameter or
symmetrical dimension associated with a
center axis or center plane.
• Attached to a feature control frame.
18
Industrial & Manufacturing Engineering Department
Datum Feature Symbols
Industrial & Manufacturing Engineering Department
Datum Feature Surface
• The datum feature is the actual feature of the
part that is used to establish the datum.
• Datum Feature Surface on Part
-
• Surface on Part
• Simulated Datum Found de inspection
-
• Provided by Inspection Equipment
• Datum Plane
• Theoretical “Exact” Plane
19
Industrial & Manufacturing Engineering Department
Geometric Control of Datums
• The datum surface itself may
be controlled by a geometric
tolerance!
• Flatness, Straightness,
circularity, cylindricity, or
parallelism.
• Measurements taken from a
datum plane do not take into
account any variations of the
datum surface from the plane.
• Geometric tolerance should
be applied to a datum only if
the design requires the
control.
Industrial & Manufacturing Engineering Department
Selecting Datums
• Datum features are selected
based on their importance to
the design of the part.
• Three datum features are
usually perpendicular to each
other.
• Datum Reference Frame (DRF)
• Datums that make up the
reference frame are called:
Primary
• ______________
• ______________
secondary
• ______________
Tertiary
20
Industrial & Manufacturing Engineering Department
Datum Reference Frame
• The surface of the part
labeled as the primary
datum is placed on the
surface of an inspection
table or piece of metrology
equipment.
• Three points make a plane!
• 3 DOF Constrained
• Measurements can then be
#
taken from the primary datum.
Industrial & Manufacturing Engineering Department
Datum Reference Frame
• The part is then
positioned against the
secondary datum.
• Two points make a line!
• 5 DOF Constrained
• With the part held against
the primary and secondary
datums, dimensions can be
verified from the secondary
datum.
21
Industrial & Manufacturing Engineering Department
Datum Reference Frame
• The part is then positioned
against the tertiary datum and
the part is totally confined in a
datum reference plane.
• One Point makes a point!
• 6 DOF Constrained
• When the part is confined in all
three datums, every
measurement made from the
simulated datum planes will
have the same X,Y,& Z origin.
Industrial & Manufacturing Engineering Department
Datum Reference Frame
• The surfaces of the inspection
equipment are simulated
datums.
• Very close to theoretically perfect.
• Measurements cannot be made
from the datums because they
do not actually exist. Surface Plate are
• The machine tables, surface Simulated datums
So is vice
plates or inspection tables act as
the datums for measuring
feature sizes, locations and
other characteristics.
22
Industrial & Manufacturing Engineering Department
Datum References
Industrial & Manufacturing Engineering Department
Datum Reference Frame
• The key is that each dimension
always originates from the
same reliable location.
• Constrains all 6 Degrees of
Freedom
• Dimensions are never taken or
verified from one surface of the
part, they are based on
theoretical datum surfaces.
• This is the standard way parts
are designed, machined, and
inspected in industry
throughout the entire world!
23
Industrial & Manufacturing Engineering Department
Datum Center Plane
• Elements on a rectangular, symmetrical part or
feature may be located and dimensioned in
relationship to a datum center plane.
Industrial & Manufacturing Engineering Department
Datum Center Plane
• Elements on a rectangular, symmetrical part or
feature may be located and dimensioned in
relationship to a datum center plane.
24
Industrial & Manufacturing Engineering Department
Material Condition Symbols
• ______________
Material conditions symbols are often referred to as
modifying symbols.
• They change the geometric tolerance in relation to the
produced size or location of the feature.
• Only used in geometric dimensioning applications.
MMC LMC
Industrial & Manufacturing Engineering Department
Material Condition Symbols
• Used in conjunction with the geometric tolerance
or datum reference in the feature control frame.
-
• Only found in the feature control frame!
• Establish the relationship between the size of the
feature within its given dimensional tolerance and
the geometric tolerance.
• Referred to as modifiers because they modify
the geometric tolerance depending on the actual
produced size of the feature.
25
Industrial & Manufacturing Engineering Department
Material Condition Symbols
• The MMC and LMC symbols must be in a feature
control frame if they are intended.
• When used, the symbols are placed after the geometric
tolerance or datum reference.
amer
20
Industrial & Manufacturing Engineering Department
Maximum Material Condition
• When MMC is used in the feature control frame,
the geometric tolerance is maintained when the
feature is produced at MMC.
= “at MMC”
• As the size departs from MMC, the geometric
tolerance increases by the departure from MMC.
• Opens up the tolerance zone!
26
Industrial & Manufacturing Engineering Department
Least Material Condition
• When an LMC symbol is used in
the feature control frame, the
geometric tolerance is held at the
LMC produced size.
• As the produced size departs
from LMC toward MMC, the
geometric tolerance increases by
the amount of departure.
• Opposite of MMC
• This is used to control the
minimum wall thickness of a part.
Industrial & Manufacturing Engineering Department
Location Tolerances
• Used for the purpose of locating features from
datums, or for establishing coaxiality or symmetry.
• Location tolerances include:
• ______________
• Concentricity
Old Standard
• Symmetry
• Positional Tolerances define a zone in which the
feature is permitted to vary from true position.
• Basic dimensions establish true position.
27
Industrial & Manufacturing Engineering Department
Location Tolerances
• Advantages in mass production:
• Rectangular tolerance zone not as accurate
• Using positional tolerancing, the location of the
tolerance zone can become a cylindrical shape.
• Improves interchangeability of parts while increasing
manufacturing flexibility.
• Material Condition Symbols provide a larger tolerance
as the feature size departs from the condition!
Industrial & Manufacturing Engineering Department
Positional Tolerances
• True position is the
theoretically exact
location of the
centerline of a feature.
• Define a cylindrical
tolerance zone which
contains the centerline
of a feature.
28
Industrial & Manufacturing Engineering Department
Conventional vs. Positional
• A comparison between conventional and
positional tolerancing will help clarify the function
of geometric positioning.
Industrial & Manufacturing Engineering Department
Conventional vs. Positional
• Applying a positional tolerance on
the same part allows the tolerance
zone to increase in size.
• A 0.7 diagonal becomes the
diameter of a cylindrical tolerance
zone through the thickness of the
part.
29
Industrial & Manufacturing Engineering Department
Conventional vs. Positional
• With the use of positional tolerancing, there is an
increase in acceptable mating parts and a
reduction of possible manufacturing costs.
*
14 5 . -.
tolerance here IS -1 .
8
19 5- 1 .
.
Bahih
Dimension
G
-
Primary datum is
always normal to
feature
second datum is
allap Parallel
tertiary is to
locate
Industrial & Manufacturing Engineering Department
Conventional vs. Positional
• To convert conventional location dimensioning to
positional tolerancing:
1. Change the location dimensions from plus-minus to
basic dimensions.
2. Add the feature control frame to the diameter
dimension.
3. Add datums as appropriate.
a. Perpendicularity of the true position center line is
controlled relative to the primary datum.
b. Datums secondary & tertiary control the location of
true position.
30
Industrial & Manufacturing Engineering Department
Conventional vs. Positional
Industrial & Manufacturing Engineering Department
Conventional vs. Positional
31
Industrial & Manufacturing Engineering Department
GD&T Positional Tolerance
• How is the geometric dimensioning & tolerancing (GD&T)
positional tolerance zone’s shape on the countersunk holes
(shown above) different from a conventionally dimensioned
tolerance zone’s shape?
