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Process planning

Determining the most appropriate manufacturing processes and the sequence in which they should be performed to produce a given part or product specified by design engineering.

Manufacturing engineers

The department responsible for performing process planning and optimizing production operations in an organization.

Design for manufacturability

Supporting the development of product designs that not only meet functional and performance requirements but can also be produced at a reasonable cost with minimum technical problems.

Equipment selection

The process of selecting processes and equipment that utilize existing plant equipment or determining the need for new equipment.

Material utilization

The goal of making efficient use of materials and minimizing waste in the process sequence.

Precedence constraints

Technological sequencing requirements that determine or restrict the order in which processing steps can be performed.

Operation ID

A unique identifier for each machining operation listed in the route sheet.

Operation Description

A description of the specific machining operation to be performed.

Department

The department responsible for performing the machining operation.

Machine

The specific machine to be used for the machining operation.

Tooling ID

The identification of the cutting tools, jigs, and fixtures required to perform the machining operation.

Operation Sequencing Steps

The steps involved in selecting the stock, identifying volumes of material to be removed/deformed, and generating the most effective/efficient sequence of machining operations.

Optimization

The process of re-sequencing and combining operations to produce an optimized process plan.

Set up

The orientation and configuration of machines and tools for each machining operation.

Factors to consider for re-sequencing

Factors such as set up, accuracy, and tool availability that should be considered when re-sequencing operations.

Automation

Implementation of technology by means of a control system that executes a program of instructions.

Closed loop

A control system in which the process variable of interest is compared with the corresponding process parameter, and any difference between them is used to drive the output value into agreement with the input.

Open loop

A control system that executes the program of instructions without a feedback loop.

Coordinate systems

Three linear axes (X, Y, and Z) and three rotational axes (a, b, and c) used in advanced manufacturing technology.

Interpolation

Calculating the intermediate points along a path to be followed by the work head relative to the part.

Absolute positioning

Coordinate system specification that is always defined with respect to the origin.

Incremental positioning

Coordinate system specification that is defined relative to the present location.

Machine centres

Highly automated machine tools capable of performing multiple machining operations.

CNC

CNC programming is the process of converting the information on the component drawing into a format that the machine control software can recognize and act upon.

Tooling systems

Consist of a range of standard cutting tools and tool holders together with the appropriate adaptors, and they may be either manual or automatic.

CAD/CAM

Immediate visual verification when each statement is entered, and the ability to see exactly how the motion commands will move the tool relative to the part.

FMS

A group of CNC workstations connected by a materials-handling system, controlled by a master computer.

Industrial robots

Computer-controlled, reprogrammable mechanical manipulators capable of carrying out a variety of industrial operations.

Non-traditional machining

Group of processes that use other mechanisms, rather than shear deformation, to remove material.

Mechanical energy processes

Non-traditional machining processes that use mechanical energy in some form other than the action of a conventional cutting tool.

Electrical energy processes

Non-traditional machining processes that use electrochemical energy to remove material.

Thermal energy processes

Non-traditional machining processes that use thermal energy to cut or shape the work part.

Electric discharge machining

Removal of metal by a series of discrete electrical discharges (sparks) that cause localized temperatures high enough to melt or vaporize the metal in the immediate vicinity of the discharge.

Dielectric fluid

A fluid used in electric discharge machining that ionizes at the location of the discharge to create a path for the discharge.

Electric discharge wire cutting (EDWC)

A special form of electric discharge machining where a small diameter wire is used as the electrode to cut a narrow kerf in the work.

Laser beam machining (LBM)

The use of a laser to remove material by vaporization and ablation.

Arc cutting processes

The use of intense heat from an electric arc to melt metal for the purpose of welding or cutting.

Plasma cutting

A type of arc cutting process that uses a plasma arc to melt metal for cutting.

Chemical processes

Non-traditional machining processes that involve the use of chemicals to selectively remove material from a workpiece.

Chemical milling

A chemical process applicable to large parts where substantial amounts of metal are removed.

Chemical blanking

A chemical process that uses chemical erosion to cut intricate patterns in very thin sheet metal parts.

Chemical engraving

A chemical process used to make name plates and other flat panels with lettering and/or artwork.

Photochemical machining (PCM)

A chemical machining process that uses the photoresist method of masking.

Cut and peel

A masking method in chemical processes where the maskant is applied over the entire part and then cut and peeled away in the areas to be etched.

Photoresist method

A masking method in chemical processes where photographic techniques are used to apply the maskant.

Screen resist method

A masking method in chemical processes where the maskant is painted onto the work part surface through a mesh with a stencil.

Workpart geometric features

The specific features or characteristics of a workpiece that determine the appropriate non-traditional machining process to use.

Holes with large depth-to-diameter ratios

Holes with d/D > 20 that cannot be machined in conventional drilling operations.

