ime 144 final

abrasive flow machining

machining process for irregularly-shaped holes; utilizes an abrasive, putty-like media that flows through a workpiece, removing material

accuracy

how close a measured value is to the target value

ball screws

eliminates backlash; automated tables in CNC mills use these

band saw

type of saw that has a big band as a blade

billet

type of workpiece raw material; usually in the form of a block, bar, or sheet metal

bonded

how abrasives are attached to a blade; example is a grinding wheel

boring

enlarging an already existing hole using a single point cutting tool; the produced hole has a precise value

broaching

process of creating an irregularly shaped, non-circular hole, including sharp internal corners; one of the five traditional machining processes

castings

type of workpiece raw material; liquid material is poured into a mold, containing the hollow cavity of the desired shape

center cutting end mill

allows a helical plunge into a pocket (allowed you to mill pockets into parts)

center drill

used on a LATHE to start and accurately locate holes; similar to a spot drill used on a mill

centerless grinding

grinds outside diameter of a workpiece in one pass (for cylinders)

chip load

cross sectional size of the chip that is used to calculate the table feed rate for the mill; in/rev or in/tooth

climb milling

clockwise tool rotation and the preferred method for milling; max chip thickness occurs close to the point where the tooth contacts the work

clearance fit

a type of fit in which mating parts always have room to move when fit together; used when movement between parts is desired

coated

method of how abrasives are introduced to workpiece; other methods of introducing abrasives to a workpiece include bonded and loose; example of a coated abrasive is sandpaper

cold saw

what we use to cut stock in lab; creates precise, burr-free cuts and corner miters WITHOUT generating a heat-affected zone

conventional milling

clockwise tool rotation; cutter rotates against the direction of the feed rate, creating a thin chip at the beginning, increasing in thickness to its maximum. leaves a poor surface finish due to the chips being carried and generates more heat

coordinate measuring machine

how parts are measured; methods include video, laser, and probe/tactical

cutting fluids

cools and lubricates (thus reducing friction) the cutting tool; leads to better cuts, longer tool life, and smoother finishes

cutting speed

velocity of cutting tool moving past workpiece at point of contact (tangent edge); influences temperature; feet/minute, aka surface speed

cylindrical grinding

meant to grind external cylindrical surfaces and workpiece shoulders; typically a lathe with a grinding wheel instead of a single point cutting tool

depth of cut

how far a tool cuts into the workpiece; radius on a lathe

dial caliper

measuring tool used in lab

die

cuts external threads (A)

drilling

most common method of producing a hole; one of five traditional machining processes

electronic discharge machining (EDM)

uses a sinker die or wire with electrical pulses to produce tiny, highly focused sparks that erode metal smoothly and precisely; requires a conductive workpiece material; forceless machining process, creating a heat-affected zone

electrochemical machining

requires a conductive workpiece material; uses electrical energy to remove material and results in no mechanical or thermal stress; controlled corrosion based on electrolysis

engineering drawing

shows dimensions, locations, tolerance, and other specs for a given part; higher tolerance equal higher costs to manufacture the part

engineering microscopes

used to inspect small, technical parts

face mill

machines a flat surface normal (perpendicular) to the axis of the rotating cutter; shortens overall height

facing

reduces the length of a part on a lathe; produces a flat surface at the end of the part perpendicular to its axis

feed rate

on a mill: N * f * t = feed rate (in/min)
- N = cutting tool RPM
- f = chip load (inches/tooth)
- t (# of teeth)

on a lathe: *same as chip load*

filing

method of deburring; finishing material removing process

first article inspection report

proving design specifications

fixed gages

go-no-go gages; "go" side is green, at MMC; "no-go" side is red, at LMC

fixtures

holds irregularly shaped workpieces

g codes

preparatory functions, cause movement

grinding

abrasive process to shorten the length, reduce diameter, or deburr a workpiece

heat affected zone

manufacturing processes change the metallurgical properties of the material; created by electronic discharge machining (EDM) and laser cutting

height gage

requires a precisely finished surface (datum) to accurately measure the height of a particular object

higher

as cutting tool material becomes stronger/harder and workpiece material becomes softer, cutting speed can be higher