Industrial & Manufacturing Engineering Department
GD&T Positional Tolerance
• What type of dimension is used to locate the true position of a
positional tolerance zone for a feature in relation to its
datums?
32
Industrial & Manufacturing Engineering Department
GD&T Positional Tolerance
• Fill out the positional
tolerance zone size for the
produced hole sizes
according to the drawing.
0 .
002
0 . 00
0 . 608
0 .
01/
o .
01y
Industrial & Manufacturing Engineering Department
GD&T Positional Tolerance
& • Where is the B datum located on the part?
Center
025 = 2 001
Luc
.
·= 1 446-mmc
.
-
33
Industrial & Manufacturing Engineering Department
GD&T Positional Tolerance
• What datum do the countersunk holes and
slot locations need to be perpendicular to?
Industrial & Manufacturing Engineering Department
GD&T Positional Tolerance
• The .700 slot has a left/right positional
tolerance relative to what feature on the part?
34
Industrial & Manufacturing Engineering Department
Drawing Interpretation Overview
Industrial & Manufacturing Engineering Department
Questions?
Next Lecture: Lab Project #2 Lathe Part Design Calculations
&
Midterm Exam Review
35
Industrial & Manufacturing Engineering Department
IME 144
INTRODUCTION TO
DESIGN AND MANUFACTURING
Lecture #03
Screw Threads & Thread Manufacturing Methods
Industrial & Manufacturing Engineering Department
Thread Manufacturing
• Threads are used in general
purpose fastener applications.
• Threads are also used to
repeatedly move or translate
machine parts against heavy
loads.
• Symmetrical threads are easy
to manufacture and inspect.
• Widely used on mass produced
thread fasteners of all types.
1
Industrial & Manufacturing Engineering Department
Types of Threads
Industrial & Manufacturing Engineering Department
Grades of Bolts
2
Industrial & Manufacturing Engineering Department
Types of Bolt Heads
Industrial & Manufacturing Engineering Department
Definitions of Screw Threads
• Know the Standard Thread Definitions:
• __________________
Class
• Crest
major diameter
• __________________
• __________________
Minor diameter
• Root
• __________________
Pitch
• __________________
thread an
ale
3
Industrial & Manufacturing Engineering Department
Screw Thread Definitions
• Chamfer All threads have chanfers
• A conical surface at the starting end of the thread.
• All threads have a chamfer to help start the thread!
• __________________
class tolerance
-
• A number or alphanumeric designation that indicates
the standard grade of tolerance and allowance
specified for a thread.
• __________________
creat top of thread
• This is that surface of a thread which joins the flanks
of the thread and is farthest from the cylinder or cone
from which the thread projects.
Industrial & Manufacturing Engineering Department
Screw Thread Definitions
trends
• Thread Engagement deeth of mated
-
• The depth of thread engagement in between
two coaxially assembled mating threads is
the radial distance by which their thread
forms overlap each other.
• Left Hand Thread
• Tightens in a counterclockwise direction.
• __________________
thread height
• The distance (d) measured radially, between
the major and minor diameters.
4
Industrial & Manufacturing Engineering Department
Definitions of Screw Threads
• External Thread
• A thread on a cylindrical
or conical external
surface.
• Internal Thread
• A thread on a cylindrical
or conical internal
surface.
• Major Diameter
biggest diameter
-
• The diameter of the
major cylinder.
• Minor Diameter -
Smaller diameter
• The diameter of the
minor cylinder.
Industrial & Manufacturing Engineering Department
Definitions of Screw Threads
• __________________
Pi + Ch
• The distance measured parallel with
its axis between corresponding
points on adjacent thread forms in
the same axial plane and on the
same side of the axis.
• Threads per Inch (TPI)
• Inverse of Pitch =
P : + Ch
• Pitch Diameter
• The diameter of the pitch cylinder.
5
Industrial & Manufacturing Engineering Department
Definitions of Screw Threads
• __________________
Root
• The surface of the thread which joins the
flanks of adjacent thread forms and is
immediately adjacent to the cylinder or
cone from which the thread projects.
• Straight Thread
• A screw thread projecting from a cylindrical
surface
• Taper Thread -
smashes together
• A screw thread projecting from a conical
surface.
• Thread
• A portion of a screw thread encompassed
by one pitch.
Industrial & Manufacturing Engineering Department
Unified National & Metric Thread Form
6
Industrial & Manufacturing Engineering Department
Unified National Threads
less larger
more -
Fine Threads Coarse Threads -
Smaller threads
threads (UNF) (UNC)
•Since they have larger stress •Stripping strengths are
areas the bolts are stronger in greater for the same length of
tension engagement
•Their larger minor diameters •Improved fatigue resistance
develop higher torsional and •Less likely to cross thread
-
transverse shear strengths •Quicker assembly and
•They can tap better in thin- disassembly
walled members •Tap better in brittle materials
•With their smaller helix angle, •Larger thread allowances
they permit closer adjustment allow for thicker platings and
accuracy coatings
• The increase in automated assembly lends
a bias towards coarse threads in design.
Industrial & Manufacturing Engineering Department
Unified National Threads
7
Industrial & Manufacturing Engineering Department
Unified National Threads
Industrial & Manufacturing Engineering Department
Unified National Threads
8
Industrial & Manufacturing Engineering Department
Unified National Threads
Industrial & Manufacturing Engineering Department
Unified National Threads
9
Industrial & Manufacturing Engineering Department
ACME Screw Threads
Industrial & Manufacturing Engineering Department
Buttress Screw Threads -
more stuff up and down
10
Industrial & Manufacturing Engineering Department
National Pipe Screw Threads -
smashes crest into
root
-
tapered
thread
Industrial & Manufacturing Engineering Department
British Pipe Screw Threads
11
Industrial & Manufacturing Engineering Department
Thread Cutting
• There are many ways threads can be manufactured.
• External • Internal
• Threading on an Engine Lathe – Threading on an
• Threading on a CNC Lathe Engine Lathe
• ____________
die – _________
tap
• Milling – Milling
• Grinding hard materials
-
• Rolling cold works thread
-
on
Industrial & Manufacturing Engineering Department
Thread Cutting on a Lathe
• The first method for cutting
threads by a machine.
• Not used often for cutting threads.
• Most versatile and fundamentally
simple method.
• Used for cutting threads on
special work pieces.
• Two requirements for thread
cutting:
• Accurately shaped and properly mounted
tool.
• The tool must move longitudinally in a
specific relationship to the rotation of the
workpiece.
12
Industrial & Manufacturing Engineering Department
Thread Cutting on a Lathe
Go" threading
tool
Industrial & Manufacturing Engineering Department
Thread Cutting on a Lathe
13
Industrial & Manufacturing Engineering Department
Thread Cutting on a Lathe
• Requires a special 60º thread form tool.
• Internal threads are cut using a tool held in an internal
boring bar setup.
Industrial & Manufacturing Engineering Department
Thread Cutting on a Lathe
• Cutting speeds are
usually about 1/3 to ½ of
regular speeds.
• Enables the operator time
to manipulate the controls
on the manual lathe.
• Cutting screw threads on
a manual lathe is a slow
repetitious process that
requires considerable
operator skill.