Non-round holes

Holes that are not round and cannot be drilled with a rotating drill bit.

Narrow slots in slabs and plates

Narrow slots that are not necessarily straight and may have intricate shapes.

Micromachining

Material removal applications where the workpart and/or areas to be cut are very small.

Shallow pockets and surface details in flat parts

Surface features in flat parts that require special machining techniques.

Special contoured shapes for mould and die applications

Contoured shapes used in mould and die applications, also known as die-sinking.

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Nontraditional machining processes

Processes that are not conventional milling and grinding, such as USM, WJC, ECM, EDM, EBM, LBM, PAC, and CHM.

Conventional milling and grinding

Traditional machining processes used for material removal.

Applicability

The suitability or suitability of a process for a particular work material.

Work material

The material being machined or processed.

Aluminum

A type of work material that can be machined using nontraditional processes.

Steel

A type of work material that can be machined using nontraditional processes.

Super alloys

A type of work material that can be machined using nontraditional processes.

Ceramic

A type of work material that can be machined using nontraditional processes.

Glass

A type of work material that can be machined using nontraditional processes.

Silicon

A type of work material that can be machined using nontraditional processes, specifically in fabricating integrated circuit chips.

Plastics

A type of work material that can be machined using nontraditional processes.

Cardboard

A type of work material that can be machined using nontraditional processes.

Textiles

A type of work material that can be machined using nontraditional processes.

Fusion welding

A type of welding process where two or more parts are joined by heat and/or pressure.

Solid-state welding

A type of welding process where parts are joined by pressure alone or heat and pressure without melting the base metals.

Forge welding

A type of solid-state welding process where components are heated and then forged together.

Cold welding

A type of solid-state welding process where high pressure is applied between clean contacting surfaces at room temperature.

Diffusion welding (DFW)

A type of welding process where heat and pressure are applied, and coalescence is achieved through solid-state diffusion.

Explosion welding (EXW)

A welding process where the rapid coalescence of two metallic surfaces is caused by the energy of a detonated explosive.

Ultrasonic welding

A type of solid-state welding process that uses high-frequency vibrations to create a bond between parts.

Friction welding (FRW)

A joining process where coalescence is achieved by friction heat combined with pressure.

Friction stirring welding (FSW)

A technique of friction welding that overcomes the dimensional limitations of traditional friction welding.

Ultrasonic Welding (USW)

A joining process where oscillatory shear stress of ultrasonic frequency is applied to the interface to cause coalescence.

Forge welding

A joining process that involves heating and hammering two metal parts together.

Cold welding

A joining process that occurs at ambient temperature without the need for heat.

Diffusion welding

A joining process where materials are bonded together by the diffusion of atoms across the joint interface.

Explosive welding

A joining process that uses explosive forces to bond dissimilar metals together.

Brazing

A joining process that uses a filler metal to bond two metal parts together without melting the base metals.

Soldering

A joining process similar to brazing, but typically uses a lower melting point filler metal.

Adhesive bonding

A joining process that uses adhesives to bond two materials together.

Brazing

A joining process in which a filler metal is melted and distributed by capillary action between faying surfaces of the metal parts being joined.

Filler metal

The metal that is melted in brazing to join the metal parts together.

Capillary action

The ability of a liquid to flow in narrow spaces against the force of gravity.

Base metals

The metal parts being joined in brazing.

Brazed joint

The joint created by brazing, which is usually stronger than the filler metal.

Clearance

The space between mating surfaces of the base parts in brazing.

Brazing fluxes

Substances used to inhibit the formation of oxides and unwanted byproducts during brazing.

Filler metals

Materials used in brazing, such as wire, rod, sheets and strips, powders, and pastes.

Brazing methods

Various techniques used in brazing, including torch brazing, furnace brazing, induction brazing, resistance brazing, and dip brazing.

Advantages of brazing

Any metals can be applied, including dissimilar metals; certain methods allow for quick and consistent performance; can join thin-walled parts that cannot be welded; requires less heat and power than fusion welding; reduces the heat-affected zone in the base metal.

Disadvantages of brazing

Joint strength is less than that of a welded joint and base metal materials; high service temperature weakens the brazed joint; color mismatch between the joint and base metal.

Soldering

A joining process in which a filler metal with a melting point not exceeding 450°C is melted and distributed by capillary action between the faying surfaces of the metal parts being joined.

Metallurgical bond

A bond formed between the base metal and filler metal in soldering.

Heating methods

The same methods used in brazing are also applied to soldering.

Soldering methods

Various techniques used in soldering, including torch soldering, furnace soldering, induction soldering, resistance soldering, dip soldering, and infrared soldering.

Hand soldering

A soldering method performed using a hot soldering iron, typically made of copper.