H700 Manufacturing Engineering : Processes of Machining are Plastics
Manufacturing:
Machining is a manufacturing term encompassing a broad range of technologies and techniques. It can be roughly defined as the process of removing material from a workpiece using power-driven machine tools to shape it into an intended design. Most metal components and parts require some form of machining during the manufacturing process. Other materials, such as plastics, rubbers, and paper goods, are also commonly fabricated through machining processes.
Types of Machining Tools
There are many types of machining tools, and they may be used alone or in conjunction with other tools at various steps of the manufacturing process to achieve the intended part geometry. The major categories of machining tools are:
- Boring tools: These are typically used as finishing equipment to enlarge holes previously cut into the material.
- Cutting tools: Devices such as saws and shears are typical examples of cutting implements. They are often used to cut material with predetermined dimensions, such as sheet metal, into a desired shape.
- Drilling tools: This category consists of two-edged rotating devices that create round holes parallel to the axis of rotation.
- Grinding tools: These instruments apply a rotating wheel to achieve a fine finish or to make light cuts on a workpiece.
- Milling tools: A milling tool employs a rotating cutting surface with several blades to create non-circular holes or cut unique designs out of the material.
- Turning tools: These tools rotate a workpiece on its axis while a cutting tool shapes it to form. Lathes are the most common type of turning equipment.
- Laser cutting:A laser machine emits a narrow, high-energy beam of light that effectively melts, vaporizes, or burns material. CO2 and Nd:YAG lasers are the most common types used in machining. The laser cutting process is well-suited for shaping steel or etching patterns into a piece of material. Its benefits include high-quality surface finishes and extreme cutting precision.
- Oxy-fuel cutting: Also known as gas cutting, this machining method employs a mixture of fuel gases and oxygen to melt and cut away material. Acetylene, gasoline, hydrogen, and propane frequently serve as gas media due to their high flammability. This method’s benefits include high portability, a low dependence on primary power sources, and the ability to cut thick or hard materials, such as sturdy steel grades.
- Plasma cutting: Plasma torches fire an electrical arc to transform inert gas into plasma. This plasma reaches extremely elevated temperatures and is applied to the workpiece at high speed to melt away unwanted material. The process is often used on electrically conductive metals that require a precise cut width and minimal prep time.
Types of Erosion Machining Technologies
While burning tools apply heat to melt excess stock, erosion machining devices use water or electricity to erode material off the workpiece. The two main types of erosion machining technologies are:
- Water jet cutting:This process uses a high-pressurized stream of water to cut through material. Abrasive powder may be added to the water stream to facilitate erosion. Water jet cutting is typically used on materials that can suffer damage or deformation from a heat affected zone.
- Electric discharge machining (EDM):Also known as spark machining, this process uses electric arcing discharges to create micro-craters that rapidly result in complete cuts. EDM is used in applications requiring complex geometrical shapes in hard materials and at close tolerances. EDM requires the base material to be electrically conductive, which limits its use to ferrous alloys.
CNC Machining
Computer numerical control, or CNC, machining is a computer-aided technique that can be used in conjunction with a broad range of equipment. It requires software and programming, usually in the G-code language, to guide a machining tool in shaping the workpiece according to preset parameters. As opposed to manually guided methods, CNC machining is an automated process. Some of its benefits include:
- High production cycles: Once the CNC machine has been properly coded, it usually needs minimal maintenance or downtime, allowing for a faster production rate.
- Low manufacturing costs: Due to its turnover speed and low manual labor requirements, CNC machining can be a cost-efficient process, particularly for high-volume production runs.
- Uniform production: CNC machining is typically precise and yields a high level of design consistency among its products.
Precision Machining
Any machining process that requires unusually small cutting tolerances (between 0.013 mm and 0.0005 mm, as a rule of thumb) or surface finishes finer than 32T may be considered a form of precision machining. Like CNC machining, precision machining can be applied to a wide number of fabrication methods and tools. Factors such as stiffness, damping, and geometric accuracy can influence the exactness of a precision tool’s cut. Motion control and the machine’s ability to respond at rapid feed rates are also important in precision machining applications.