14
Industrial & Manufacturing Engineering Department
Thread Cutting on a CNC Lathe
• CNC machines can be programmed to machine
straight, tapered, or scroll threads.
• Uses the same type of threading tools as the manual
processes.
• The CNC lathe has a set of preprogrammed
machining routines (canned cycles) for cutting
threads.
Industrial & Manufacturing Engineering Department
Threading Dies
• Straight and tapered threads
up to about 1½” diameter can
be cut quickly using dies.
• Dies are similar to hardened,
threaded nuts with multiple
cutting edges.
• The starting edges are
beveled to aid in starting the
dies on the workpiece.
15
Industrial & Manufacturing Engineering Department
Threading Dies
• Dies are made from carbon
or high-speed tool steel.
• Some dies are adjustable so
that you can compensate for
wear.
=
• Dies are usually held in a
stock for hand rotation.
• Lubricant is desired to
produce a smoother thread
and to prolong the life of the
die.
• Lots of Friction!
Industrial & Manufacturing Engineering Department
Thread Tapping
• The cutting of an internal thread
by means of a multiple-point
tool is called thread tapping.
• The tool used is called a tap.
• A hole diameter slightly larger
than the minor diameter of the
thread must be made before a
tap is used.
• Flutes on the tap create cutting
edges on the thread profile and
provide room for chips and the
passage of cutting fluid.
16
Industrial & Manufacturing Engineering Department
Thread Tapping
• Drill & Tap Chart
Industrial & Manufacturing Engineering Department
Thread Tapping
• The flutes can either be straight,
helical or spiral.
• Taps are made out of carbon steel or
high-speed steel and are usually
coated with TiN.
• There are a couple different
with
types of
starts
taps: - thread
no ,
with
taper tap ends
• _________________thread
S•• Plug Tap
tapt
_________________
-
No taper
bottoming
happy
• Spiral Flute Taps
Medium
• Roll Form Taps
J
17
Industrial & Manufacturing Engineering Department
Thread Tapping
• __________Tap
taper
http://www.youtube.com/watch?v=oEpzH8iVvJI
Industrial & Manufacturing Engineering Department
Thread Tapping
• Plug Tap & __________
bottoming Tap
18
Industrial & Manufacturing Engineering Department
Thread Tapping
• Spiral Flute Tap
• Used in CNC machine applications
where rigid tapping is performed.
• Chips get directed upwards out of
the hole through the spiral flutes.
Industrial & Manufacturing Engineering Department
Thread Tapping
• Roll Form Tap
Compresses metal for roll form
These taps form the thread rather than cut.
Cold forming is possible in all ductile materials.
The core hole diameter must be larger than with a cutting tap.
Good lubrication is important , more torque is required, and the
minor diameter of the thread will appear rough due to forming
process.
19
Industrial & Manufacturing Engineering Department
Hole Preparation
• ______________
Drilling is the most
common method of preparing holes
for tapping.
• When close tolerances are required
reaming is necessary.
• The drill size determines the internal
thread contour.
• Unless otherwise indicated on the
engineering drawing, the tap drill size
for most materials should produce
approximately 75% thread
engagement.
• 75% of full thread depth.
Industrial & Manufacturing Engineering Department
Tapping Problems
• Tap overloading is often caused by:
• Poor lubrication
• Lands that are too wide
• Chips packed in the flutes or at the
bottom of the hole.
• Tap wear.
[
• When a tap looses speed or needs
more power, it generally indicates that
the tap is dull or that the chips are
packed in the flutes.
• Improper hole size causes wear and
more power to be utilized while cutting.
• Make sure that the tap and hole axis
are aligned up.
20
Industrial & Manufacturing Engineering Department
Cutting Fluids for Tapping
• Cutting fluids should be used while
tapping.
• They should be kept as clean as
possible and should be supplied in
copious quantities to reduce heat
and friction and to aid in chip
removal.
• Tap life can be increased by routing
high pressure coolants though the
tap to flush out chips and cool the
cutting edges.
Industrial & Manufacturing Engineering Department
Thread Milling
• Highly accurate threads are often
form-milled.
• Larger sizes
• A single-form cutter has a single
annular row of teeth.
• The milling cutter is tilted at an angle
equal to the helix angle of the thread
and is fed inward radially to full depth
while the work is held stationary.
• The workpiece is then rotated slowly
and the cutter is moved longitudinally,
parallel with the axis of work until the
thread is completed.
21
Industrial & Manufacturing Engineering Department
Helical Thread Milling Spins around Inc
• Helical milling can also
occur on a CNC machine.
• Single-form cutter.
• Cutter is rotated in a helical
path around the stationary
workpiece.
https://www.youtube.com/watch?v=Rnkjpkl9aR4
Industrial & Manufacturing Engineering Department
Thread Grinding
• Thread grinding can produce very accurate threads.
• It permits threads to be produced in hardened
materials.
• There are three basic methods used to grind threads:
• Center-type Thread Grinding grinding ·
• Center-type Infeed Thread Grinding for hard
• Centerless Thread Grinding. materials
und
accuracy
22
Industrial & Manufacturing Engineering Department
Thread Grinding
• Center-type Thread Grinding
• Most common method
• Similar to lathe cutting.
• A shaped grinding wheel replaces a single point tool.
• It is how our taps are manufactured!
https://www.youtube.com/watch?v=jUXeuUUnXfs
Industrial & Manufacturing Engineering Department
Thread Rolling
• Thread rolling is used to
produce threads in high
quantities.
• Cold-forming process in
which the threads are formed
by rolling a thread blank
between hardened dies that
cause the metal to flow
radially into the desired
shape.
• No metal is removed in the
form of chips.
• Cold working makes threads
stronger than cut threads.
23
Industrial & Manufacturing Engineering Department
Thread Rolling
• Threads are smoother,
harder and more wear
resistant than other
threads manufactured
using other methods.
• Process is very fast.
• Production rates less than
one second.
• Good consistent quality.
https://www.youtube.com/watch?v=bclnb_Cp4sE
Industrial & Manufacturing Engineering Department
Dimensioning Threaded Fasteners
• Fasteners and threaded
features must be specified
on your engineering
drawing.
• Threaded features:
Threads are specified in a
thread note.
• General Fasteners:
Purchasing information must
be given to allow the
fastener to be ordered
correctly.
24
Industrial & Manufacturing Engineering Department
Dimensioning Threaded Fasteners
• There are different
types of thread forms
(shape) available.
• The most common is
the 60 degree V
thread used in both
________________
Unified national
& ______________
metric
threads!
Industrial & Manufacturing Engineering Department
Dimensioning Inch Threads
• There are three methods of representing screw
threads on a drawing.
• Detailed
• Schematic
• Simplified
• The screw thread representation is in accordance
with the ASME Y14.6-2018 standard.
25
Industrial & Manufacturing Engineering Department
Detailed Representation
• A detailed representation is a close approximation
of the appearance of an actual screw thread.
Industrial & Manufacturing Engineering Department
Schematic Representation
• The schematic representation uses staggered
lines to represent the thread roots and crests.
26
Industrial & Manufacturing Engineering Department
Simplified Representation
• The simplified representation uses visible and
hidden lines to represent the major and minor
diameters.
Industrial & Manufacturing Engineering Department
Simplified Representation
27
Industrial & Manufacturing Engineering Department
Unified Threads (inch)
• After drawing a thread, we need to identify the
size and thread form in a thread note.
