0esigning

Parts
for

Fine-blanked
parts cost morethan conventionally
blanked
parts-for the first few. Afterthat, the reductionin
secondary
machining
associated
with fine blanking
beginsto pay off. An additional
benetit Fine.bl;ked
pansare strongerthanthoseconventionally
blanked.
MARIO NOSEAIZO
Pratld.nt
Modorch Die Corp,
Mineola, N. Y.

lvarh.r bt.ntld from lOtS rt..t t. 0.230 tn.

thick and3.9 in, in dhncta( lolanncaa
aru a0.0025 In. Ramovdot bul|! on
wlrhar t.!th ia tia only lrcondrry

FonMs-\Dlthclosc tolctrnca! . . . coln!, rtnbo3sas,

or.pedorate! . . . rcducasnaad for sacondatyDlE:
chlntng. ._. cutJ untt colt Jt youte tooH;8 to!
e.proce$ that har thcle chanctari!flc! elong irith
tlr e. charectcdatlcl allociatad eith convanfloDal
onn|<|ng,take a look at llm blanldnr
k a r!-llnenoat oll convrnttonal
.. Flno blanldng
DranKmg_
in phlch rnatal psn! er! punchad from
ooll or shaetltock. Slrnilaritta! batsecn thala fi9o
Focesse! i.lclude tha typar ot Detadal! thlt cln
Da lonrad; ltr grltlcrll natarlrh thrt can ba cold
r.orfieo can atlo b. flne blEhked, Table t. Thr
or erance! betsacr: fltra and convandonalblankhg li. in thc fldlhed colt ard rhechantcat
DropeF
gas of the part!.

Utor lkr toart

Clrcular psrtr up to 16 ln, In dt|rn, or lqulrr
psrtr up to tB ln. crn b flne blsnked. Tha
tnin!

Guid. t3 btant.dtrom lO3Sst..t, O.t8g tn,

tnick, lol.ranc!. on loca0onand
daam.t.r of hot.! ar. !0.0004 In. tbr th.
lmall hol. .nd 10.002 in. ior th.

Ptrt lor l.tch mcchrntrmit bt.nk.d

from 1020 Bt!.t that i3 0.325 in. ttiick.
Lcngth 1.35 in. lot.rrnces on hote
diamltfi's are +0.001, -0.003 in.
t05.

ttxt.BrAx| (t D

P A nl S

mum natelial thtcknessis 0.030ln., and t}le max.

imum thtcknssis 0.5 in. Tlle tlrlckneGs
mirllmum
(no fector in conventional
blanklng)ls need.alto
permitan inpingementring to holdthe part to be
blanled,Fl8. l.
llcr

Cbr

?6le l -{eco;iraded
mol.dol3 for
'. llna blqnking
:'
.
1008thrcr8h 1024i&ft .nd N h!.d
1030llmuth 1095jonly in lully an.
n .led, lDb.rcidlz.d cordition
{140, {140, 8630.snd E640;dl fllly
aM..l.d, Dr.f.r.blt |! rDlt.roidiz.d

lolcroncar?

'Fine-blanking
on llneardirnensiotsot
tolerances
I in. or less can be a0.00O3in.: for dimensions
ovcr I in.. =0.0005-in.
toleranc* can be held.
Tolerances
on holediamtelsdepandon the ma.
terialandthickncls.Insteelto 0.187ln.thick,toleraDce!as small as *0.0002 In. can bc achievadi
lor lteel thickertban 0.187ln,, 10.0005ln. tolel.
Ince! ate piactlcal.
Th.re arc no limitatlonson baxlmumhole !ize!:
howcver, practicel mlnimum hole clianeteB ar!
summarized
below:

Tr?G! 302, 30,1,305, .nd 40t {nol

h..t-tr..t!bl.); tyD.r 301,303, J00,
316,3!t?,403,410,ta2i h lully msolt, t/. hfd, N [r!d, X h[d
Tlrh |,dnt
All "H" h.rdne!&, (not h.rt.
tLrt-i!.rtd
"O" l20la . d 2024,
''O" t.DDq onl* 60l r'd ?0?5Tl
d T{)
Solt or roll h.rl.n..l, not h..t-

Itilo

solt
Not b.lt{c
Nol lln th.n !8% .oDD.r

Bol. Dbr/stocl luct!.rr

t2
25

d..l rld br.r .E no! .!Dt!.rd6d

h..ru!.
'l.d.d
p|d! blllLd tro'r t!ar! do rot h.v. lnootl .d8.r,
lPlllotyt. rr.,tr .hould ba .wlu.r.d 9r'or to tull...rl.

liZ

t."l

D.dtn

SpaceBatw.en Hola* Minlrnun wall wldth de.

pen& oD part contiguratlon rnd 6toak thlcktar!.
ln most cales,wall wldth shouldbe equal to at
, leEsthelf th naterialthlckne!!,Flg,2c.
Flattelr .nd EdgeEnkh: Flatnessol 0.001In./
lD. canbe expectldil partsar blankedfron sheet
or 6ttip materials.Whe[ parts are bhnkrd trom

coil rtock. flatnc!! ot lbout 0,002 in./lr. csn be

obtalncd.
Fige lurfaca tlnt,h depandron meterlalcompG!
tlon aDd 3tock tl ckncai The tlble brlow lists
typtcel flnilhas lor verlour thlckn$se! of pa.ts
blanked fron h.lt-he.d AISI 1008*eel.

Bhili|lo Pdrci

f
lflIfllflfinmll

ffidilt]lillillilllflhm
I 06

Fie. I -Codprisn
or
conv.rdonal
.rd
lin..
bl,.n*ina !ie.s4.
Ac
tion of .ih. idpin8.oc.t
lrtc 2!d coua|.rDucn r..
idt
io clot. - tol.Efte
p.ra
with
r.liriv.lv
(!o die
c4.r
rdmth

-f-

I
n, Z A.1l
at z a.o5/

Fir. z-D.ri8I

linit iou of finabtft.d

p.r!.

Flnbh

0.030.0100

l-20

>o.ti7

Parts blanked from materlel! such aa alurninurn

and brass rlloys rormally have bette! edgefln.
ishcsthan Bteelpart3.
Dle Roll .nd Edge Squrencr!: Dle rolt, Ft8.
2b, ls largely a functloa of rnaterial tblcloe$ and
6noothness of the part perimeter. OD rtralght
lihesaDdsrnootlcurves,dle rolt i3 $ually llmited
to l0% of the matedal thlck ess. Horrever.on
shnn noints (15_or less).dl6 roll cen be as much
as :3oA ot the naterial thicknss.
Dcviationfrom edgesquarenes3
for parts up to
ya-in.thick is usually betveer 0.0005end 0.001
iD. On partsover %-in,thick,lt may become0.002

2,000

4,000
5.ooo
!3OO
Iun!.l ot Podr
Pi& 3-Corr <@r..iro,| of corv.ndodt .nd fin. bl!.t.
it:8 J9! r_ rrpiol" bLrt.d p.ri Toolina (d. fo. tinc
Dr!.llnt r. ap4!.rEd br u, , r.Fr.r.rrt @li.[ cnn

Wh.l

Dc.. lf Co.t?

' Coftrs Sharp comeru contribute to lncreased

di roll and,in extremecases,can evencausedle
break.liminatirgthe sdvantageof fine blanking.
Minirhum radii of outsidecomeri should b et
least l07o of stockthicknerEiradll of insidecorners shouldbe at least 5% of the tldckness,Flg. 2c.

ToolinScoststor tiDeblankingare usuallyhlSher

than firose for conventlonalblanklhg. Thus, some
minimumnunber of parts must be producedbefore the cost edvshtagedue to the ellmination of
secondarymachiningbegins to accrue,Fig. 3. As
paft c.tnplexity incfeass,the cost ad!,antageof
fine blankirg also ilcrases; the cost-vs-number
ColDh& Fordhg, E[rbo$ln& Extrudin$ Fine. of parts curve for conventionalblanking will be
blarking car be usedto perforete,coin,torm, em- much 6teepei.
boss,an.l extrudeparts in a sinSlepressBtroke.
Another cost-relatedfactor tiat inlluences the
In genernl,thete aaeno limitationson tlle com- choicebetweenfine blanking and conventional
ple:'rityof embossing
palts. Coinirg is subiectto
blanking is qrhetbe! or not the paft Fill supporl
the sarneiimitationsas hole diameteE.Formine the required lo8d. Colvendonal blanking tends to
(bending' shouldnot exceed60o, and tlle heighi weaken parts arould their perimeJer
due to the
of a stepshouldnot exceedthreestockthicknesses, dle b.eak. Equivalentfine-blankedparts do not
Fig,2d.
havediebreaks,andthusare sttonger,
t07

SPINNINC & I'LoW TlJXl,llNc

Spinning
Metalrorking by spinning is a,versatile process fo! 6haping
sheet
haterials.
It is a universal uethod foi producins .t.pe" .orro"" platr
section
ale circular.
The process is generally usea tor !;mpte shapes shere
the
quatrtities_do dot justify
coEprehneive press too:ing, flared shapes where
press tooling would be difficult
or iopoisible, ,"_"ii..ii
shapes where
seS'ented tooling can be utilised and iarge *oikpi.c"s toi t,trictr
othet.for's
of fabrication rould involve.ptohibitive
iapitat'-o"is.---Spinoiog
is ,rot
Dornally applied to oass groduction althougir there are so'e
exceptioDs
to this rule (eg kitchen utensils).
spinii"g
cilri"a
out on
dachine tools of codvntional design, either !p""i"fiy
"oiL-iJ naiutactureltor
ttre
purpose o! 6iEply adapted cenrle lathes, utili;itr8
to;1ing that is siuple
and relatively inexpensive.
!1o, tur[ing,

whilst at fitst
6ithr very si-oila!, ha6 Eany fundaeetrtal
both ir principle and application. 'rij, i-iiru".r"t""

9ift:::::":
Ene dr.rrerent concepts of spinning end f10v turning.

rt should be noted
that spinninS ie essentially a fotEiDg process witi
no significant chante
in section-rhickness, wheress,shear sfinning i" .
rorgirrg
frogr""3i.,"
--- operarioa irvotvilrg cotrsidersble oetai dispiaceoeni.'Th. technique of_ spinning is a lanually opeleted plocess
where E blank
-;1i";;_"osed
of r.larivety
thin ducri.le oetal-is acied'up"n
or rolt.!
-ti"
tool, sooetiEes lever assisted, ia o.aer to' persu"J"
"il;
l"t".l"f
to
adouoe the shape of the chuck-o! forDer to pioduce
irr" i""ii"a
corEponent.

A scheoatic vie!. of aanual erd l.vei .""i"r;;

ti;ni;;

iJ-s-io"n iu rig. z.