hole

most common method of producing a hole is drilling

honing

creates smooth internal cylindrical cavities (bores)

in/rev

the unit used to measure LATHE feed rate and chip load

in/min

the unit used to measure MILL table feed rate

jigs

guides the tool

kerf

thickness of cut (smallest possible radius); width of cut is made by a saw blade

laser

type of coordinate measuring machine using a beam of focused light

laser beam machining

energy source is a laser, which focuses optical energy that is converted to thermal energy on the surface of the material

lapping

the machining process that produces the tightest possible tolerance by slowly removing material from the workpiece one surface at a time, typically using a large granite block and some sort of cutting fluid

lead screws

previously used on automated mill tables, but still used on lathes in the lab; causes issues in tolerances due to backlash

least material condition

the size of the part when it consists of the least material; "no-go" side of a go-no-go gage

loose

parts are loose when there is a clearance fit between the two

lower

as cutting tool material becomes softer and the workpiece material becomes harder/stronger, the cutting speed becomes lower

maximum material condition

size of the part when it consists of the most material; "go" side of a go-no-go gage

m codes

cause actions to occur, like turning on and off, cooling, or switching the tool

micrometer

most accurate hand-held measuring tool

milling

the process of machining flat, curved, or irregular surfaces by feeding the workpiece against a rotating cutter containing a number of cutting edges; one of five traditional machining processes

nesting

process of producing a pattern of parts that produces the highest number of parts in a given area; typically applies to sheet metal

non-traditional processes

doesn't use shear stress to remove material from the workpiece; different because they're slower and more expensive; uses an energy mechanism to remove material

operation sheets

detail the process of completing one step in a routing

optical comparator

touchless measurement, calculates distances and angles using points placed on a light and shadow projection of the object

optical encoder

figures out how much a part rotated; closed-loop feedback on a CNC

post processor

makes g-code so a CNC machine can understand CAM code used to create a part in SolidWorks

press fit

two mating parts are pressed or forced together; the shaft is larger than the hole; used for permanent attachment

production planning

an entire company works together on the design of a product to create the best potential design and prevent issues during the production, launch, or other phases

pitch

how far the screw travels linearly per revolution; calculated with 1/threads per inch

reaming

most accurate way to make a hole; slightly enlarges a pre-existing hole with a tight tolerance diameter

resolution

finest possible reading of a measurement; apply the rule of 10 (measuring device is 10x more accurate than the required tolerance)

routing

individual part recipe; details the steps and tools needed to make a given part

RPM

lathe: N = 4V/d
- N = workpiece RPM
- V = cutting tool speed (feet/min)
- d = workpiece diameter

mill: N = 4V/d
- N = cutting tool RPM
- V = cutting speed (feet/min)
- d = cutting tool diameter

sawing

multi-tooth blade that removes material from the workpiece, often to split the workpiece into multiple separate pieces; only works in one direction; types include: vertical and horizontal band, circular, cold, and abrasive; one of five traditional machining processes

shear stress

how conventional or traditional machining processes remove material from the workpiece

sheet metal

type of workpiece raw material; thin piece of metal, typically with larger length and width

step over

width of cut

surface grinding

for prismatic or flat surfaces

surface speed

velocity of tool moving past workpiece at point of contact (tangent edge); influences temperature; feet/min; aka cutting speed

tactile

a type of coordinate measuring machine using a physical probe

tap

cuts internal thread

test indicator

tool that can measure the parallelism or perpendicularity of an object or surface when used in conjunction with a precisely finished surface (datum)

three jaw chuck

most popular work-holding on a lathe

tolerances

directly affects the cost of making a given product; provides the permissible limits, amount of variation permitted, and the degree of accuracy for a part

tool length offset

how long a tool is in the CNC mill and how far the tool holder needs to be to not contact the workpiece

turning center

CNC lathe; workpiece spins as tool moves past it

turning

reduces diameter of part on lathe

ultrasonic machining

uses an abrasive slurry and moves the workpiece at a high frequency to slowly remove material, requires brittle or hard materials, like glass or ceramic

video

a type of coordinate measuring machine using cameras and software

waterjet machining

mechanical material removal process capable of slicing into metal or other materials using a jet of water at high velocity and pressure; can cut through virtually anything

width of cut

step over