Thread Note
Industrial & Manufacturing Engineering Department
Unified Thread Note Components
form
00p the caus as
28
Industrial & Manufacturing Engineering Department
Unified Threads (inch)
• Major Diameter: The largest diameter.
• Threads per inch: Number of threads per inch for
a particular diameter.
• Equal to one over the pitch (1/P)
Industrial & Manufacturing Engineering Department
Unified Threads (inch)
• Thread Form and Series:
• The shape of the thread cut.
Unified national course
• UNC = __________________.
fine
• UNF = __________________.
unified national
• UNEF = Unified National Extra Fine.
29
Industrial & Manufacturing Engineering Department
Unified Threads (inch)
• Thread Class: Closeness of fit between the two mating
threaded parts.
• 1 = ________________.
generous For rapid assembly and disassembly.
• 2 = ________________
medium
• 3 = ________________
fight
Industrial & Manufacturing Engineering Department
Unified Threads (inch)
• External or Internal Threads
• A = __________________
External
• B = __________________
Internal
30
Industrial & Manufacturing Engineering Department
Unified Threads (inch)
• Depth of thread: The thread depth is given at the end
of the thread note and indicates the thread depth for
internal threads
• This is not the tap drill depth.
Industrial & Manufacturing Engineering Department
Unified Thread Assumptions (inch)
• Thread class is assumed to be 2.
• Threads are assumed to be Right Hand (RH).
31
Industrial & Manufacturing Engineering Department
Dimensioning Metric Threads
Industrial & Manufacturing Engineering Department
Dimensioning Metric Threads
32
Industrial & Manufacturing Engineering Department
Cutting Fluids
• Common Industry Machining Goal:
• Raise productivity and reduce costs by machining at
the highest practical speed consistent with long tool
life, fewest rejects, and minimum downtime while
producing acceptable surfaces that are within print
specifications.
• Cutting fluids aid greatly in this goal!
Industrial & Manufacturing Engineering Department
Cutting Fluids
• Cutting fluids should be
used while turning and
milling, drilling & tapping.
• Reduces the
______________
frictive as well
as ___________
Cool the tool
and workpiece!
• There are four main types:
• Oils
• Emulsions
• Gasses
• Pastes
33
Industrial & Manufacturing Engineering Department
Canvas Weekly Lecture Assignment Overview
Questions?
Read about Material Conditions, Fits, & GD&T for Next
Week’s Lecture! (Pages 21-26)
34
Industrial & Manufacturing Engineering Department
IME 144
INTRODUCTION TO
DESIGN AND MANUFACTURING
Lecture #02
Machine Tools, Operations, Speeds & Feeds!
Industrial & Manufacturing Engineering Department
Machining Processes
• Machining is an exciting field broken into three
categories:
tradition al
• _________________________
• Abrasive Processes - waterjet
• Advanced Machining Processes / Non-Traditional -
wire edm
1
Industrial & Manufacturing Engineering Department
Machining Processes
• ALL machining processes are performed on
____________________.
↓ achine tools
Industrial & Manufacturing Engineering Department
Machining Processes
• Four elements are
required to perform
machining processes:
• _______________
Workpiece
• _______________
cutting tool
• Machine Tool
• Production Personnel
2
Industrial & Manufacturing Engineering Department
Machining Processes
• Disadvantages of machining over primary
processes / near net shape:
• Waste material
Chips-labor
8
-
• Longer than most processes
• More energy required than forming or shaping -
large
lots of
(Machine Tools) machines
• Removal Process
Industrial & Manufacturing Engineering Department
Machining Processes
• We will start with traditional machining processes!
• All traditional processes remove material from a
workpiece in the form of chips.
• Traditional Machining Processes Include:
• Sawing
• Milling
• Turning
Drilling
• _______________
• _______________
Groaching
3
Industrial & Manufacturing Engineering Department
Machining Processes
• No matter what processes you are performing
they all have three similar variables
depth of cut
• _______________(in)
Chip load
• _______________ (in/tooth or in/rev)
cutting speed (ft/min)
• _______________
·
RPM
·
feedrate
https://www.youtube.com/watch?v=Mq66lRhST6g
Industrial & Manufacturing Engineering Department
Sawing
• Sawing is a common process dating back to around 1000 B.C.
• The cutting tool is a blade (saw) having a series of teeth, each
tooth removing a small amount of material with each stroke or
movement of the saw.
• The process can be used for all metallic and nonmetallic
materials and is capable of producing various shapes.
4
Industrial & Manufacturing Engineering Department
Sawing with
of aut
• The tooth set in a saw is important
in providing a sufficiently wide-
kerf
for the blade to move freely in the
workpiece without binding or
excessive frictional resistance,
thus reducing the heat generated.
• Tooth sets on saw cfteeth provide
clearance for the saw blade to
prevent binding during sawing.
• Sometimes friction or abrasives
are utilized instead of teeth.
set for specific material
Teeth are
Industrial & Manufacturing Engineering Department
Band Saws
•Band saws have continuous, long, flexible blades and thus
have a continuous cutting action.
•Vertical Band Saws
•Horizontal Band Saws
5
Industrial & Manufacturing Engineering Department
000s in
Circular Saws
0
Precise 5 -
.
- burr free
• _______________
cold saws create precise, burr-free cuts
and corner miters without sparks or generating
heat.
• These saws usually have a* coolant delivery system to
cool and lubricate the blade while cutting.
Industrial & Manufacturing Engineering Department
Abrasive Saws
• Abrasive saws are usually called a
cutoff saw or metal chop saw.
• It is almost always electrically or
pneumatic powered and is used to cut
steel and stainless steel.
• A thin abrasive disc spins at a high
speed and the grinding action of the
spinning wheel cuts the metal.
• The disks are consumable items and
they wear and have to be replaced
regularly.
• Abrasive saws are much more
inexpensive, portable and lightweight
than band saws.
-
electrical/contract trucks
6
Industrial & Manufacturing Engineering Department
Filing
• Filing involves the small-scale removal of material from a
surface, corner, edge of hole-including the removal of
burrs.
• First developed around 1000 B.C., files usually are made
of hardened steel and are available in a variety of cross
sections, such as flat, round, half-round, square and
triangular.
Industrial & Manufacturing Engineering Department
Cutting Tools
• All cutting tools, whether
you have a milling cutter,
drill, or a single point
cutting tool for a lathe,
share four common
shape features:
• rake angles
• lead angles
• corner radius
• clearance angles
7
Industrial & Manufacturing Engineering Department
Cutting Tool Definitions
is roll
• Rake ~ are
i
angle
– A metal-cutting tool has rake when the tool face or
surface against which the chips bare, is inclined for
the purpose of either increasing or diminishing the
keenness or bluntness of the edge.
• Lead Angle
– The angle between the cutting edge of the tool and the
workpiece.
Industrial & Manufacturing Engineering Department
Cutting Tool Definitions
• Corner Radius
– This strengthens the cutting edge, improves
finish and influences tool life.
– Too large a radius increases radial forces and
induces chatter.
– Too small a nose radius may result. in
premature chipping or prevent proper
distribution of the heat and break down the
properties of the cutting tool material.
chipping
tool stroes tool
-
↑
round-rough
Point-finishes
8
Industrial & Manufacturing Engineering Department
Cutting Tool Definitions workpiece
• Clearance Angles -
only edge touches
– Primary clearance is directly
below the cutting edge and
is selected for the material
being machined.