Siaple.Ehapec can usually be EadG-tith on pags,

riril6t-""ip
intersrage

aqr.alilg ia ueed for the loore difficqlt

FolEeta ceu be DAnufactutad

floE

""i"ri!r

s'-.i

i!*

Boftwood, hrrduood, plastics

aluoioir:o, easr iron o! 6teeLr ttre crroice'aeleiJiii'"i"i-iii

"r,"p.r.
lEirretes,

a".y arra
ecorolrice. spilnins rools ere usurlly of ,;*d:;;s;.;;
ioir",
typ"
illusrleted in Fig, 3 uounred ia lisid't;;e;;.
iiJ-uJi ii'r,,u"i..n., "" io
spiaafug ia essenrisl atd sorips ena-taffowa-aie *:.1'"fi-.".i.'
' !1o* turEing
(Sheer spinoing, powet roll f,oroing, power
spinniag, rotary ertlusion,
hydro spinninS).
Itre coopotrerltsof a ftorr tulning rethe are siuilar to those
tethe, but are Buch 6tuldier. Rolleti ."" :iii.J- to-ti.-liois of a 6tanararal
sliaes, ana
these shape the nork ageitrst a lotetinS ,.1i4;;;";;";i:
-'"For irregula! shapes, the cross. slides-are ttacaE
conrrolled.
and cro6s slides are senerarry hydraulicalty opJi.i"i-iJ"liJl

3;i.*irf;;:""
Ploduct!
trlblerE)

lrai! slidea

involved. Marerialflo.o t;- . -;;;i;;.;;;-ii=a""p.r.n"

a".,'i,,s

(eg Eetel
ralge froD sDalt iteEs Dade ia larSe qaantities
iq sEall quantiti.r.
to lerte cottpodcBts (aeroapace applicationg)

llar*s es large ao 5 E in diaEeter a[d plate atock up to 25 q thick

llhen heated, blalrks es thick
ca! be powe! spun vithost applyi!8 heat.
spuo.
auccessfully
have beeo
I,lon turning ie a gevete cold working opelation aad has a Eerked effect
otr the Dechalical propertie6 of the nork Detal.
craitr size i6 refined and alrisotropy le6ults.
Surface finiEh is usuelly good alld ao additional finishiag is usually
required.
decleases.
StreEgth and hardiess increase ald ductility

a! 14Oq

2.

Iis-!-&-.

!e

titb th'
ln
N't b' d"isD'tl
Lori's
&it
'quip!'nt
loc'doDs
for th. 'ccotduc'
co!!'cuttr'
of tb. i6!E Lc.!
pla.
cboic.
te...
I! Y'ry ilportqt'
.r. !.!lon6il
tlo lnaiYiitu.I o!..!tion.
ir tt. p".t
"ttl.
rui
h. c6n.ia.r.d.
Fu.tio!..l
iLt@
grEci.l

r,htt

3,
rmEncfltNcplDlE

g ,|Ut c,tt RE

!h. eih re!6or for th. s. of !r.t.M

.onpon.bt. vbich virr .srcDbl. toA.ti.t

ol nlirit!
t rlt.i
.t r.ndo!.

i.

ldl rili.I
lllitt
ot.it.
!u to h. rit
A cdtrllc
choic. aor tb. ldtlu
dtlov r !..don.br.
MnufacturitrB v.ri.tio!
ln rctu.l .ir. oa thc conpoc.t!,
of fit h.te..n thd d a...rlt.
vtlich vill nlvly. givc q.cc.pt&!.
drl...
sy6te! ht. ib.

lollwlDg

.cororlc

!!a o.uFirF Eoui@nt

toG

ro! Lllli.

D.ti!:ttlo!.

.bs4'-

(...

t rlt!

to dt
!.!et
Et. t.r
qd .oi lut
to circd.r

Bsl'oo

(r.btc

diEnrion

.rt.d.l
b.r..

to hrgts

uottt))
of

'

c@tE"nt

to
but

.ilyut!a..:-

a)

sith 1..! iLuld otr .tllt

corponebt. cs n. eade in quqilty
gaug.. ard t@1ina !r. u.a.
nr. qr.dity
n.t!
if .uiilhlc
be lutftci.Di
rD.ct.l relr.s
co.t..

b)

dr "fiit,.it"r
cobponnt. cad b. !'as!.Dbl.d!' in6t.d
o. ! srirha
it o!d.r
tinlI aiUuterts
ch.r.ctlr

sd.do't
h@.E!t

i. ti.y viU not n..a

to proiluc. t.ti,a..tory

"trol.i -

tbi.
to

t.tn

i.r
Ev

lot

odv

-7-\t-

nobc-oft"
(not. thlt for tn. clsc o! .!.cir1
lt b6c@. o.c....rt
to
!rcltmtr
pong r'to suit{ tb..tl.tih!.qclF..t
rioc. th. co.t!
@nul.ctu6 r6pl.c.@.t
b.cG
of.!.cld
toolina 6d soDs.! c.nDoi t. j@ti!i.tl.
th... ptrt. tb.t.for.

to th.

ol ! cilcDlu

di@te!

hol'

but

itt!.nrio!.

l.t.hil

by . .tpl.
.t.t.!
or EDlicdat
AsE.,bIl..
.o Dde can n. ..nic.d
i.lt.
fo! th. u.! dd i. .h..!Gr thu
ilraq frd otock.
1ti. is co@.i.Dt
to.I.ct.t
r.conilitionira,
vhicb woufil irrolv.
tb Nut
ct@ ol a.s ttrt.

.)

ol th' worl'
tb. .ccq'cv
t@)lda !u.t b' cb'ct'il

l! oritet to .oDlrol
llrrt b. d..im.tl
ol ih. !.r|a.. ..d.p.cl.I
lt..ccq..rr
.teil.t&
.
F.ct.io!

to lleiid.

l! .]hin!t.it.!il
th. !.tt.
@
If thi! i! ..hi.v.rl then "fittt4"
th.
cen.fully th. co.t o! !,roducltod i. r.dE.il n...u.
.
"i Bt r.hdg..b1.'
volt r.tlu..
tb. ti!.
r.quir.d to hull.l tL. DDduct.
Gllninrtion or th. tittins

Th. i.t.rchaDs.*t.

0.u..

+'J-'t|l l |
\i
I

i-.

Prc-!couIsit.!
E.lDbly
B.foE a Bylten oa intelchlngeabl.
lundeontll
conditiont luBt b. !.t:i)

rh. D.hirribr.

ii)

I1r. utirS

va.latiotr

(torcrsc.)

c.n b. oD.r.t.d
ol .ich

condition 6! ..ch D.ir oa ptrt.

ccrtrl!

dien.loo

!!...bl.d

lut

n. fired.

rust b. d.ciil.il.

iE .ic

8tr."

l.

th. .tddltn.lzo

tl.-.r"iii

tor tb. !.!t

tr,. uiibs,'rb;!ft,.

4tr

i.

th. !o!

lor botl

(^r!o cdr.d ,'&4I!!@s,')

-a

Procedur
To.h6urc thot cobpo!.nt. ar. uitc rr n.lrlr
ltl.ntlcrl
Mnuflctuina
to b. .hpfot.il rut h. c!r.f!Iu
lrocerr..
T1,o?roceitu. involve6 l,h. follosinA:1.

A Pro.e 6s Plshi n.

Fo..ibl.,
cho.eo.nd

tb6
clEcili.a.

nout c

1t!i. i. ! bcbeilur. of th. indiviilutl

.t!o bc il.cid.d.

op...tions,

oil

th.ir

d.qucnc. rui

Z.!!

aaa

IlD.

laalc

or,o

-3'LIrt!.

of s&q"

the !ut!u
Itilta.c.

ed llnlM
b.ty.r

.i:.r

!.Et.Ibl.

tb. tvo 1tdt.

o! th. ?.rt.
'Mlni.!

of.L..

a l|dlt@

Clcc&c.'

(o! Irt.

...ac.

yh.n n.cc!..ry)

g
r Sol' l
"0nd6 ol Tor.r.nc.'Lltr
.ult
ltt.y

idlcrtlob
or !h. d.gi.. oa &cqGy
ot lrut
ctu.
f,o_
.Il, b!!ic .tr.r.
ttl.
l. d..laD.t.d
br th. r.ri.r.rrr.'
ians. frr
Im1 up to ttl5.
!!.d.
th. rb.llc
lo! tor.r,

"Upcr

p.yi.tlon"

Th6 @ht
D.rianrt.d

"Id.!

!6ri.tion"

lr .toy. but for th. rtnt@

fot no1r, t.tr for .r!aft..

Ircr
rX|

!tr." to th. sdr

ud t..r ror !r!ra!._
1ldt

or.k..

ttrit

of !l!..

D.rtB$r.d

tldd'

sl

[oI."

rtude.ltlr

D.al.ttont'

lrrP!r!-!4Yg-gl
raild.dt.l

dil
biss.!

r.rllM
the

bo16)

rqr tude.lt^l
aertdtiotr erl tbis id
tLl. i. . ho1. eii!
!!.clli.d
ar !!Xgr bem. tL. lov.! lirit
or th. bol. .oinctde8
rith tt. !!.1c !i!.
of th. itli.rsion
requlr.d.
g.nde IT?
.a . hol. tol.E.c.
rith it vi.tlor
fi nra tol.ranc.
i. d..tan.t.d
11.

lt. Er.l
i! to !.I.t.
t.t.tr to . !Mg. ol nrtlottaril hols'r
tb. llEit
Dnf....c.
(cs ..u.F)
.r.t.!).
Thir vllr .trit rtdrarit
to1r,
fo.
{1. . bol.-bsi!
th. .n.fr.I
cd,lon.at {i. th. r.halt')
.d be Dor
DrcitrciDa th. hol.. Ed !.ca!.r
.dtrr
Yut.a l! .i!.,

nE

llLi{u
(shrlt

ridEF

rxl.

"D.!ic

Ed

,.rl.ttd.

I. th. A.d.tlo!
t th. r.E tb.
aor .ttber bol.
!.d.rt
or .h.ft,
lt ft!..
th. Do.itloo of th. tollrsc.
,onc
In r.hlion
to !h. icro tln6,

rftll.t
l. t

noI.t. ti. t.nil..cy

rD.!1b1. itlfl!.nt
[Ur tor e6t tir.hch.. ol .nAin..rirA.
^!d
6oEtlx.,vh.E
r tndt
hE tb. r4
!!.lc
.1'. tbrougt.qt .tril cc!l..
6!v.ra1
vltb dilr.nnt
d..!bl!
flt!
li voulit !. t.it.!
to s. d
Dal. rtich tut
sylid.
!.r. ih6 .r!.ft l. uchlr.d
to tb. !d.
liilt!
throlshout
".h.!t-buir"
&il t!. oth.r Frt!
torlt
!o id. ncc.r.lrr.k.!
to siy. th6 !.quiEil
flts.
!ft1. .ft{?L .4.!.1r.
Dcrrlnlns o! tL. .h!l!.
4o..ry
odt G.

b..ic rlt.
th.!. d.28
r a.r, ..r, 1L!8, 19

-5-

-5 C.lcul.tton

ol Tot.!dc.

Ibr s'.d.6
ror.rdcc

q) to I l.cludins

IT5 to lfl6
uir,

$r. D ir itr dr]iD.tr.!

{s.. BE.lr'oo lor tohul&
A.lectiv.

roo D.l.c!-

1/54 + o.oorD

o.!,

L!!s!

fosil thlt lt lr &t .conoiic

of ac.ulcy tor thci! corm.t

to Eoufet@
fuctlo.irs.

b.rl!

.r.

lnto .Ell.!

ihn.r

'rs6bl.d
6die b!rl. c.n b. E.cnbt.il ltrto edl6
lD.r
t.!ae irnc. nnil ofi.r !lng., o!.u11
t@.r on
aE61r }!lI!

c)

arc is..!bl.tt

lDto trrsel

c@po..ntr

to tt.

.!a r!.d.ii, o. .or!.d l.h

eitht! clo.. lbitr.
!..n.irlluly
sx!d...

r rdacr

i. o
!.U..

lnoinc. ex@plc of d.lectiv.

@toF.ar
crltnii.!
bore.
.s

isluu.

&rt

.Lirt

r..6}ly

! 5toE noEtn.r br.,

clelrlnc.

sil

lo! Dirton

Iol.ilo

on bo!6

a.

Toldrucc

on llrio:

dra

i.

out.r

tn 4tirs.ruinlu

62.0{rr. lolml
O.r2-

Dy erzdinA eit Ellina

th.. a. folloer!-

Dl.ton.

Dirtor

dir.

r.qu ir . d. .

.!ch Arou! girios

..

Ur. d.slr.rl

..

t6

y. .6urA r.1.crtr.t,

O.l2 ct.rr!trco

63.02
62.9O

ploduc.n by th. Friicnfc!