Answer:
Manufacturing:
The term machining id defined as a manufacturing term that includes a broad range of various types of techniques as well as technologies. It can be simplified by stating it as a process which helps in removing material from a particular work-piece by the utilization of power driven tools of machines to provide an intended design to it. During the manufacturing process, different metal parts requires some types of machining. Others materials which are also fabricated through the processes of machining are plastics, rubbers as well as paper goods.
Types of machining tools:
In order to achieve an intended geometry for a particular object, different types of machine tools are used. They may be used singly or in conjunction s with others at different steps of manufacturing to get the desired structure. The tools are:
Turning tools:
This tool helps in rotating a particular work piece. This is then followed by shaping it with cutting tolls. One example is the lathes.
Grinding tools:
This helps in rotating a wheel so that a fine finish can be achieved of the work piece. It also helps in forming light cuts on it.
Milling tools:
This helps in employing rotating cutting surface consisting of several blades. They help in forming non-circular holes and also help in cutting unique designs.
Drilling tools:
These tools are responsible for creating holes parallel to the axis of rotation. They are mainly two edged rotating devices.
Boring tools:
They are helpful in enlarging the different holes that were previously cut. They are categorized as finishing equipments.
Cutting tools:
They help in cutting materials with predetermined dimensions just like using a sheet metal in to a particular shape. Examples include saws and shears.
Oxy-fuel cutting:
This method mainly uses a mixture of fuel gases as well as oxygen in order to melt and then cut away material. Therefore they are also called gas cutting. The benefit of this method is includes the capability to cut hard materials like steel grades, high portability as well as low dependence on primary power sources. Due to their high flammability there are many gases which serve as media like gasoline, Acetylene and propane.
Laser cutting:
This cutting uses a laser machine which sends a high energy beam of light. This causes melting, vaporization as well as burning of metals. Some examples are CO2 and Nd:YAG. This process is often selected for etching patterns into a piece of material as well as in shaping steel. The advantages of using this is that they produce high quality surface finishes and also in extreme precision.
Plasma cutting:
This type of cutting uses a plasma torch. This helps in firing an electrical arc that helps in transformation of inert gas to plasma. It reaches to a very high temperature and at this point it is projected on the work piece so that unwanted material can be melted. It has its utilization on electrically conductive metals as they have the requirement to cut in a precise width with minimal preparation time.
Types of Erosion Machining Technologies:
Erosion machines are helpful to erode material from the work piece with the help of electricity as well as water. The two types are
Electric discharge machining (EDM):
This process uses electric arcing discharges that help in creating micro-craters which helps in rapidly forming cuts. They are also called the spark machine. This process is used in different domains which needs complex geometrical shapes and also at close tolerances. However it has a limitation. They cannot be used in ferrous alloys as they need an electrically conductive base material.
Water jet cutting:
This is a process which helps in cutting through the material by the utilization of the -pressurized stream of water. This process is used on material that can suffer damage or may also be deformed from a heat affected zone.
CNC machining:
CNC machining is actually Computer numerical control machining. This process mainly is based on the computer-aided technique. This is used in conjunction with other different equipments. It involves software and programming done in G-code language. This helps in guiding a machining tool that helps in work piece shaping according to preset parameters. This process is entirely and automated process. Benefits include:
Uniform production:
When the machining is precise and helps in producing a high level of consistency in the designs among the products.
Low manufacturing costs:
CNC machining is a cost efficient process mainly due to its low requirements of manual labor as well as die to its turnover speed. Therefore they are helpful in high volume production runs.
High production cycles:
After properly coding the CNC machine, it would require less maintenance and downtimes and therefore it will allow a faster production rate.
Precision Machining:
This machining process include any types of machining processes that includes small cutting tolerances (between 0.013 mm and 0.0005 mm, as a rule of thumb) as well as surface finishes that are finer than32T. They are applicable to a huge variety of fabrication methods and tools. The exactness of the precision tool cuts are influenced by factors like damping, stiffness as well as geometric accuracy. Other important factors are the ability of the machine to respond to the rapid feed rates as well as motion control.
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