• It prevents the cutter or tool
from rubbing on the workpiece.
– The secondary clearance is
on the tooth form of the
cutter or the shank of the
single point tool.
• It must be large enough to
clear the workpiece and permit
chips to escape.
Industrial & Manufacturing Engineering Department
Cutting Tool Materials
High Carbon Steel
• _______________
• Less expensive drills, taps, and
reamers.
• Rarely used for single point cutting
tools or milling tools.
• Hardening is very shallow.
·
wood/al
• _______________
high speed steel /was
• Retain sufficient hardness at
temperatures up to 1100ºF
• Harden very deeply “regrind”
9
Industrial & Manufacturing Engineering Department
Cutting Tool Materials
carbide Chips
• _______________ erates
• Retain a very high degree of
hardness at temperatures up to
1400ºF. -
Ti cutting
• Very fast cutting speeds can be
used to obtain a good surface finish.
• More brittle than HSS and, must be
used with more care.
• Four distinct types
• Straight tungsten carbide
• Crater-resistant carbides
• Titanium carbides
• Coated carbides
Industrial & Manufacturing Engineering Department
Milling
• The process of machining flat, curved, or irregular
surfaces by feeding the workpiece against a rotating
cutter containing a number of cutting edges.
10
Industrial & Manufacturing Engineering Department
Milling
• Milling is one of the most
versatile machining
processes, in which a
rotating cutter removes
material while traveling
along various axes with
respect to the workpiece.
https://www.youtube.com/watch?v=UgMuyW9--Xk
Industrial & Manufacturing Engineering Department
Milling
• Milling includes a number of highly versatile
machining operations taking place in a variety of
configurations with the use of a milling cutter – a
multi-tooth tool that produces a number of chips in
one revolution of the machine tool’s spindle.
https://www.yo
utube.com/wat
ch?v=U99asu
DT97I
11
Industrial & Manufacturing Engineering Department
Milling Machine Axes
• Basic CNC milling machines have three axes of
movement, with the motion imparted through ball-
screws and electric servo motors.
Industrial & Manufacturing Engineering Department
Vertical Milling Machines
• Column-and-Knee-Type
Ne
machines are used for
general-purpose manual
milling operations and are the
most common machine tool
used for milling.
• The spindle in which the cutter
is mounted to is vertical for all
machining operations:
• Face Milling
• Peripheral Milling
• End Milling
• Drilling
• Boring
12
Industrial & Manufacturing Engineering Department
Horizontal Milling Machines
less common
·
cu + years
Industrial & Manufacturing Engineering Department
Machining Centers -
CNC With ATC
• The term “_______________”
Machining Center describes almost
any CNC milling and drilling machine that
includes an automatic tool changer and a table
that clamps the workpiece in place.
https://www.youtube.com/watch?v=LV9Rx1SwjeM
13
Industrial & Manufacturing Engineering Department
Machining Centers -
Not enough tools
• Milling machines have been rapidly replaced by
computer numerical control (CNC) machines for
all but the lowest production quantities.
• These machines are versatile and capable of milling,
drilling, boring, and tapping with repetitive accuracy.
Industrial & Manufacturing Engineering Department
Machining Centers
• The orientation of the spindle is the most
fundamental defining characteristic of a
machining center. tool is vertical
• Vertical
• Horizontal
Zu
tool
is horizontal
14
Industrial & Manufacturing Engineering Department
easy access - workhorses
Industrial & Manufacturing Engineering Department
15
Industrial & Manufacturing Engineering Department
Milling Direction
thick
• _______________
conventional this to
•The cutter rotates against the
direction of feed rate of the work piece
and creates a thin chip at the
beginning and increases in thickness
to its maximum where the tooth leaves
marks
the work. This will tend to push along ·
leaves
and lift upward from the table and ·
excess stress
eliminate any effect of looseness in -
bad
the feed screw and nut on the
machine. Chips can be carried into
the newly machined surface causing
the surface finish to be poorer
(rougher) than in climb milling!
Industrial & Manufacturing Engineering Department
Milling Direction
• _______________
CLimG Milling
• Max chip thickness occurs
close to the point where the
tooth contacts the work which
tends to pull the work piece into
the cutter and hold the work
against the machine table.
There is less of a tendency for
the machined surface to show
tool marks and the cutting thick to this
·
process is smoother with less less stress
·
chatter.
16
Industrial & Manufacturing Engineering Department
Face Milling
• Machining of a flat
surface ____________
Normal
◦
(90 ) to the axis of
the rotating cutter.
Industrial & Manufacturing Engineering Department
Peripheral Milling
• Also called plain milling or end milling,
(profiling or contouring in the CNC)
• The axis of cutter rotation is ____________
Parallel
to the workpiece surface.
17
Industrial & Manufacturing Engineering Department
Milling Cutter Geometry
Industrial & Manufacturing Engineering Department
Milling Cutters
•Milling Cutter Teeth
• Determined by the workpiece material’s ductility!
•Center Cutting vs Non-Center Cutting
P -Getter
space to
& dr Surface
move = 11 Finish
crips
,
soft =
gumne
18
Industrial & Manufacturing Engineering Department
Face Milling Cutters
Industrial & Manufacturing Engineering Department
End Mill Types
19
Industrial & Manufacturing Engineering Department
End Mill Types
Industrial & Manufacturing Engineering Department
Bull End Mill Types
less stress
t has flat no se
20
Industrial & Manufacturing Engineering Department
Ball End Mills
Industrial & Manufacturing Engineering Department
Specialty End Mill Types
21
Industrial & Manufacturing Engineering Department
Edge Finders
• Locate the edge of the part in milling machines!
• Finds the Work Coordinate System (G54) for the
X & Y Axes,
Industrial & Manufacturing Engineering Department
Feeds & Speeds for CNC Machining
• The tool moves through the material
at a specified rotational speed,
defined in revolutions per minute
(RPM), and feed rate, defined in
inches per minute (IPM).
• Probably the most vexing problem for
the beginning CNC programmers is
selecting proper cutting speeds and
feeds.
• More difficult on a CNC mill compared
to a manual mill because the operator
can feel the cutting pressure on a
manual mill and alter the feed based in
part on the cutting force.
22
Industrial & Manufacturing Engineering Department
Milling Parameters & Calcs
N = Rotational speed of the milling cutter, (rpm)
F = Table Feed, (in/min)
D = Cutter Diameter, (in)
n = Number of Teeth on cutter (teeth)
V = Surface speed of cutter, (ft/min)
f = Feed per tooth, (in/tooth)
Industrial & Manufacturing Engineering Department
The RPM Calculation
23
Industrial & Manufacturing Engineering Department
Milling RPM & Feed Rate Calcs.