U.* !..n .ri&iD6t.it.

v..latio!.r-

Du. to th. }lalut.ctuin{

PF6c..r-

l! D.bln.
b.!.lES.,
ib.dl
di.toriio!

Duc to tl.ctdlcnl

r.cl of t.p..t6b1tity
id @chln. tool!.

ot eyeD.rr

..1oog

F&!.rtl.r,
or ib. vorLt'l.c. Et.rl.r,
rchhirs
aivhA r.rrl.s

r.ri.tlon.
is tb.
cqttiba torc..

.ir.

oa

pu. to Otsntor,
.&

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uE

to ?.D.hru..

.a.

vcl.tlo!.

l!

tlght..i6S

ubl.lt

.,t .hBL.,

t.tD.lrtui.t

or cl&q'Iba

.ft

ctilg

th.

cdtDrltr

in . vic.

colpooenr .ire.

lw t..t!
vhlcb .!. csrl.a
out to tl.t.h1n.
th. I)rc...
dDiri..
th. ctt ct. or a.ctor
D.b u i@t r.61 lc*iDs

rut.btity
o.ry r!cto!6

r!.sr..

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.

63.01
62.69

l.

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tlbtla

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I
63.OO
5?. 60

or i!n.r.nt

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o! vei.ilo!

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l!
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b!rpl.c.
t.ror.

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( r o.o2l
. 0 o2m.163+ o+ o'o2l
- o.o2E[62.88+ o J

th. borcr dil

2.

I
out.r

6d out.t rt!s.,
out.r thg..

ld.r.!it.DU.r

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lb l!ra..t
lr6rc! rculil SiY. O.r! b
ll.torc
,
sil l.rAest I'iston io 66ll..t
bor. |
0,1O n

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Usu.rlt . r'rcl.ctiv.
adroblyr! .r.td
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.q b. lelldceil r.tn.r th.n it! inillvlttu.l
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lot
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Iot.v.r,
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.llil.varr

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or thl. !y.te. occq. h D.ll !.sioa
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!rt.r

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and I li In !icM.t!.6ior oth.! tol.r.rc.

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Irrt.arl they !!6 uil6 ln d lconortc !db.t, &uudt

ol tb. .e
.lr.
srcup. .ach or vhich cont.ir. tuir
It.y ltc th.r lrserbl.it vith utl.a
D.rt. dtch t.E

.)

I. th.
ts..!r

toseoblY

It ir !oeti!.!
Rquir.il des...

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r|bo il.t.nbiDs
cols.rtlr
ail

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c.r'alllltrt
lt
th. ca!.tiIity

l. !.c..!.ry
io !rcarc. a !ube!
fto! q edy!|.
oa thcs..

or

du.

rz

r 6.4 SurI.e n'shies

eatB pmdrc.d b, odtun

ptudrcdon p&es6,

@ti,!'

RoLshn.cs vdu, R.tin @j

Ebcrc dbchsrsehrdinins

rl
12
t1

awEse apDticaon
ls

L6s toquenr,poticarjon

Ie

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re74

lollEplEFqe.EshrqeIijuoyEfule*.jtdfu'

*f;*."['fltrtr"l:trT'.:;fn
pan2:1972J
tFisur
11:BS1134:

BRITTSH STANDARD

SELECTEDISO FITS-SHAFT BASIS

4500B

slq

,n "if

-T--o

-r_

ts

_.9.
t0
I8
l8
30

30 40
40 50
50 65
65 m
EO IM
t00 120
120 140
t40 t60
160 r8l0

IA

!E

;i'

=i

-i

-n

IO

t0
l8
l0
40
50
65

l0
40
50
65
80
m I00
t00 t20

r20 l,l0
t40 160
160 I80

tm 2m

\n

225
225 25fr
250 280
280 3t5
ll5
355
355 400
4{0 450
500

-q

l m 2W
2m D5
-t'

225
zfl
280
ll5

2fi

280
ll5

155

4m
400 450

450 5m

a'

E R ITIS H

S TA N D A R D

SELECTEDISO FITS-SHAFT BASIS

45mB

qdP

%.

\'',
.\SN

@)

';

.\)

V<._- 6st
+

y-"1

'-"

cflr

r.

-if

6
l0

6
t0

-i

12

l8

t8
()
50
65
80

lm
t20
t40

t60
180
200
225
250
280
I5
155
400

l0
l8
30
40
50
65
80
10.,
I20
140
160
180

30
4t)
50
65
80
100
120
140
t60
lB0

2m
225
250

zm
225
250
280
315
155

un
3t5
355
400

t8
q

50
65

80
100
120
l4t)

t60
180

2m
225
250

1m
ll5

155
400
4m 450
450 500

Afi

500

i I:

\Z5.ooo
\zct. Q6<>

,' | \1 5

'

io t'

\rz;.our

l'\crr

C leAvhce

\l s,\o6
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11.1" 2
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SUn]IACETE]ITURE

the Ndture of Sulface Texturg

producedby chip reeoval process depalta
frod the desired perfect

-i"iiil;;
enr
:::.",:? Tj.:::i:H ::, :;ii:ii. ina.*" pres
?l:3,"i.f"""

lst

-;; recoglise

fout

Orde!

arising out of inaccuracies in the Eachine

I:::!::iri.i"f
5lEai,gh!trelr-in
lhe l'eys or guides,.or out of defolDation rool, r.ck of
of the lrork unde!
Ene cur!in8 forces dnd under lhe lrei.ght
of i rr"-r!i".:-ii-i. i"ri .
2nd Order
Irretularl!ier,cEused by vibralions of
aDy
t a c o r r e c t c u E ! i n g e n g l e s, l o o 1 vi b raEiolls kild, et chatrer-dsrk! due !o
etc.
3!d ord.!
I!rrgule! i!i.!
rhe.nachiningitsIf end characr.ri.rric of
rh proces!,
trhich rould be :::::!-by
preser! evnif the i:chine rre!e perfect

".a

4th order
Ir!cgul!!i,t ier arising froE lhe ruptule
of lhe Eelerirl
of tb. chip.

fri" ii"r'rifr"iii",

drlling the lepes.tion

E S t I 34 - 1 9 7 2 Centte-1ilre .varage height

Dethod for the aEgGlssent of turface
Eextute.
.,re !t{[derd
RouRhn!!r
IJavines!

defides 2 cla86e of !e:<ture.

(PriEaly textule)
(secoDdary t*ture)

Roughnerr
The ir!eguldtitias
in the lurtece lextute uhich reault fro6
thc inhelent ectiotr
o! rh. produc!ion p!oces6. rhe.e ate
a"e.eJ-io i;;i;;"-;;;":;""
reed ,iarks
.nd the irteguleri!ies
lrithin Ehen.
Wavinca!
lf.l:-"o.no""o.

of-surface texrure upon Fhich rouShness

is 3uperiDposed,

:;:i:ff: ffi].':::i:,:::',:";:,;:ilo'",",,'*"t in"'o.*.t-a"ii"i.i".", vibrarions,

S ur fa c et o p o g ra p n y
trrrs wirh th. *antcd .xcuEioE of thc {vlus' rnd 'n
wh'n thc
oacricc rr'c conUi.*io" can bc lcc'Prcd onlv
rnd cldc cnoush rosdh'r tor
a*p **et'
!'"i;".
radis ro bc shau con'
Ji.'.".i"* "..
'li.fsi"cn
"rir'.
stylus.
ofthc
orrcd with thotc

Fio. 3. (.) Skid S tlidas ov.r crasts of sptciman

to in't'Ptndent
(i, .cc.pt.bl.
.Pptoxim.tion
'Jiti
ol
n's'tiv'
skid .ttot.
t"t
'ieniiic."t tu whsth't th' skid
iii,anc
'stvlus
'nd
'i'jli,i dovc in or out ol Ph,sa ld) acc.ePttbla
n;chanicat filtrr.ian of wav.lengths which ara
of skid
with s.P't'tion
iii
'nd
""^p-"a
Thc di.mond lrvlu mav h'v' tht lorm of a 90' con'
liP rrdii
*'.t'
* l-,ia."
'quival'nt
'tandardi!'d
l6nN
"i,".ia.
l
0
o
r
0
.7
h
I
/n
r o**
i"a
rm
t:
ot
"p *tha.
i ' - . uD. .rc "3h..P
cnoughfor thc gcn'r
whrlc
'un

."di..'ii"

i'i.r"".'.

do*n ro 0 r/rn .000r s0

'zrirg
s. ui'o in lo.cialscd idtruhcnlr to grv' b"tcr
".i
ofsaus' blo'trr'
n".",*lu16
i*.r",i"^
'' 8 thd'
"t,1.
riBduccr!, follow.dbv ihcir 'tr'nden( 'mPr''
Elccrric
airplrc.mc't-5'Eitiv'{i'd'P'nd'n'
n.i..i..rr*.u"a.,
rnotion'icnritivc(d'P'ndcn! on ttllu
lii.,
"i
vclociN,. Tlc
-a djllincdon i! ihPorlcni and thc ut'r mult

ri"* *uJ ri'a r'. i' *l'g, bc;au!' tb' form'r n'cd h'vc
frcqucncv rimn:rions, rnd c" rcProduc'
ii-'r-,i"""i
*.*ir"nn
r"'c.[a bv thc ltvlu! r'lidvc !o lhc datun
n.tuain""u-t tingt. gt*"s and rh' lonS'lr w'vcl'ngtht
r"*' hr'. ficqucn* UmiratioN rhat rcn'ct
-iir.
'n'.
thc ran!. ofDrofild ro which rh'v cln b' aPPIicdwirhoui
scriousmisrcpr*cntation.
Dhoto-clccrricand modulat.d-cldd
-r. *.-"'r.r'
rranrduccB;r. disPlaccm.nGscn'itif''dovms co'r rrrnF
d u ccc.r . nonona. nt nv ' P i ' 2 o -c l c c rfl c
b (o m r
dsDl re m. d- ( s m k r n r h crb rn tc o i l c rx ' 9 c ^ b u I
ro rn ahPrific- ni 6nn'
*t'.'
-"1i".-**i,*.
-"."t'd
Th. cl.crncrl 5iqnJ froh a disPlrccn'nrrnturc
nav Providc thr" kinds
,'"*i'*"
"ri.. ".irin'"u"n
I) !n a'arosu' rc'ord ' c r Pronr'
;i
';;";,,;;
rcc".d<' ,ndtor '2) r disi'ar rccord
;";i;;';h"',
,p.-d o.oinrtc! of thc Pro6l' srrph
li.'.:"r'th. sidc ol thc chai bdng rccord'o on
tal.n f.om"ir-a"
o u n .h .d o! nden< ucr a P' l o r " ' l _ rl u ' r' Pro c A{ n g' n
o ' n u m c i .r
3 n*r
:"";;;-,,; " . ; ; ; ,
' n i rk ' r' u n 5
!h.
of
ralucs
.i i .,;;.t
ddcriprtlc
Pro6lcdc r i' c d fr;m m o ti o n ' !' n ri tn ctn n s d u c e^
uit J or " fo r m' rd n o ' ' a u u n ' ro r ' h i L h
;.;;; r r '
^'. .-,rt.
f . ' 0, . " . 1 fu n e / \r' u ' ( d ' h b ' rrrd '
.,.*

rz

Som. ryPrcrl Profilca oi rou8hnds Iaturc'.honzon'3rr!

