Design for machining

Machining processes are material removal processes which are a family of shaping operation
in which excess or undesired material is removed from the work piece finally remaining with
the desired geometry. The design of machining considers the conventional machining
processes. In conventional machining a sharp cutting tool is used to mechanically cut the
material to achieve the desired geometry. Three major machining processes are turning,
drilling and milling. There are other machining operation include shaping, planning,
broaching etc. Figure M3.1.1 shows the cross-sectional view of machining process.

Figure M3.1.1: A cross sectional view of the machining process

Advantages of machining processes

Machining can be applied to a variety of work material. Virtually all solid metals can
be machined.

It can be used to create any regular geometry

It can produce parts with dimensions to very close tolerances (0.025mm)

It is possible to achieve very good surface finishes (roughness value less than 0.4
microns)

Disadvantage of machining process

Wastage of material in the form of chips ( though chips can usually be recycled)

Very time consuming operation when compared to other alternative processes like
casting or forging.

Typical machined parts

There are numerous applications of machined parts in industrial and consumer products. The
materials used for machined components are both ferrous and nonferrous metals. Machined
parts can vary from as small as miniature screw, shafts, gears, and other parts found in wrist
watches and small precision instruments to as big as huge turbines, turbine housings.

Recommended materials for machinability

Parts made from both ferrous and non-ferrous material can be machined. However, materials
like plastics (with or without reinforcement), hard rubber, carbon, graphite, wood, and
ceramics are also often used. A summary of the machinability of common metals has been
provided in Table M3.1.1. Table M3.1.2 summarizes the influence of certain materials
properties on machinability.
Table M3.1.1: Process for flat surface. (Source: Design for Manufacturability Handbook by
James G Bralla, 2nd Ed)

Process
Sand-mould casting

Maximum
area
3 3 m

Die casting

0.6 m2

size,

flat Deviation
from flatness
4.2 mm/m

Surface finish
1225 m

1.1 mm/m

0.81.6 m

Planer
and
shaper Planer to 14 m
machining
Milling-machine machining Planer type to 14 m

0.4 mm/m

1.612.5 m

0.4 mm/m

0.86.3 m

Surface grinding

1.2 6 m

0.08 mm/m

0.11.6 m

Sheet metal (cold rolled)

1.8 3 m

1.3 mm/m

0.83.2 m

Sheet metal (hot rolled)

2.4 3.6 m

5.2 mm/m

12.525 m

Magnesium tooling plate

1.2 3.6 m

0.8 mm/m

0.8 m

Table M3.1.2: Effects of Material Properties. (Source: Design for Manufacturability

Handbook by James G Bralla, 2nd Ed)
Decrease in
Material factor
Strength/hardness

Machinability Finishability Tool life

Improves

None

Improves

Ductility

Improves

Improves

Improves

Strain hardenability

Improves

Improves

Improves

Coefficient of friction

Improves

Improves

Improves

Heat conductivity

None

None

Reduces

Heat capacity

None

None

Reduces

Chemical reactivity

None

Improves

Improves

Grain size

Improves

Improves

Reduces

Abrasive insoluble

Improves

Improves

Improves

Free-machining additions Decreases

Decreases

Decreases

Design recommendations
Design recommendations for machined parts are listed below
1. It is always recommended to avoid machining operations if possible. It is always less
costlier to produce a surface or feature by processes like casting or forming.(Refer
Figure M3.1.2)

Figure M3.1.2: Avoid tolerances that involve machining without affecting the parts
function.

2. The prime operations are to be simplified by considering the most liberal surface
finish and dimensional tolerances consistent with the function of the surface, so that
the costly secondary machining operation like grinding, reaming lapping etc. can be
avoided. (Refer Figure M3.1.2)

3. Parts should be designed in such a way that it will be easy for fixturing and secure
holding during machining operation. (Refer Figure M3.1.3)

Figure M3.1.3: Design planer and shaper machined parts to withstand cutting-tool
forces and to be solidly clamped.

4. Since sharp corners and sharp point in cutting tool are more prone to breakage, in the
design these features should be avoided.
5. Use stock dimension whenever possible. This will eliminate machining operation or
the need for machining additional surface (Refer Figure M3.1.4).

Not These

These

Figure M3.1.4: Use stock dimensions whenever possible to minimize machining.

6. In all single-point machining operations, it is recommended to avoid interrupted cuts,

if possible. These will shorten the tool life or will not allow the use of faster-cutting
carbide or ceramic tools.
7. Parts should be rigid enough to withstand the forces of clamping and machining
without distortion. (Refer Figure M3.1.5.)

Not these

These

Figure M3.1.5: Design the part to be rigid to withstand cutting and clamping forces
8. If possible rectangular shapes are preferred because of simple tooling and setup than
the use of tapers and contours.
9. It is recommended to reduce the number and the size of the shoulders as these usually
require extra operational steps and additional material.

10. Avoid undercuts to avoid separate operation of specially ground tools as shown in
Figure M3.1.6.

Not these

These

Figure M3.1.6: Avoid undercuts as much as possible

11. If possible, it is preferred to substitute a stamping operation for the machine
component. Cost wise stamped parts are more economical. (Refer Figure M3.1.7)

Figure M3.1.7: Stampings are often less costly than machining

12. Avoid machining of hardened or difficult-to-machine materials unless until their
functional properties are essential for the part to be machined.
13. Sufficient allowance should be provided to the stock for both rough and finish
machining. Often stress relieving between finish and rough machining is
recommended. Recommended stock for finish machining is 0.4 mm.
14. Number of operations required are reduced by using the same plane for subsequent
machining or same diameter if they are cylindrical.

15. It is required to provide access room for cutters bushing and fixture element.
16. Work piece is to be designed in such a way that standard cutters can be used. (Refer
Figure M3.1.8)

Not these

These

Figure M3.1.8: Design parts so that standard cutting tools can be used.
17. It is recommended to avoid parting lines or draft surfaces for clamping or locating
surfaces.
18. It is required to provide relief space for burr removal.