• RPM
• Table Feed Rate
G-per minute
Industrial & Manufacturing Engineering Department
Feeds & Speeds for CNC Machining
• CNC Speed & Feed Calc. Example:
• Surface Speed: 750 ft/min
• Depth of Cut: .125”
• Width of Cut: .300”
• Tool: ½“ 4-Flute Carbide End Mill
• Chip Load: .002 in/tooth
Tom
so
f =
200 . 0.000
24
Industrial & Manufacturing Engineering Department
Lathe Coordinate System
Industrial & Manufacturing Engineering Department
Lathe Components
25
Industrial & Manufacturing Engineering Department
Lathe Components
Industrial & Manufacturing Engineering Department
Lathe Components
26
Industrial & Manufacturing Engineering Department
LeBlonde Cross & Compound Slide
read diameter ,
cuts radiuss
so double tic
Mark value
min CROSS SLIDE
250 GRADUATIONS PER TURN
8 THREADS PER INCH
0.125 INCH MOTION / DOC PER 1 REVOLUTION
0.250 INCH OFF OF DIAMETER PER 1 REV
COMPOUND SLIDE
200 GRADUATIONS PER TURN
10 THREADS PER INCH
0.100 INCH MOTION/DOC PER 1 REVOLUTION
0.200 INCH OFF OF DIAMETER PER 1 REV
Industrial & Manufacturing Engineering Department
Turning
• One of the most basic machining processes is turning,
meaning that the part is rotated while it is being machined.
• Produces straight, conical, curved or grooved workpieces
such as shafts, spindles and pins.
Turning
(Forward Gear)
TOP VIEW OF LATHE
LONGITUDINAL FEED (TURNING)
27
Industrial & Manufacturing Engineering Department
Turning
Industrial & Manufacturing Engineering Department
Facing
• Produces a flat surface at the end of the part and
perpendicular to its axis.
CROSS FEED (FACING)
Facing
(Reverse Gear)
28
Industrial & Manufacturing Engineering Department
Facing
https://www.youtube.com/watch?v=8EsAxOnzEms
Industrial & Manufacturing Engineering Department
Single Point Cutting Tool Geometry
• Tools for turning and facing.
29
Industrial & Manufacturing Engineering Department
Single Point Cutting Tools
• Right Hand vs. Left Hand vs. Neutral Tools
Industrial & Manufacturing Engineering Department
Single Point Cutting Tools
• HSS Tooling
30
Industrial & Manufacturing Engineering Department
Single Point Cutting Tools
• Brazed Carbide Cutting Tools
Industrial & Manufacturing Engineering Department
Single Point Cutting Tools
• Carbide Insert Holders
31
Industrial & Manufacturing Engineering Department
Drilling & Drills
• Drilling is easily the most common
machining process and can be done
utilizing many hand and machine tools.
• Drilling involves the creation of
cylindrical holes with a twist drill.
• Twist drills are commonly held in drill
chucks during their use.
• Drills come in four different sizes:
• _______________
~ etric
• _______________
Fraction al
• _______________
Letter
• _______________
Number
Industrial & Manufacturing Engineering Department
Drilling & Drills
32
Industrial & Manufacturing Engineering Department
Center Drills Drill bit center
Punch
• Center drills are short and very rigid drills used to
create a ____________on
Conical hole the surface of the part.
• They resist bending and are used to locate the hole
precisely before a drill is used.
• The conical hole helps prevent the ensuing drill from
walking away from true positon.
• Also used for lathe centers on long workpieces.
Industrial & Manufacturing Engineering Department
Center Drills
33
Industrial & Manufacturing Engineering Department
Reaming & Reams
• Reaming is a process which slightly ___________
enlarges a pre-
existing hole with a tight tolerance diameter.
• Similar to a mill bit in that it has several cutting edges
arranged around a central shaft that remove a little bit
of material from a predrilled hole.
Industrial & Manufacturing Engineering Department
Boring
• Boring is an operation in which a hole is enlarged to a
precise value with a single point cutting tool.
• Can be performed on a mill or a lathe.
34
Industrial & Manufacturing Engineering Department
Lathe Parameters & Calcs
N = Rotational speed of the workpiece, rpm
f = Feed per tooth, in/tooth or mm/tooth
D = Workpiece Diameter, in or mm.
V = Surface Speed, ft/min or m/min
Industrial & Manufacturing Engineering Department
Turning RPM & Feed Rate Calcs.
• RPM
• Feed Rate
f= Chip Load (in/rev)
35
Industrial & Manufacturing Engineering Department
Lathe Checklist
Before and while running the lathe in the IME 144
lab please make sure the following steps are
followed:
• The lathe has been lubricated
• Fine/Coarse lever in the Fine position
• Leadscrew disconnected-side collar to right.
• Spindle nut is tight and wrench is in rack.
• Halfnut lever is disengaged.
• Powerfeed lever in neutral
• All tools are in the rack.
Industrial & Manufacturing Engineering Department
Turning Centers
• On a traditional turning center the ___________
Workpiece
rotates, generating the cutting speed and the
single point _________
to o is stationary relative to
generating the cutting speed.
• The orientation of the spindle is usually horizontal
however there are vertical turning centers.
36
Industrial & Manufacturing Engineering Department
Work Holding for Manufacturing
•HIERARCHY OF
W ORK HOLDING
DEVICES
Industrial & Manufacturing Engineering Department
Work Holding for Manufacturing
• Regardless of their types workholding devices have to fulfill
the design objectives of:
• Provide a positive location for the workpiece vs the cutting
tool and axes.
• Allow loading and unloading of workpieces in precisely the
same repeatable location
• Provide a clamping force that holds the workpiece
immobile against all cutting forces.
• Maintain the clamping force during machine operation and
not distort the part when clamping.
• Withstand the punishment during the loading, unloading
and machining cycles.
• Be ergonomic for the operator to apply clamping force and
quickly change the workpiece.
37
Industrial & Manufacturing Engineering Department
Chucks
Industrial & Manufacturing Engineering Department
Collets
38
Industrial & Manufacturing Engineering Department
Mandrels
I
Collet
on the
inside
Industrial & Manufacturing Engineering Department
Machine Vises
39
Industrial & Manufacturing Engineering Department
Parallel Sets
Industrial & Manufacturing Engineering Department
Workpiece Raw Materials
• Metals for machining are
supplied in four forms:
• Blocks, Bars, or Sheet
• Castings
• Forgings
• Custom Extrusions
40
Industrial & Manufacturing Engineering Department
Workpiece Raw Materials
• Metals for machining are
supplied in four forms:
• Blocks, Bars, or Sheet
• Castings
• Forgings
• Custom Extrusions
Industrial & Manufacturing Engineering Department
Workpiece Raw Materials
• Metals for machining are
supplied in four forms:
• Blocks, Bars, or Sheet
• Castings
• Forgings forging more
-
• Custom Extrusions uniform
41
Industrial & Manufacturing Engineering Department
Workpiece Raw Materials
• Metals for machining are supplied in four forms:
• Blocks, Bars, or Sheet
• Castings
• Forgings
• Custom Extrusions
Industrial & Manufacturing Engineering Department
Lecture Assignment #1 Time
• Fill Out Assignment on Canvas
• Have a great weekend!
42
Industrial & Manufacturing Engineering Department
Questions?
Read Information on Mills & Lathes in the Lab Manual!
Next Week’s Topics Cutting Tools & Thread Manufaturing
43
Industrial & Manufacturing Engineering Department
IME 144
INTRODUCTION TO
DESIGN & MANUFACTURING
Lecture #01 Course Introduction, Manufacturing,
Engineering Drawings, & Basic Measurement Tools!