r'
c o m P r c $ c d I n t h c c u , l w : Y i t ' 5 h o 'L nI n R

Mtgnification
Fig. 4. f,/Pictl Profil.s
I
hori2ontat
icel
thus: vert

is 3hown

NUM EFTCALASSESSMENT
Significancaand Prsparatlon

caP'ci'llvon drlwirrgs'
ForourDos ofcommuDic'!ioo,
nuhcncalY'rnd
!c'!u(
. a..;*,urf'cc
r, i,i"i-'l.
A t!m'nc!
cocid'rcd
bc'n
hrvc
thit
to
mlnv rDororchca
trr. td(turc i! oRcnrcr'ncd
.;;i;";iJ;;i;-"
dcn
"r
ro s i p.!ah.!.r'.-p*,ThG hciSh! tP:cng' !loP'
ditt'ibutiod
.--**.'"iii.
"d
roushn'3
-0";1el'nJvrnou'
of
th.
corrcl.don f:c@E
'nd
rdorhruotr
ot
rottl
bc icni 6cant.nd conribu G to lhc tum
ihrr-mav bc rcq'ired: t"t no 3in8lcPandclcrlrP'ndcn'
can colnPkklv dcrribc ,ti' {rrrr '
i" , .i""r. *.Llt.
h.vin. qu'; difcrc'r p'o6l'5 rrn '"
s...*
1,rr*'
num.nc.l l v .qurl Mth raP " ' to onc auch P i rrm' r' l
(o o(ncr3 rrdninrh
whil. b.inq uncqud wilh rcsP'a
tnc numb' r adh{ tcd t^ * ' )rr'
ai .L" ,t' .
...' ' a-" .;*
us. sbouldbc dinidiscd'
shoD
"
i"'"a bv rh. Pic['uP m'v ']hibit d "ll
ir."iJii
(r\ gcncr.l cu^rr"'i
r(jruvc rc rhe,srruh.nr darud.
/
h'
cls.d d 'w.vind' r'd
., i.* **a*"*"
rcrrccc
rhown
s
cts.d
.ho^*---.t.nrf"
'oughn's
s(.' Th' fi Ft rw oorth6' b' i ns
i ' .r' i " ,r' . o." ni . i " ri g.
".nd rourth' rcmc
Pr'Prrrtion ^f
,,i,i'" lhird
b'q'n
'.*r.';"i
or.nr. i' *qu;.t lcfo.. u3cfulhcdu r'm'n t 'rn
'i.
rccognition and isolatron t rh'
Prcrararion ii"ot'c

i.;Iil;;;;'

;;;. .*'u'ia. .no rh' s'rbri5n-'d'r

r r n ' f r o n *h r c h
.,
'l " " u l .
'" . , . *.
Llcced.
J n 'r o r 'h a '
R t - o q n r u o n o l r h c o ! t r c r 'n r k i n d 3 o f 'e \ ( u t
I 'n
!
o
m
c
o
l
u
d
s
"rn"n'
o
c
q
r
"
n
!
o
r
v
c
l , o u n d . r c s 'n a
Jrr
i
t
'i
u
d
'
r
o
. '" " , 1 - , . "
Broadtv. .oushnc$ n d"hcd

F2

S ur f ac eto p o g ra p h y
Parameters
prG
Erccpt lor lhc fai.ly p.riodic t.xiurca 3oh.tjh6
dd.cd by dttihg pro.c$d, 3urfacc rcxlure t.nd to vary
.nndomlyin h.ight .nd ipaciDg. Th problcm ofdecnbing
thc diFcr.nt tin& ofr.itur. ofcF full *oFt ior lhc d.vic6
nf (h. ltttirticib. frod rhc aihplqt fo.tu ofav.rrSing ro
ih. <omplcxiti6 of cotrclatjon flucrioN-

d c p r h . B . a . i n g r n r . r c c p 6 p . r u n 'r l c n g t h , r _ J g i v . n r c v c l
har. rko br...oun,.d
I n a n c w d . t h o d '' a l l t h c c o n $iru.n$inusidal
wrvcl.ngthr fou.d within a gilco w.t.band, wcightcd according to thci. amplirudcs. ar.
'al.!
into account in an avc.agirg proccdurc.

Beaing arca
Height
Th. mor comho'lv 6.d and cdilv mc$urcd h.ight
par.mrr.r n
av.r!$ d.panur. from th. mc.r L'nc
Df thc fih.i.d 'h.
pronlc. ft i! tnowr i. rh. US.{ 3 rhc .{-A
rallc. In Grcar B.ihin ir wa and Bcndall_t ir kno*n a
rhc ch v.lu., bu( it is noq !o b. knowD d rhc R. val!(
ro lin. up virh ISO tfhinology

A conccpt frcqu.nd:/ cn.ount.rcd i! thar of 'b.tring

arca, lhown in abltracr p.incipl in Fig. 8. th. l.vd of
th. intcB.cring linc bcing crprcscd cith* a I dcprh
bclow thc hi8h.!! p..l (an un.cftain ..icrcncc poiat) or
a an ofs.r iron rh. ncah linc.

_l
-li-T_rJ

_ _-t

Fis.7.cta- Lf,!vtot.,-"= (Lrl|,^"|

Thc rtu v.lu. h! bftn $cd in.pproximatc forh,
obt.ind by mulliplying th. AA v.lu. by l.ll which is
thc convcFio! iacrcr foi sinc w.v6.
Thc hcight froh fi. hjghdt pcat to dccpcarv l.y lound
anyehcr. .long r rclcckd part of th. pro6lc, lnown a
&, i! u.d crpc.irlly in Eu.opc, bul it k un!.d!f.(or:bcc.ulc thc singl. crrcm.! .r. loo grc.rl),d.pcnd..r on
th. chanc. porition3cl.c!.d.
An.v.rascd ovcrall hciFht k morc r.prca.nt.tiv. (han
R,. Thc 'tcr poirr hcishr Rr' ir obBincd bv avcr.chs
thc fivc Nghd p.!b .nd frvc dc.p6r vrllcy! in th. tottl
tnver]e. ln 1 rcccn! Gcrh.n v.n.nr, ttrown a &., th.
avdagc of fie R, v.lu6 in fiv. coB.cutivc t.npl.3 or
cqual l.ngth is tllcn.
'llhoosh rhc rario ot on. h.jshr n.a!r.
to rnothcr
! ,.r wirb rh. 3hrD. of th. Drofil.. !om. dcqrceof ronvcFion is g.ncrallv p$liblc.! lhown bclow:

--

BEAFIIIG
LIN E

-i

--tIIN E

Fig.8. Not tinsl bea.ing arc. of s.t rple 3/a= a \ 100

It mulr bc rchchb.r.d th.t thi! Ec..ur. i! connn.d to

a !m!ll i.mDl. of th. lurLcc .nd do6 rot r.riacnt rhc
ov.rrll b..ring .rc. taling w.viD.s .rd orort or rorm
into .ccounr. lor do6 n .[ow for clrdc deforftrtiotr of
th. p.ak und.r load. Th6c atrd othd cotrlidcrlrjont

Crcstcurvaturesand height distribution

Th .vcnsc radiu of u.v.r!'c of th. c'6t!, tnd thcir
hcigh! dirributiotr, rr rcfcrcd to in connclion wnh thc
ol.lticilv ind.x in Sccdon Fl. whilc d.!.r idic.tioru
..c nor gcncrally .vaihbl., thcr. qu.Dridca c.t re.dil.r
bc cofrpulcd rron disi*cd prc61. rcco.&-

Corelation techhiques
l0pr
"1"
L l8 t o l- 30
t_ 25

5. o;

8 .0

' Wnh cLan cur i.oB.ou.d-nd. '@1.

spacing
T hc 5pi.inq oi ih. no r c s igt if ic anr P. : i! r lonq t hc
. : : rf..c. rdl 5. tun ctio na llvim poilint
l.r{th h rv c bc c n . o! iI . Lr ' ' pf r . 1r . , , , 1
P crts pr '
'rn'r
h t cd as ! o.1 , "fl\ ri (h c ldja. ent r allc v c \ . . c dr r c ' ! "n

Thc!. m.thod! hav. b.cn inilodu.cd a5 .n .id to distinguishing b.!w.cn thc ah3pc! of characrcrisric profilcs.
An accourt ofthcir us i! tiv.n in Rcfcrcncc I L

STRAIGHTNESS,FLATNESS,
BOUNDNESS.CYLINDRICITY
AND ALIGNM ENT
3.PaF
Alrhough rhac sp.cs rE g.ncrnllv.ons'dcr.d
aklv fron lurfacc t.rrur.. rhcy can b. highlv iignifi.ant
rhc lunclioninq of rurf.c6. rnd mur rh.r.forc r.c.ive
'o
1 lcd softc n.;don id th. prdcrr scction.
Th.sc sp.cls ar. gcncBUy m.asurcd wnh a blunt nylu3
(h!t rrac.s onh thc crdts oI thc roughnc$. a.d do.s nor
appr.ci!blr .nrcr rhc nar.ow.r scratch harks
Sfaiqhhc$ and fainc$ !.c now bing ncasu..d wirh
rhc saoc basic tvpc orappararus 6 io. tciiure in Fig. L

Thc'oteticalroughness

.n,L.6lti.L.i

$r{.*rr.t

' 'l-;a

,r,r -_._4_-t :--

r ro.

M illing ih eo reticol r oughn

ess .
How a wlper works

i--^;"'--0.00t-0,005i

i
ll

Fi g.19

nr.l l fi rl ! C l l t N

fr

S urf ac e rou9nness o i b r oad iinis h r nilling

(NB. Rill 2Rs )
I

BS11: 14: Par t l: . |972

t.rtu ro E du.a?|nldrn
.t rt. rk. h ;ikr ....rrnt l
b.ka

-L

hFiooL,
L lL tl* ot
tr.t .tlon .a rL rlr h riLl

---g:-.t:l
l:.--:+l

/.

|- -'z'g*"-

SE

"

d4'-

lilUffiil*-.w

c.dt a I tD .lir aa{d

cl'lhrto t Af .aF4dlo..f
lhiLrh
rr&l
. tit
l b...d

M
C
R
xtn l.t

lt .|brdr dn*
lL6ln dfirn.

iliar.
biL -

A,' .d..ld, ,.3 irdn b t

dlr .a t rtd k ru.l rl.

aatt.-rriiat..dr..hde4.*ath.o-4.r-rr&.rr.r.E

IsrlIt,an,lYILrmalr.t

r.rt,arFirIk.a.aJt

tfi
-antui

flo.r. Swnu.latt'.t r.cionolLy

-2

:r o inch
L nis h

32

R ouahnes s
Nur nlE I _

M l c ro D e t1 6 9
Flnlsh

N6/

N 4/

A pptrcarl oos

n eco@ondod
rnd

lr odr od,

Tur o vt t h
sqlar o
nos6 t ool elt lr dr aa
r en! ,
h&od t lt e
lnoot b,
bar r ol
11r r ,
p lano br oldcut ,
co@or clol
g. t - nd.

f eed,

fttc

Sd o o th ll nl sl r,
rl thout
ccratches
or oth6r
d fe c tl v e
D drk..
c.g. cyl l oder
r' ored, deol
a u rl a c e r,
B oootl ! ruD nl na l r a.l uss ,

Flt o
llr at

o .'/
V

(l ntrh
Il ta h c l d ss grl ndl nA
ron
- hy.r.sul l c
.u rta c o 6 !
aho.r bl rder,
hrgh spoed l pl ndl .
ball
rrc e r,
Iocatl ns
bu!her.
A udgoon pl os,

St r st
clr ss
c6nt r olosr !
cyt lndr lcil
gr lnd.
6 ur t xco
lr p,
hot r o.

or/
V

v l ro d ro * l ng
dl ss.
col d str!l '
rol l s,
)oc6tl on
p l n r,
r ebovrbl o
burhos,
very hl gh dp.od
6 p l n d )s 3 .
roD s, ptstol a!
cyl tnder
bor6.

Sur nt sb,
polt sh,
supor I lnlsh,
spcclal
cyllndr t cal
gr t nd,
ler r es
8r r nd.

o 05/

E e Il

tt one,

O O?5/

C h ro D l u ! pl ated
A uuaoo, .l l p
l l .ts .
dl aoond tool i .
spocl rl

Jl lilliltil,ttlrl

apd Ttptc.l

A e l rrn a
surfqce
rh6r6 s' oothucsr
eosenrl al
to o l b s r k. oD j octl oorbl s!
c.A . hl ah l peod
B h a l ts .
rol l
bodl es and o.cks Jour:nrl s,
perts - runnl og
h o rd e tre d stacl
aod sl l dl D a
at blsl
vsl ocl ty.
e-a. e.r pl qtes

t6

D e s c rl p _ tl on

rrc o tr' rckr,

col d rtrl p
rol r.,
purp bo.ee.
dl os.l
A u u Ae b o .r.
sdu8os,
col d

D rGcl sl on

oprl csl
rotl r.
' rrtp

and Pot lsh,

lr p,
cls! 6
cyllndr lcr l

dor lee

Dr y lop br r r or
scr los
ar t . d.

t lno
r ur r ,
r oar ,
and sur laco
gr lnd_

ahd

sr t bd.

r lnt sh,

r et

r ap

'nat r

t lnt r \

II

IF

!!!Fl9!_!t_tr-!r!t
T ho r elv ao r Aft tl s h

inish
LOOO

\rv

a-S.3Oa;

Pl n1s h

!9!9r.1-c!1etrg!q_f,r,et!gf,4!p1lsa:!!e

25/
V

A v o ry.ouA h

\2.5/

u.s/

3 2/

:' ;;;".,

onl y _

lf dch I ue,

":::.::"

y ,.oo th surtrce
w t rr, tro spr l nt6rs
^o_r r6rrrrrs
rrondbt
--sl l gtrrl
),
trreautqr
n,uy vnry
-" :rj ,.
- (or cl earanc.
D o l oe(r
Intrn o.o62s"
_
tru t tdr [so ,hore r
unl to.D
cohroct
t6 reqrttre.l ,
s u rfa c e

roqul rl oa

l .tt"
.dvl
urrace!
D
o sEo
r' a Il a,

125

ll999g9!!!d

E .ch tne dresstnr

j;.il;":'

.t,o ns,on6ir y
p u rp o ses

500

pdrr

Su rl 6 c e

requtrl nA

good fl otB hed

oppaorance or
rtth
tatrl y
crose toterance
brL
s.g. traso ptares,
D nror (e6r.
cl ore

dl oeosr(

surroceerrirch ;,;-;;;r;;";;:::i
i?1r",,:
rrrs .t

;;ilT,

surfacos,rth
runDrDa ,nd srrdrns
i,
to, eoloclty _ su.tsc6
rachrnod tor

uethods
hr n. t gr t nr t , cht t ,

ssw,

ier t le

ili:";.it;t'.tlil
Shqpo,

! r r r n,

olll,

Shape, be. llur ! t ur n,

pr cle loo cdst
.

bor o,

r ot I I ,

p. t ano,

dr t I l,

bo_r o, plano,

63
Do,r..tery crosc (orerunce.
l':.,:-::.r"":,
o,g- bore! dnd deAt! ot
shertE tor DeurrnA

l l .:
vl li ro
c try

.*1r ""

.nd 6r r dr ns .r td tr , oedr xo

_ IntGrteronce

aD d i rey rtrc

Sbap6, Dr t l,
r ouAt l gr lnd, r o6a, r r r osch,
olot ,
haod ecr ape,
oor e, coonar clat
t u. t r ,

SI'RIACE

OR PART

!
J
{;

N-

0-@06

valve stens (autorootive)

o/Iinder bores (?u
Pist n pins

s s sglg,$R

( auto l o ri v e )

C a I0 I obes

Rod bushings (autoDotive)

cyli-.lder boles (O-rings or 1-artrer
Surfaces for

soft

gaskets

sr:rfaces of fl-ura seaL!-sliainS

crorind scree
Pi sl on

rhreads

a iorE

gs o!

packings) *
no gaskets or se
-louslnq flls
Sllde ways 8 gibs
ets &
(hearr], Io
(ordjns-ry servlce
selvlce

Gear leeth
cea! teeth

over to Dp)
over lO Dp)

li ,

.TournaL bealinos
or !a9-cut
th.reads
Clearance su! aces (nachined)
Datue surfaces
\rnder O.@1 in)
ove! O.OOl-!n)
Push fi!s
MilIed threads
<Iiding surfaces of Eatlng
ng sulfaces
Eatln9
DecianlsDs or Palts-PleclsioD
sut!aces brackecs ?
faces, bases, etc.
Pressed fltss genelal keys &
I{orE geals

af
foadlnos
eraL cans & followers
du
Rotat.ihg surfaces general pjvot p.Ins
and holes etc.
-

Worr! qears - hea

Rofling surfaces

I chased

tith

-t-

thleads

legul.ar

sEootiest

cross-hatch

possibfe

finish

woviness not consideled

patteln

6
o

!
o

-L

no

\D

\6

yl t

Guiclo to 'tito Gelecilion

U! . d t ! 9l v . r l. x l b i l l t y
! . da r loia, ?. 3 y . ! t . I b l t
. c los . lir ! t . l. v . r , . d
r or t t n9 l. npc r . t u . e 5 ,

Hll-cll

l9 -dl0

o.

12 Ml 4 OIA H 1i -c11
44 t,1rl OrA
fl 9_d l O
i at.r' i ri r
Itr n .

U3. d r or ! liid
i.ti.
loot.
ps llay !
r id v ar y l . r q e

8 9 -.9

- So r.trDlA
t19- e9

u e e d l o r rl d e l y ,cpi .rt.d
b ..rl n 9 s o . r.v.rr l b.rrl ngs

A A - 17

lAMMO
HA- l 7

5! i ! . bl!
lo. r pp l l . . t i o n 3
qu.li !t
r ! q! ir in9. 90od
t h. l t ! e. 3, t o p r 0 d u c . .

l7 -96
Slld l^ 9

o-f fi,i:s

!r'j

li I

6 t,1^rD tA

r r ot nor nr lly
03 e d l o r c o . li. ! out ly
r un. in g b . ! r i ^ 9 t
u^ ler s loiC i3 . l i q h t .
Sui r ! bl.
r or or e c l s l o n
r lldlig
r nd loc r t i o n ,

12tl M OrA
ll7 - h6

Suj trb l .

Irt- k5

Ur . d f or loc r t lon
ll!3 rn..
r llght ii! . r f . r oic . ,
ihich
. llr l. . l. r
! ov . { . n t
of or.
lo ! . ! o t h . . ,
D. . t . . 1. ! lv .

tt

lt-p 6

fo r n .n y non-.unni n9

Ut r d v hg. t h. d c g r . . o f
c r . . r r ic a
ihr t cr . . . r u l
r . on | . N/ - t 6 f t I i 3 i o L

F .r.o u r rrrt! rr..ot

3 trr!r.d d !rl n !.t!..bl y

* .," ' t,r" o

bv.ro.

l o r p.r .... t

/80 rlM clA

cr.r,ut. r, r
rl-F!_;jpr Hz-^6
I ri
i|;:::ft
'h.r
;.d
3h.tt
2OO MN I D IA
H 7-p6

au$

rl N l 0l A
Itl i r,l rr
-1OO
H 7_ s6
I i r.r i ^

on

.-;
Manual oI Bnish Standads in Engin" ln| Dnwing and Desiln

Ig4

22
21
20
19
18
17

{
I

12
11

a '10
I
^9

5
t+
!

2
1

0.025 005
(li'.

01
7 /,,.

0.2

01

.. tn ,f-)'q a

0.8

1.6

3.2

6.3

125

25.0

500

in r nicfooe' r es

Exarrplr.' Shoulda givnareaof surfscsbe surfacegrcundto 3.2/rm /q! takingapproximatetyI minute,

thento achi.v0 2 /,mwouldtakeapproximately
2.5minutss.
{Figuret1:BS1134:part2:1972)
Ytsrue6.2 Trpbol rcIatbnshipof swt'acete utc to productiontine fot connonty-usedtooh@d md?nats

Nor.r This ASureis Dot intended for makidS @st @mpaliens b.twed

difierc-ni prc@ses

192 Manual of British Standardsin Engineefing Drahiing and DesiSn

T;bIE 6.4 Surface tuughness valuesproduced by common prcduction prccessesand motcfinls

Roughnessvalue,R.(in pm)

Flamsqutting
Snagging
Sawing
Planing,shaping
Drilling
Chemicaimilling
El6ctro-discharge
machining
[4illing
Broaching
Reaming

Boring,
tu.ning
BEff6lfini3hing

grinding
Elctrolytic
Roll6rbumighing
Gdndjng
Honing
Polishing
L3pping

Sup6rfinishlng
Sandcasting
Hot rolling
Forging
Pelmanentmouldcasting
Inv6etmnt
castrng
Exlrudlng
Coldrolling,
drawing
Discasting

Averageapplicetion

Fs\r

Lessfrequentapplication

V,rer Th. reg.s shoh above .r

,1

r\o,./
.,
" /Ahcs

{\ vartla

N.. =

[Iablo 1: AS 1134rPart2 1972)

rypical of lhc pro@$cs lhte.L Higher or lower valucs dai b. obtained un<lq special @nditiotu.

il t'".\ (-+J r1t

JUcllonlo tsngineering
Design
Generaldata on.manufacluring
is readjlyavailable,rom books,journalsano teafnedpapers.
Srrr.irc daia will be more ditticuttto
becauseit witi be ;;d;ieJ;or particlrlar
company
a.5 prcduclconslrainls.The use of_obtaio
lrends,indicesanA ratios
oaa,qn"r,
lo
compare
processes
al lhe desigtgtagebut thesewouldnormally
"ito*,
vaiidated
be
by
making
prorotype
a
to owed
.!nS.
0f1enby pre-proJUCtion
Tooling is an inlegralpad of riJanulaclufe
and consicieration
must be givento lootingat the
oesrgnslageof the product. Commonusesoi lootsinclude
shapjng(die-s),
mouldjng(;oulds),
holding(tixlures),maniputating
0igs), rnspeclrng
etc.
G E N E F ALD E S IGNC ON S IOE R ATIONS

s l: e;

theq!antityol materiaj
invotved;
thedimensions
andweight
to be
lo break,down
inro
pans,
wirh
tocations
an!
rypesof joiFls:
fT|lj_"*
reiauonsnlp
to processing
plant;relationship
to maletjal
sizeavaillole.

f orm:

shapeof component;
simpticity/intricary
and relatlonship
lo pfocessin-o:

mate tia l:

famjtiariry
wirhpropedjes
and processino:
:-llil]
":ldjtign'
rtatroFship
belween
prcp8rtjes
and processing;

qua n tl ty:

pro0uction
raiesreq!ked;
planlandsystemsavailablei
jnvestment
required;

aco n o m yi

quantity,
hand:in9,
processing,
inspectjon,
quatitycontroj,
wastaoe:
relareolo ptantand toolsavailabjlity;
skillsavailability;

accu r a cy:

t0lefances;
fits;qualityof surface
tinish;

surta cS:

appearance;
resjstance
10environment;
property
enhancsment:

3tandard i sa tlon:
assem b ly;

trl' bought.our
pafls: conrormarton;,or
sa,ery;

It-.j.T19?19fl
producl
riabitity
prorecrion:
reduclion
In costs:

manual
or auiomaljc;
avojdance
of rrors;modularisaljon;
fastening
andjoining;
t0ols;standards;
responsibilities;
relationshlp
wjthspecilica
on;

-ac,( a g in g i

handling;
sizeandshapeof packst;needtorin.transl ,
Prgtecli:n;
insoeclion:

lnsifu c o n s:

c'arilylor installer,
user,maintaineri
languagEs
fof exportpfoducts:

Further
Reading:
Dieter
G

. A Malerials
Engineering
Design
& processing
Approach

( M c c r a w- Hil |)

ccil

D ES I G NC OT {S ID E R A T ION
F OR
S MAJORPFOCESSES
Der3rls
of processes
caEbe obtainedfrommanutacturing
technology
texts. This sectionis only
conce.ned
wilhthe desjgn c0nsideralionsrelatedto typesof process.
a) M al e r i a l R emo va l

forahoice:
R-a?sons
malerialprOperties
requked
ior producldicfaleformSuiledto process:
producllorm fiay be ditiicult
to achieve
usingothefprocesses;
accufacyet dimensionand/orformwoutdotheruise
be impractical;
surlaceroughnessrequired
demands
Drocess:
ayailabilltyol plant and expertise
in company;
produclionfates indicate
process:
taclllty lor computarconuol of processdkectlyfromdesign;
Nole: Accufacy
of torm (controlled
by goem.trical
tolrances)
withlna specified
dimensional
rolerance
allowslnierchanoeabiliiy
nd pre-detgrmlned
'tirs,,Accuracy
of surface (conrrolled
by machining
rduces
symbor)
stresF
concentrations
andcofrosion
andi! imponant
whnsurface
loadinlensily
(eg:
is hjgh
cams,Oears
etc)andclosely
fi ingsurtaces
arerequrfeo.
Bothrheabovedependon thespecific
marerial
removar
process
used(Detairs
areshownon the
dalasheetin theEngineedng
Dfawing
Course
Noles),
ll2ra tlac

i^ ^lr A6

m a t e fi a l w a sta g e ;
r e l a t i v e l yexp e n sl ve l a b o u r;
expenslve tools to maintainqualltyi
Consider
ihe tollowino:

m achInabi l l ty ol mats ri al ;
clam p a bl l l l y of s hapei
process
moslapprcpriate
foraccuracyrequired;
pl
ant;
a va l l ab l l l ty of
accessability
ot surfacesto be processed;
tool locationandclearance
- provlderun.outit necessary;
cosl ot processing;
lase of ptoducingfeaturson matingparts:
In general:machlne only where necassaryfor lunctjonto specilica
oni spcilyleast
demanding
tolerance
and surfacefinishtor correctfunction;
gsometrical
forms(plane,tapers,
cylindrical,
conical,helical,
irregular)
maybe produced
generation,
by surlace
surlacetorming
and non-cutting
forming,
b) S hap in gb y Sol l di fl c atl on
Relersto casting
usingsandor melalmoulds
including
injection
moulding
of non-metals.
Simjlar
principles
holdfor solidiiicaiion
ol slurrieslikeconcrete.

conv

Thc m{nuficturingsysrcm

(b)

CONCEPIUAL
DESIGN
shoniisrroo shon?
ordinary kcftlc

breakdown conccpts
inro deiaildobjccrivc

not crouShinformalion?r

(d) clectric

manuincturi.
roues

DETAIL
EESIGN

G) plasticsjug

Drffcrcit waysofhcatitrg wa!.r

(..s, a ldth.)
Iodcpcndcntly
dcbu.riDs c.ll)

Fl.xiblc
c.s.fMS, IAS, dc.)

(c.9. ct.hi6l

plart!)

Produci quaotily

of keyefrects.
6a)Asprfiguraboveor similerwithbricferplanation
A classifiC3tion
of typicalp.(iuctio sysr..ms
and industricsapf,lina this rcchnology

and
typ$, cortrolsy$cms
6sin fig 6b.CNCmrchine
b) Typicalconfiguration
andtkoughputconsiderations.
equipment.
Ce flerdbility
handlinc
ofdtiicrtiorl oolingor fixturingspecficto thecell.
Machiniloirdinganddegre.e
in operator
interactiofl.
reduction
timeincreased,
Machine
oDeration
quality
chacHng
if
CMMasp.r of ce[.
iri line
capability,
Procoss
dduupdare
thcsurft4e8tpredctrrmi&danglcallwvs
ofouttcrto addrcss
c)Fig6c.C0pability
Thisalsoallowsfor featutcs
finfuhandgtateraccurasy,
ofsurface
for optimisation
of
placcd
angle
to
the
surfacc.
Crcatcrcomplodty
at rpccifc
holerto be
such-ar
to moreplocise
asthecuttrcarmemanipulated
allowable
zurfacc
geometr)'
onemauons,
Truefonncuttinrcaoabilities,
in cornparison
to sifiPlr3 axigsolutio$,
ofprogranming
oncdmpl'adty
Cornmcnts
3Dmodels.
byutilisingCADproduccd
butthiscanbeovercornc

'l -

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qt.rrr.g
ut!.
brr &d hrgh cgrr
turth.eE,
trEy !5u.tly
h.va t]e .ftct
of lt larhg
tL tuts.
jlr.rded.
ic drtcrr th.y E!.
s. F19-{.

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of th. s*,

.o tn.!

De IEdIrl.d.

fftt.

of ih.
Et

stt

b. t.t

t,l. ncc....rt,

I.

n rjto

teAtlo

Ir tllu.trarGd

uE ...enttal
..fur

coiuttE

tlErrg

i.e.,

hoir.rr

td

thc ton
h9.,

tte.lgn

.tc.

lllqa

--

c0

ln Ft9.2(.)

ttnllt

l mr't

rlr.

2a

D..tn

npErt

ror ctptibfiri,
(d)

D..tot!q

foi

EtIrLlE

crG delqcrr.
Ft

!..d.d.

lvall.bl

orEltldE
u.41e

Toor

EEry
r@t

d..rgr*

esulFnt,

cdrr..tly
ot u't.

t.

.nd
ahou

.o

dilgD

tr

oEFf@

ti.t

b.

.&.Fcrfy

Eing

tD F.t9.3.

II

!t

to

oclt

.btd

'n-rlr#r{

yly

4ch.
to b.

r!

thlt,tct

po,!!..;

tUsEId
.rr..

td
ro

I t@L
or .

urr

{.
or

44!.

s-srdrr'

a a..*rrq.-

r"

(.)

i"u

Ft..
lo.

3. p..rE
E{.rt..

eulrua

4t!!-

fl
-(

a.Ihdhs

laulEbt
b.

tEttcy.hdtd

Prahtnt

t..

u4!

(b)

n r.rr

tr

rr
rool

r*!!

'

I:s4

(t)

pr r r t $s

-r-1-

lF.-

- -1F+
tFr

J--f,.--,

---1__t'_

a- --tt---fl-f

Am

,/a\

/ //'h\

\y w

@l El

@ ffi
(D)

@
@

sg

a
lFl

Clo.&

Cro6.d

fffrfi-frffi*
_uu'_
uuu\)J

frfifr-

mt

...:>
Grp
({)

n,

{\\ th
"\\--7l

'i'

Tu

.=l-_,

Notrp

(r)

V
H-

e
H*'""
U
rF\

ChrtnLr

{ri ThE noriod cqoi.cd for ii..nioi5

(^i

'

LJ

tiery Dflkult

Fig 2 Sinple

to Orbnt

Easy b Orient.

lor
Arear ol rolerare
v.rlous mod6 o, $iembly.
lutotnilk
Nole
tbl
lssembly demlDd5 n.rrow

%WI
tr--r--l

!'

fll

VZt-i%
I

/i\

ITT
Funclil(Dl l&6@

lif-r

r O-2

rlt .3seobly.qutpoE r a Ol-

Thl3 pl.strc nhg lor u* ln ECG .letrcdE .

requlrB oot bor toleran.es ln orde! lo fun.doo lcti,rilng

io Eqults|Hrt

But dghler tder.ne5 on th. rng.re Equtld h regatd to ih. .si.rnw

.spdclly lhe tedlDgand hrndlng equlpneht

n tE

.qulpdErt

|l
,U

!:

n
\_l
a

@)
- 1'-

DESTGN
FORASSEMELY
INOIVIDUAL
ASSEMILY
EVALUATION
fOR

I lFrdosdur.!'1rE*r

t.srr*dsu1r'r6

3 t^mmuDbuorunY

tr ''^',s

CNC M A C H I N I N G
Programming,Tooling,Machine,Tool Design,Plannlngand Control
_

NC Numcrical Contsol- CodcdilsEuctioDsfed to tbe rnachinetool control slide movcmcnt,spitdlc rotatioDandtool

fccd. The standaldproglanming tecbrdquewascstablishcdon this t].?eofmachinc.

CNC CompulerNumerical Contol - the instructionsarc storcdss a proglam in a micro-computerattaahedto thc

machilc. Tle computtwill also handlcmuch olthc contol logic ofthe machidc,makiDgit morc adaptablcthad
carlid hard-wiredcontrollcrs.As thc cost ofDiq@-dafiorics 6!d Ecmory lsr fsllc!, fscilitils bva Eow! to iD.ludc:
.
.
.
.
.
.
.

Scvcmlsrcrdprogra.qa
Srccncditing
'Ca!!cd clcles', i.c, storedpattcf,lsubprolFsls
Enhrncdcuttar compadatio!
OptirdiscdinschiEingspc.ds
Programprovitrg
Diaglortic EcEsagcs

DNC Direct Numerical Control - a cntal coirputarcomJlllrlicatedwith cachCNC tool, do*r oadilg progasra cld
scrupinformationfor tha opaBtors.

FMS Flcxiblc MaDufacturingSyatcm- a gloup ofvaricd CNC tool6,!o6ot! aodconvcyorsundcr ccntEliscd coDtol,
organircdto producea ralgr ofparts,

-,

CNC Appllcatlons
Machlnlng
I 3D
2.5D
.

, r- . -T|rEilg::Iathes, fuEdlgcenEe
. Milli!8 - Machi!.ing Cc$tes
FomiEg
.

Plarna .nd I$cr Cutting

Blankllg, Dibbljl1gsnd punchbg

RapidPrototypilg

-3D
Benefltsof CNC
_

.
.
.
.

Productivity
Quality
Rcduccdilventory
Machil]irgcomplexsbapes
Managcmcnt
CoDtrol

Advantages
of CNC
ProductlvW
.
.
.

Ma.hinc utilisatio! is ircrtsscd bccauscmorctimc is spclt euttingaDdlcsstimc is ts.kc! by positio[iDg.

Reduccdr.t!p timc il]crcascsutilisatioa !oo.
R.ducednubnidg lcvls;machi[cs run llrupcrvi.srd?

Qua ty
.
.
.

Prlt! nrcmorc accuntc.

Partsalc morc rcpaatablc.
Lc$ w8tc duc to scrap

Reducedlnventory
.
.
.

Rcduccd
s.tuptLlc pcnnitssmallorcotroEic
batchquantiti.s.
Inwr lcadtirncallow,lowarEtocklcvcls.
Lowd siocklavcbrcduccintdlst cbargcs.nd worblg crpitalrcquiEDcDts.

- MachlnlngComprexstapes
.
.
.

Slidclrovcdrcltsuldd coeputcrcontol.
Computrrcotrtollercancdcuhtcttcps.
FirstNCrlioNnc built 1951rt MIT for ailcraffskinmilling,

ManegdmentContrcl
.
r

CNCl.rds !o CAD
hoocsspla!.litrg

'-- - -.--- ?rb-dw$drurn@--

Dnwbacksol CNC
.
.
.
. .
.

Hig! capifalcost
Rctrahilg 8Ddrcctuitlctrt of strff
Ncwsuppofifarilitics
Maiftcnancrro rulain bighutilisation
RcdurdlDcictioperatoricsist&c!

CNCPROGRAMMING
.
.
.
.
.

OdlincprograrDmilg
lilkcd to CADprcgr&E.
prograi'miDgby thcop6a!or.
Cotrvgtsatiolsl
MDI - Manu8lDatalDput.
MarNalContol usirgjog buttollso! 'clectotrichatdwh4l',
Word-Addrcss
Codirglsing staidardc-codrsalldM-codcs.