Week #1
Industrial & Manufacturing Engineering Department
IME 144 Class Overview & Syllabus
• Lecture & Lab Overview
• Office Hours
• Lab Manual Info
• Assignment Overview
1
Industrial & Manufacturing Engineering Department
Manufacturing
• Textbook Definition of ___________:
Manufacturies
• The application of physical and chemical
processes to alter the geometry,
properties, and or appearance of a given
material to make parts or products;
manufacturing also includes the joining of
multiple parts to make assembled
products.
• Economic Viewpoint:
• The transformation of materials into
items of greater value by means of one
or more processing or assembly
operations.
Industrial & Manufacturing Engineering Department
Manufacturing Industries
• ________________
Primary -mining
• Those that cultivate and exploit natural resources
• ________________
secondant-Mfg
• Convert primary industry outputs into products
• ________________
tertiary -
service
• Service sector of the economy
3
Industrial & Manufacturing Engineering Department
Manufacturing
• ________________
discrete Products
• Individual Items One item
Industrial & Manufacturing Engineering Department
Manufacturing
• ________________ Products keeps
continuous coming te
naturales
4
Industrial & Manufacturing Engineering Department
Manufacturing Processes
• In order to convert raw
materials into products
four different activities
must occur in the
factory:
• ________________
Processio a
and Assembly Operations
• ________________
Material handling
• ________________
inspection and
Testing
• ________________
Coordination and
J customer
doesn't Pay,
must be
Control efficient
Industrial & Manufacturing Engineering Department
Processing Operations
• Use ________________,
mechanical thermal electrical or
chemical energy to add value to a material
• Solidification process
• Deformation process
• Particulate processing
• Material removal process
5
Industrial & Manufacturing Engineering Department
MFG Processes
• Casting Processes Joining Processes
• Expendable Mold & Fusion Welding, Other
Permanent Mold Welding, Fastening &
• Bulk Deformation Bonding
Processes Machining Processes
• Rolling, Forging, Extrusion, Focus of IME 144
& Drawing
• Sheetmetal Forming • Manufacturing processes
Processes decisions are driven by
• Shearing, Bending, Drawing, engineering drawings and
& Forming economics!
• Polymer Processing
Processes
• Thermoplastics,
Thermosets, RP Methods
Industrial & Manufacturing Engineering Department
Machining Processes
• ________________
machining is a group of processes that
consist of the removal of material and
modification of the surfaces of a work piece.
• Parts created with casting, forming, and shaping
sometimes require machining. ·
most things
• Secondary & Finishing Mfg Processes need
machining
re casting ,
metal Printing
6
Industrial & Manufacturing Engineering Department
Machining Operations
• Machining is the process of removing unwanted
material from a work piece in the form of
________________.
ChiPS
• Often called metal cutting or metal removal.
• The US spends more than $60 billion dollars
each year performing machining operations.
Industrial & Manufacturing Engineering Department
Machining
Material Removal Processes
https://www.youtube.com/watch?v=dsSo5qOGk6c
https://www.youtube.com/watch?v=A49l8ljcPis
7
Industrial & Manufacturing Engineering Department
Machining
• Tolerances can be in the
ten thousandths of an inch.
(.0001)
• Machining is the most
important of the basic
manufacturing
processes.
• Machining produces chips
using a few different chip
formation processes.
• ________________
turning - atte
Precision is costly
• ________________
Mill
·
Milling
-
• ________________
nachivingisana
·
Drilling Drill
-
• ________________
laming-saw a process
• ________________
B roaching irregular
-
sized
holes
Industrial & Manufacturing Engineering Department
Inspection and Testing
• Purpose of testing is to ensure that the product meets all
of the established design standards and specifications.
• Tolerances
• Quality Control & (SPC)
• Where do we get the inspection data (tolerances) from?
8
Industrial & Manufacturing Engineering Department
Manufacturing Processes
&
Engineering Drawings
(How are they related?)
Industrial & Manufacturing Engineering Department
Multiview Drawing
The majority of engineered parts require the
specification of measurements, sizes, and allowable errors
of features on the parts.
Engineers need to be able to specify part sizes so that
everything fits together and functions as intended.
9
Industrial & Manufacturing Engineering Department
Multiview Drawing
This specification must be completed before the parts can
be ________________.
Manufactured
Procedures for size specification must be followed to ensure
these specifications can be easily interpreted, checked, and
controlled for proper function of the parts.
Industrial & Manufacturing Engineering Department
Multiview Drawing
When an engineer is presented with a formal engineering
drawing, whether it is a mechanical device or a construction
project, that engineer must be able to read all of its contents
correctly.
________________
Drawings are legal documents and, as such, are
required to contain certain information to ensure that the
creators and the receivers interpret them properly.
designs are
Patented with
drawings
10
Industrial & Manufacturing Engineering Department
Multiview Drawing
Guidelines must be followed to ensure that completed
drawings are created, updated, and approved in a manner
that establishes a line of accountability.
Industrial & Manufacturing Engineering Department
Creating a Multi View Drawing
&1ST ANGLE PROJECTIONS VS. 3RD ANGLE PROJECTIONS
ISO VS. ANSI
focus for
Europe uses 190 , our
course
complete opposite
11
Industrial & Manufacturing Engineering Department
Multiview Drawing
• Multiview drawings are also
called orthographic
projection drawings.
• Orthographic projection is
the process of explaining
three-dimensional objects in
two-dimensions.
• Multiview drawings typically
have ____________
3 views,
but may have as many as
four or more for complex
objects.
• ________
kit angle projections
are used mainly in Europe.
• third
________angle projections
are mainly used in the US.
Industrial & Manufacturing Engineering Department
Orthographic Projection
• A Drawing representation of the separate views of an object
on a two-dimensional surface. It shows the width, depth and
height of an object
• There are three principal or coordinate planes of projection
that are typically used in orthographic projection
• Frontal plane shows front view
• Horizontal plane projection is called the top view review
• Profile plane projections are called the side views
this
Front
forrathe
12
Industrial & Manufacturing Engineering Department
Creating Dimensions
• There are three types of dimensions on engineering
drawings:
112
• ________________
-
linear
-
anal
Angle
• ________________
-
holes , chanfer, Fillet
• ________________
Note
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
• The process of defining the ________,
Lize form and
_________
Location of geometric components on
engineering and or architectural drawings.
13
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
• Unidirectional System
• All dimension figures are placed to be read from the
bottom of the drawing upwards.
• All dimensions are ________________.
horizontal
• This is the recommended ______
Angi industry standard.
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
14
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
• ________________
Extension lines :
:
needs" gap from Part
• Used to indicate the
termination of a
dimension.
• They are usually drawn
perpendicular to the
dimension line with a
visible gap of
approximately 1/8 inch
beyond the dimension
line.
• When used to locate a
point, they must pass
through the point.
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
• ________________:
Leader lines torches with arrow
• Thin straight lines that lead from a
note or dimension to a feature on the
drawing ending in either an
arrowhead or dot.
• ________________
Arrow head :
• Used to terminate leaders that that
end at a specific point or outside
edge of the part.
• The dimension or note end of the leader
has a horizontal bar approximately 1/8
inch in length.
• The leader angle should be between 45̊
and 60̊ and should never be drawn
parallel to extension or dimension lines.
15
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
• ________________
Chain Dimensioning:
• Dimensioning a series of features, such as holes, from
point to point.