A Rpicallin. ofa pan-prograuwrlnenir variabtcUioctiornat:

N020G02X88.021
03.7T0202S500F0.05M03
primitivcs).ntaxrcflccti theorigimlwisbto keeppapd tapereclsshortandlaiarto makethcbcstuseof
Thecornpact,

Pan-progam'words'
N Sequence
numbr.
G Prcpararoryfirl1ction.
X,Y,Z Slidemotionalongaxes.
t,J,!! L|rclecenEes.
T Tool codeandoffserrdendfication.
S Spindlespeed.
F Feedrate(speedofslide ba!elj.
M Miscellaneousfimction.
% Progra& start.Rewind lape.
/ OptionalBlock-Skip,if switchedon.
*,; End ofblock
The numbersfollowing thesewordsmay b subjectto formatres!'ictions(e.g. 2 figures or four figures only. or with
assunedlocationfor a decimalpoint. Modemmachinesarc siightly morc forgiving.

PreparatoryFunctions
PrcparatoryFunctiotu changethc modeof opeEtio! prior to a machiningaction. 8S3635 (1972)now obsolcte,but
mostmachincsfollow theseconvntions,
C00 Ripid rbovemrnt
G01Linear interpolation
G02Circularinterpolation
- clockwise
O03Cilcularilterpolation- anticlockwise
G04Dwell
G33Tbrcadcuning
G40Cancelcutter compcnsation
Gr'1Cu$ercompensation,
lefr
G42Cuttd coDpensatioD,righi

'

(J/l MeElcuruts
G80ctcBuilt-incyclcs
G90 Absolutccoordillateg
G9l llcremcatal coordinates
O94Fecdper minute
G95 Fcedper rcvolution
G96 Constanlsurfaccspeed
Manyofthesecodsaremoda.l,thcyremainin folceuntil caDcclld,
This appliesto mostofthe otbercodelerte$too,
allowing morcompaclcodc.
MiscellaneousFunctions
Tum oDandofvarious machineactivitiesM00 Programstop
M02 End ofprogram
M03 Spindlesun. clockwise
M04 SpiDdlestalt anti clockwise
M05 Spindl.stop
M08 Coolanto!
M09 Coolantoff
M30 Rewind
Axis nomenclatue
Z-a{is
pamllel to main spindle (tool or workpiece).
PositiveZmovementin dirctionofincreasingdislance
betwen
workpiecearldtool. On verticalmachining
centses,
+Z is upwardsftom the worktable; or tuming certes +Z is away&orn the spindle.

X-axis
-

alwayshor;onial, pa!al1e1
to work-bolding surfaceandorthogonalto Z-axis.
If Z-a{is is venicai, +X is to ihe right whenviewedftom ihe spindlelooking tov'ardsits supponingcoltlmn.
If Z-axisis horizontal,+X is to the right looking fton the spindlelowardsthe workpiece.

Y-axis
odhogonal!o Z andX, completinga rigbt handedsetofa,(es.A lathehas
no Y-a-\is.Extraaxes
are desigdatedU, V andW to correspondto X, Y or Z if th extsamovemen!is parallei to oneofthe ars. Extla rctary
movementsaredesignateda B or c.
Becauseit is the wolk that movs,not the lool 6pi!dle, the directionofslide travel on a milling machirc canbe
confusiDg.The morc experienccdth operator,themoreconfusingCNC axis notationanbel It is casierfor thc
prograobr io rcgardthe 6iuer asa computerpen-plotler.
Coordinatesmay be absolute,i.c.rclativ to datunf or iDcrcmental,rlativeto thc cureDt position.Normally selectcdby
C90/G91,but FA\(JC contoller usesU.V aDdW asincrcmdal valus.
Dairm choicc anddatumscttingarevital opietations.
Wc canidctrtify a dlawing datnD, componentdstur! pan
programdatun and rDachinedatum,Th lasttwo mustcoilcide, needingdocumentatioD
to commuticatebtween
Progammcl andopemlor.
Fixed datummachift - opcratormusl setwork in corcct place.
Floatingdatum- opcratorrcsctddatumto suit worq bul plogarnmer docsnot know preciscposition,
Datum shifi - O50 (sorDctimesG92) caoresctdrtum within plogram,or <169>piesctAbsoluteRegistcr<170>.
Zero offset - or <169>Work Shift<l7D canrcpositionmachinedatum.Ior a lalhe,dachine daturnis often X=0 on
spindlccmtclide 6ndZ=0 at rear facc ofchuck. Usc Wolk Shifr to resctZ-0 at cnd facc of finishcd iob. All Z values
ncgativc.
Rcfdcnc. Poinl - a fixd poinl on thc ma.hineto which thc slidcsmustbe
tnversed on startup, whrepresetcoordinalcvaluasarc loaded,

CNCTOOLING
Clrbondteel.Easilyshaped,
for amateur
useonly.
HighSpccdStcel(HSS).Solutionhardening
at highrcmpclaturc,
Tough.Uscdfor drills.
Sint!rcdCa$id.r (Crmented
Carbides).
Hard,butbrittle,Highcuttingrarcswith low wcar.
Ildcxablecarbidi!8erts.Manygladcssndshape6.ISO
classification,
- e[bi.'BordrMtrtdclcts\r); HardErdrdtougfitr6an]rdbidas; -- - (r/min)
SulfaceCuttingSpceds
Worl(pi.ciMaterial
Tool
Mild Stecl Cssthon Al. alloy Blass
Carbidc
170
100
250
180
HSS
28
18
t20
75

Spind/espeeds
permi!u1(!pm)by:
Spirdles?eedis givcnin rcvolutioDs
1000* cuttingspeed(m/min)
pi * workor cutte!diameter(fla)
e.g.to tum 30&mdiamctcrbnssusings carbidelool:
S = 1000i 180/ 3.142* 30= 1910- say1900lpln

Feedratesfor turning
Mld Steel CastIron
0.25
0.25

Al. alloy
0.3

Bmss
0.3

mm/rcv

Finalchoiccdepends
oDproducrion
rare.loolwearandfinisbrequned.

CNCMachinoTool Deslgn
Fcaturcscsscntiaito CNC opcratior:
.
.

Slidc positio! mcasurcnlcit atromovcmcD!

CoDtol slstcd fccdba.k - positioDand spcd.
Spindlcspccdcontrol
Automatcdwor*holding?

Fcanrrcsrcquircd to c]cploitCNC caspsbilitics:

.

Wcar ralist l1cc!o copc with high utilisationsndmpid slida tavcl.

Rcsolutio4 r?eatability,od &ccuacyto foUowprograo cofiortds andrciicvc quali, {.ithout human
iDtcrvcttio!"
Swdfcotrtol to rBtch high mcblicmowl stes achicvcdby carbidctools 6ndhigh udlisatio!,
Safctyfot llrlmrnncd opentiotr rpithrapid slid. t'avel, 6uddc! mov.Erclt uDda!progra$ control rtrd possibly
vioirot collisioD!.

CNCMachlneTool DeslgnFeatures
Somcsolutio!!:

_
'-

DC rcrvomotonwithpositiotrl aDdtrchogelcrator
fta&aal.
LincargratilgssndMoitt fritrgc!.
Rldi6l gratius or rotarycncode$,
Rigidconstuction.
Covacdslidcwsyrto cxcludccuttilgr.
Pl.sticrlidaray hetcdals.
Card! scDlorsitiDg.
L.sdscrcwsrsplsccdby r.cilcutatingball-agraws,
Sklt-bcd hthc withr.ar.hou cd hrncl
SwrrfoolvayorssDdcbutcs.
TotslcDgloEu&
aDdintcdocks.
crcpbic.l dilplsy5for pmgranproviDg.
-sw?EfRfib-oTel
ftod cuttingarcaor wsshitrgstltioD
glavity
slad b.d
coolaDlflood
arIJltl

l'scuurnpump

iom rnachilcaDdworlGiop
coDvcyof
uDdcrfloor
chutcs
toll)s
&lrp scparatio!fo! rcclamatio!

Illurtation of Slsnt-BcdLathc.
Mdnufacturing
SysteEr
Tnditionalapploachcstomulti-componc.DtproductioD:

' Il
HicellDemoProgramdoneon SmartCAM
%
02222
r * r,*** r* * r.i *;i
* i * * r,* r,,r,
1*
/ + ****r ** r+ i

*i **;i)

r.* * * * r,i \
I.l T a E T T * i tr * -;
'r

G10P02250.0
G28UO
G28V0W0
G50S3600
G144M28
G99G18
G3OUO
G30V0W0
M01
Nl (ROUGHFACE& TURII)
G30U0V0W0
G10Ll0PlR0,8Q3II0
T010100M41
G144G18
G97S3000M08

' G00G99Y0.020.3M03
x64.0
20.2
G0lx-1,6f0.25
21. 4
x8.8
24.6
G00x65.023.0

x6s.u3.r

x59.0
@tz-39.8
@0xs9,23,1
x53.0
G0lz-39.8
G00xs3.223.1
x47.0
G0lz-39.8
cfi0x47.223.1
x 41. 0
G01Z-39.8
G00x41.223.1
x35.0
G01Z-9.8
G00x7t_22-5.9
I{iccll Programftom SlrtaICAM

Page:I

Calculatethe maximumand midmum shsft and hole sizesfor the follbwing examples.Also oslqrlate the amountofclearanceor interference.
Sh8ft

Hole
Mn

Max

lvtro

Mrx

Claraoce/iotf,ftf,trc
M.rx
Min

90mm hl l Cl I
220mn h6 N7
l)mm no b /

Within the box provided,draw the path ofthe centreline oftlrc cr tr that the following programmewould creale.

l0
20
30
40
50
60
70
80
90
100
ll0

GX
00
01

00
01
00

YZ
ll0

50

F ST
01

100
l0
l0
50

l0
ll0
ll0

30

60

lo

60

lfiro

Sroo *eJ
Mol

T-- t""L

d'

o0

ut
s

-5

Brieflv explain what the itemsin bold mean.

-c"p,/
GOO
Cfil Fecl
FIOO Fe") loo *k
M06

s r s s8

M
06
03

..

14i*J l"

c\-

+o"L

?he File Fornnat

r. r ne.-\ I L tlle tormet

Jh:jiD
asTt ,.,"r"oiit-\oeraphy) fiie is the de-ibctosrandardcAD rep.ese.talionft)r Rp. It was established
by
s;/sreiuin rhejateBos.The .srl formatofa cAD mocielis a racetedsurlbcerelresertation,i.e.
- a
list ofihe triansurarsu.faceswith ao adjacearyinrb.matio'. This is the standardinput fol
most Rp
syslems.lhe.e aretwo format for .sfl- files: biaar-landASCII which difers asfollow:
. Binnry.STL file
Thebi* , S'Il- fi]es fornat consistsof an g0 b',t?sheade.usedto describethe solid
contained
within the file, then 4 b),tsrepresentthe total numberof{bcets in tle file. A facet is described
as
fbilow: the fust 12 bltes (3 x 4 blres) representits rlormal,the next 36 bltes (3 x j x 4
blres)
representits (tiree) verrices,then tlro unuseCbytesarepaddedto achievea block size
oi50
bltes.
. ASCII .STi, ritcs
AscII iiles usekeywordsand are selfexDlanalorv.The ASCILstl file must startwith the lower
casekey'vord solid and endwith ndsolid. Within thesekerrords are listingsofindividual
trianglesthat defile the facesofthe-soridmodel.Eachindividuartriangledescription
definesa
singlenormalvector directedawayfrom the sorid'ssurfacefollowed by the xyz componentsfor all
th'ee ofthe vertices.Thesevaluesare all in ca.rtesiatrcoordioatesandare floating point values. :
The fiargle valuesshourdan be positiveand containedwithin the bu ding vorumi The normal
veqtoris a unil vecroroflengthonebasedat theorigin.Ifthe normalsarenot includedthenmost
softwarewill generatethem usingthe right handrule. Ifthe normalinformationis not included
thenthe three valusshouldbe setto 0.0. Thereis a variety ofenors in ASCtr 6lesthat do not
appearifl binary iiles. For instance,it happensthat keywordsare eitherskippedofadraneous,
hindringthe extractionofdata.Here,san exampleofan .STL ASCII file:
60 ttd so t t dnahe
fa ce N ror m at ?. 33a605e- 01 3. 226134 e _ A 2 t . ? E O O 3 ? . _ C 1
.u rer r o. p
vertex
- 1, 070000e+ 02 0. 0000r 1 C e +0 0t . A l d O i O e +0 2
ve * a
- 1. 060000er 02 0, 001] O 0 0 e +0 01 . ? 6 O 1 O O . r O 2
ve rr e:
- 1. 010000c + 02 1, 20000 0 +0 0 i , 3 1 3 3 o o e +0 2
e nd i!ce l
fa .et n or nal
r :tex
verr e: r