• When these dimensions are toleranced, overall variations
of the features may occur that exceed the tolerances
specified.
#rance inc
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
• ________________
Datuh Dimensioning:
• Also called base line dimensioning,
features are dimensioned individually
from a datum.
• This system of dimensioning avoids
accumulation of tolerances from feature
to feature.
• Where the distance between two
features must be closely controlled,
more ideal
without the use of an extremely small
·
tolerance, datum dimensioning should dimensioning
be used.
• Used for absolute positioning CNC
operations.
16
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
Tolerance Stacking!
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
Do not duplicate a dimension!
!
go for simplicity
17
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
Dimensioning _________
Holes & ________!
Arcs
measure holes
from Center
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
Dimensioning Holes & Arcs!
can't measure this point
O
18
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
Dimensioning Holes!
thro blind counterbore counterbore
Countersink
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
Need
Locating Hole Position!
·
I dimension
· diameter
Of Moe
19
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
Dimensioning Positive Cylinders & Holes!
Contour rule :
for it best
dimension the part where cay see
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
Dimensioning Chamfers!
20
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
Contour Dimensioning!
dimension use, for see the feature
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
Dimensioning Threads!
Common
21
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
Dimensioning Threads!
Industrial & Manufacturing Engineering Department
Dimensioning Fundamentals
Do Not Dimension to ____________
Hidden Lines!
22
Industrial & Manufacturing Engineering Department
Tolerances
• Conventional Tolerancing:
• The control of dimensions having a range of acceptable
sizes that are within a “zone.”
• This zone depends on the function of the part.
• Design Intent
D
S
Within
these
values
Industrial & Manufacturing Engineering Department
Drawing Tolerance
Formats for Tolerances!
Tn-
23
Industrial & Manufacturing Engineering Department
Dimensions and Tolerances
Nominal Dimension of 2.500
Bilateral Tolerance Unilateral Tolerance Limit Dimensions
Press fit
Figure 5.1
Industrial & Manufacturing Engineering Department
Conventional Tolerances
60tT avoids
or navy
Bump
surfaces
24
Industrial & Manufacturing Engineering Department
Working Drawing Sizes
• American National Standard (ANSI)
• A – 8.50” x 11.00”
• B – 11.00” x 17.00”
• C – 17.00” x 22.00”
• D – 22.00” x 34.00”
• E – 34.00” x 44.00”
• International Standard (ISO)
• A4 – 210mm x 297mm
• A3 – 297mm x 420mm
• A2 – 420mm x 594mm
• A1 – 594mm x 841mm
• A0 – 841mm x 1189mm
Industrial & Manufacturing Engineering Department
Working Drawings
revision
generic tolerance
·
·
Name
·
NOA
25
Industrial & Manufacturing Engineering Department
Working Drawings
• Title Block Elements
Industrial & Manufacturing Engineering Department
Geometric Dimensioning & Tolerancing
26
Industrial & Manufacturing Engineering Department
Geometric Dimensioning & Tolerancing
• _______________Frame:
feature control
• The means by which a O
S
geometric tolerance is
specified for an individual
feature.
• The frame is divided into
compartments containing, in
order from the left, the
- eometric charitaristic
________________ symbol
followed by the tolerance.
• Where applicable, the
tolerance is preceded by the
diameter or radius symbol and
followed by an appropriate
material condition symbol.
Industrial & Manufacturing Engineering Department
Geometric Dimensioning & Tolerancing
27
Industrial & Manufacturing Engineering Department
Working Drawings
o
O
too bottom
must be
Parallel
within . 002
Industrial & Manufacturing Engineering Department
Working Drawings
28
Industrial & Manufacturing Engineering Department
METROLOGY
Metrology is the _____________
Science Study of measurement.
or
Measurement is a procedure where :
• an unknown quantity is compared to a known standard,
• using an accepted and consistent system of units.
Measurement produces a ________________
numerical value
value of the quantity of interest, within certain
limits of accuracy and precision.
Industrial & Manufacturing Engineering Department
ACCURACY VS. PRECISION
________________
Accuracy The degree
to which the measured value agrees
inherent
iv S
with the true value or against the
Process standard. Instrument must be
Markto maintained by proper and regular
Fix calibration.
________________
Precision (repeatability)
wanted is achieved by selecting the proper
in
C
instrument technology for the
Proklebes
application.
Rule of 10 – the measuring device
must be ten times more precise
than the specified tolerance.
29
Industrial & Manufacturing Engineering Department
INSPECTION
Inspection involves the use of measurement and gaging
techniques to determine whether a product, its
components, subassemblies, or starting materials conform
to design specifications.
1. ________________
variable Inspection – dimensions are
measured by measuring instruments for length quantities
in process
2. ________________
Attribute Inspection – gauged to determine
whether or not parts are within tolerance limits.
- (Go / No-Go Gage) – Done quickly at a low cost
- Covered Later in Lecture & Lab
Industrial & Manufacturing Engineering Department
Micrometers
• Reading a Micrometer
· there will be a
question on
reading
calipers or
micrometer
30
Industrial & Manufacturing Engineering Department
Vernier Calipers
• Reading a Vernier Caliper
http://www.phy.ntnu.edu.tw/ntnujava/viewtopic.php?t=69
Industrial & Manufacturing Engineering Department
Dial Calipers
• Reading a Dial Caliper
http://www.phy.ntnu.edu.tw/ntnujava/viewtopic.php?t=69
https://www.youtube.com/watch?v=1qy3PzrxX4o
31
Industrial & Manufacturing Engineering Department
Dial Calipers
• Reading a Digital Caliper
http://www.phy.ntnu.edu.tw/ntnujava/viewtopic.php?t=69
Industrial & Manufacturing Engineering Department
SolidWorks Overview
• Canvas Tutorials!
• Design Parts
• Assemble Parts
• Virtually Test Parts
• Part Drawings
• Program CNC
Machines to Make
Parts.
• Perform First Article
Inspection Reports
https://www.youtube.com/watch?v=4jbn0ah3u9E&t=14s
32
Industrial & Manufacturing Engineering Department
Questions?
33
cutting speed
S
high uncoated ceramic
Carbae carbide
Steel
Super
aluminum Steel allops
RPM :
Nit
N = RPM
v= Cutting Speed (f+ min)
1 = :11f +
of part or tool
# = 2 .
14
ins rev
feed rates
example chiploads
F Next
rouch Finish
=
0 604
.
- 6
0 . 002
-
1 F= feed rate
N = cutting tool PM
reulmin
f Chip load
in/tooth
- number of cutting teeth
#
I
C 50t 02/
. .
k= 2 .
22- .
52 -
.
-6
d= 2 -
14
·
189-1 .
00 :
-E
008 = -2 818
-2 821
- .
· 018 = .
Allowance = Muc
hole-mmcshaft
Clearance =
Luchole -
(McGhaft
hole
Shaft
Allowance = 1 .
114-1 . 12/
0 002 = .
2 62.
-
A
clearance = 1 121-1 .
123
.
0 .
012 = 3 621
.
-
A
0 .
002 = 2 624
.
-
A
3 .
62/
(1 .
00 -
002)
-
·
112
600 12 25 - 1 500 001)
02) 23
-
.
,
-
2 .
-
.
-
,
(1 . 315 + 007)
.
- C . 315- -
002)
(0 15 + 02) -
(02) -- 02)
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