9, 324258e- 01 9. 2Cg56i e - 0 2 I 6 2 3 . r 5 9 _ O t
- 1. 0r 0000e+ 02 t . 20000 o e r 0 0 I . B l 3 e O O e +O ?
- i, C54000e+ 02 0. 0000C 0 e a 0 0 L . ? b o i 0 O e ! O ?

e nd loo p
en dfa .pt

4. The .SLC Iile formrt

.SLC tiles areusedin the tuseddepositionmodeliry (FDM) processfromstsgtsgy!,bg They describe
the contoursot\ andthe thickless otl eachbuild layer.
. The .SLC fite foruat is an ASCtr text file format
. Commentsmay be illcluded. The beginwith a "#" andEndat tlle end oftiat line
. Units arc in inches.
system:
h thecaseofrie FDM 1600rapidproLotyping
. x,y,z shouldbe positive floats in the ftnge from 0 to 9 inches'
. Layerthicknesses(aL)rangefrortr 0.005to 0.015inches'
The standardlayer lhicknessis 0 010 inches.

Eaa0ple:
The bold charactenshouldbe fyped asis. Th italic charactsrsshodd be substituteds.ith thir
correspoadiagvalues.
911c. Y0
lIlJl {fi.lcnanc)

srrer o

Z
x
x
tr
x

+
#

0 = zero
fi.lenarte tnay include

#
#
#
#
*

z = absolute z of tayei,
dz
- taye! thlck:ness
plovida th. cooldLnatca of the
cornc! polnt!
along cach contou!.
Do not duptlcata the
f1!st polnt.
lhe ls.no upper ].ielt oE the. ,
I1u&b6r of poiDts 1n a contou.r.

z dz
y
y
y . .
y

xv

C
x y

*
t

xy
xy

#
ll

xv

C
Z z dz
x y
xy
xy
xy
xy
c
tl|!t

*
*
#
ll
*
ll
il
*
#

fut L path

Talid.nate tbc contou! wl.th a trCtr.

Bcgin thc.B6cond colrtour otr tbj.s ].avaL...

Tcrrlll.nrle Eh. sccond contouE.

BGgIn s nclr 1ay.i (z
- z.o1d + dz)
Ba91n a nw contou! on a lard Icv.I...

?arfiinala
th.
AII foLl'owing

colrtour.
IlDc! e!.

lgnord.

N.QX. y z T l ' 1
l om
a^
Av

(, tl

3o

oo

?-

+o

t35

t5

-Z

50

1 r5

15

6o

a5

4o

Ol

06

Jt"
-icqt'6here

for numericalcontrol I
Datapreparat-,i4.l

-h
.{,

2
Hole

Explanation

^'ogrdm statement

N01q
'020
N030
'( J
N0s0
:050
NO70
1080
N090

G90
G7L
G00
G00
G01 ,
G00
G00
G01
G00

T1o0 Goo

F400

s3000

M0i

,M05
YO

2300

T02

LZJ

M0s

M03

x150
277
225
XO

G0 0

JL?O

GO1 ;

z3

r\r1?n

/:nn -

J140
N150

G00 _lJ
GO1

22,5
'x150

+{ IAU

\rUV

N 17 0
*.n 80

M 00'
M30

T01

x100
zL7

1 1110.

2300
225
s3000

YO
Y100
F400

XO

x100

L5

zz5

Se]ectabsolute
. Select.metric
Load centre drill
MoS
Above 1st hole
Centreddll
Retract
2nd hole
'
Centre drill
RetIact
Load 10 mm
M06
rlirmaicr

Y100
r350

225
s2000

M08
M03

s2000

M03

M05
F350
M05.

M09

rt ri 1i -

Above 1st hole

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CAMProgrammihg
Systemsand
Postprocessors
BACKGROUND
The NC programsrequiredby ComputerNumedcallyControlled(CNC)
machines
wereahvayswriten by handasa seriesof linesof code(G codesandNl
codes).This
is still by far the most commonway to createtheseprogmms.
Howeverit was
recogmsedthat much of the code is repetitiveand thir theseprograms
could be
generated
automatically
o. semi-automatically.
A systemfor creatingclde in this way
is klown asa CAM programmingsystem.
As with manualprogramming
the staltingpointis the selection
of the toot. The
^ . _ _ progammingsystemrequires
CAM_
tool data. This includessuchthingr-ar,o. ,,""
andshapeofthe tool, andthe cuttingspeedsandfeedswhichare to be-used
for the
tool. The p.ogramming
softwarehasa graphicaluserinterfacewh"r" tt a opar"to,
drawthepaththathe or shewishesthetooi to follow Thesoftwarewi
"an
thli comOine
thetool datawith thegeometrydatain orderto ffeatetheNC code.
The style of a programvariesaccordingthe machineryand the particular
preferences
of the machineoperator. The codi itselfis depenienton the'machine
controller and the machineto which that cottroller is fitted. This means
that the NC
codegeneratedby the softwaremust be customised,
or ,,postprocessedii
to suit a

operating
in a panicular
.ornp*y. ih.'C.tM p.grurn*ng
T":lti*
l1,_gir
sotf$rale
wrll
havepostprocessors
wrinen

stylesof progam.

for ir to giveit rheabilhyro ouipuidiff.erent

HISTORY
The earliest CAM systemsused the AIT programminglanguage. A
computer
programmerwould usestatementssuchasGOTO andPROFILE
tolefirte the Dathof
the tool. In other words the earlyCAM systemshadno graphics. Later Apa;$erns
.
hadgraphicalAort endsin which a line or a curvedrawninjhe screenwoulJginerate
APT commands.
The.system
converted
the inputstto a CL (CutterLocation)datafile. This CL
-,
ue was then convertedto the ISO code (G codesand M codes)required
by the
parlicularmachine.The earlypostprocessors
werewritterl ill the Fonrao p.ogra.^ng
languageand then compiied. In other words tlre only people,to'.oiiJ.*"
modifications
to the postprocessors
werethe programmeis
who hadthe souicecoOe.
Udil recedly Unigraphicsstill usedthis methodfor their CAM system.
Approximately10 to 12yeaxsagocustomjsable
postprocessors
appeared
on the
scene_based
arounda macroprogramminglanguage.Importantwork in this areawas
doneby CambridgeCAD Certre; manycufent CAM sysiemsfollow the
structurethat
they dfined. The big advartageof the macro_based
programming
systemswas that
.
you did not have to be able programmerto use them. The b-asis
of creatrnea
t\4E338
ChrisBeatly

Postprccessors

Pager'l

was to fiIl in the fields ia a "1ook up table" This

customisedpost-processo(
softwareat runtime
by the postprocessing
informationwasthenintery.eted
(such
MastercL:\l,etc)use
packages
as
SmartCA"\4,
CA,V
Curent stMd-alone
this principle. The userc.eatesgeometticlinesand points. Data on eachof these
basisinto
featufesis heldin the CAM system.Thisdatais corveitedon a lineby li11e
the look up tablefor a particular
whichreferences
the NC codeby the postprocessor
modulesofi high-end CAD
particularly
the
CAM
machine. Some CAM systems,
This is considered
to be an
systemsstill use CL datawhichis then postprocessed.
inferior approach.
In spite of the structure of modem postprocessors,which allows nonprogranrlIrersto write or modify them, in reality very few peopletry to do this job
themselves. They rely on the CAM softwaresupplierto do this job for them. The
supplierscunentlychatge!300 to !400 per day to do this job. HoweYerbecause
*riting postprocessorsis relativelyeasyin a macrolaryuage,engineersfamiliar with
the metal cuttiflg processandwith cNC machinesin particular,can carry out the job.
This is cleadya muchbetter situationthanrelyingon computerprograDmers

SMARTCAM
thefollowingmodules;
TheSmartCAMprogradmings6ftwarecomprises
r Thejob plan
r Themodeldatabase
(.SMF)flle
r Themachine
r Thetimplate(.TMP)file

TheJob Plan
This is wherethe usermustinputdataon the toolswhichwill be used Associated
witha toolatel
r Thetool number.Thisis thepositionwhichthetool will havein thetunet or
of themachine.
magazine
r Thetool geometry.Theradiusofa tool is veryimportant.In particularfor
turldrtgtools, the softwarewill makecalsulationsfor "tool noseradius
thecorrecttool path.
in orderto generate
compensation"
with thistool.
r Spindlespeedwhichwill beusedfor cuttingmovesassociated
with thistool
r Feedratewhichwill beusedfor cuttingmovesassociated

TheModelDatabase
The main processin using CAM softwareis to &aw the tool patls The opelato!
selectsthe tool which theywish the machineto useandthetrdBws the pathwhichthey
wish the tool to follo\r. A tool pathis madeup of a seriesof geometdcelementssuch
aspoirts, linesandarcs.
The softwale maintains a databaseof geometric elements This database
contams:
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Postprocessors
ME338
ChrisBeatty

P O S T PR ODPOC

'

r,Thesequenceoftheelements.i.e.rvhatordertheyshouldbeperformedin.
r Dataabouteachelement;
whattool is used.whatis the startpoint,whatis the
endpoint,the radiusofan arc,at whatdepththecut is takingp1ace,
etc

Themachine(.SMF)
file
Thisconsists
andoprionswhichtell SmanCAMhow ro formar
of a lisrof quesrions
codefor a particularmachine.Someofthe information
in thisfile is:
r How manyplacesof decimals
shouldbe outputfor X,Y, andZ positions
r Whichtemplate(.TMP)fileto use
r How to outputbiocknumbers
r The udts (mm or inches)
r The formatto outputspeeds,
feedsard dwells
r How to specifya tooi change
r The format for rapidmoves,linearfeedmovesandcirculararcfeedmoves.
r andmanymorepiecesofdatato coverall thefunctionsofa machine.

Thetemplate(.TMP)
file
The templatefile determines
the final formatof the codegeneruted
by SmartCAM.
information
from the modeldatabase,
tbe job planad the
SmartCAMcombines
file andoutputsit rhroughthetemplatefile.
- machine
Templatefiles are organisedinto functionalsectionsstartingwith the "@"
basictypesofinformation:
symbol
andcontaining
thefollowing
(for programheadrs,
r Literalcodeto outputasentered
tool headers,
etc.)
r Templatewordsfor outputofprogramirformationard controlofthat output
to makesomeoutputoptional
r Condilional<> brackets
sections
areasfollows:
Someexamples
ofthefunctional
r @TOOLCITANGE
(at startof profiledothefollowing)
r @STPROF
r @LINE(at a linea!feedmovedothefollowing)
whetheranactionis a tool change,
Themodeldatabase
dednes
a linearfeedmove,etc.
Thetemplateflle defineswhatthecodeshouldbe like for this particularsction,alld
references
themachine
61eto de6nethefomat ofthe codewhichis cenerated.

WRITINGA POSTPROCESSOR
normallyiavolvesthe following:
The processof writing a postprocessor
r Look at the programmingmanualswhich accompanythe machineto seewhat
codesare usedfor eachcommand.This informationeoesin the machiaeflle.
ME338
ChdsBeatty

Postprocessors

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