1. Design for Mill/Turning/Drilling or how to save yourself or your machinist a lot of time and effort

2. Overview Drill Mill Lathe Surface Finish Tips & Tricks Process Planning

3. Drill Make a hold in something Drillpress OR hand-held drill Usually need clamps to hold part in place Not highly accurate but often good enough

4. A BIG distinction MANUAL machines vs. CNC machines

5. A BIG distinction MANUAL machines vs. CNC machines

6. Lathes ManualCNC

7. How do choose the correct machine? Round geometry Axial alignment Axial and milled geometry Flat/planar geometry Odd (not circular) shapes Pockets, holes, surface geometry Lathe Drill or Mill CNC Lathe With live tooling CNC Mill

8. Surface Finish

9. From 2.008 class notes, SP03

10. Surface Finish From 2.008 class notes, SP03

11. Tips & Tricks

12. For high precision, watch out for Overhanging geometry (deflection) Thin sections & tubes (vibration) Drilling incline planes

13. For ease of manufacturing Standard shape & size holes Proper tolerances (discussed tomorrow) Reference everything off one point Avoid deep pockets & holes NO inside right edges! WATCH OUT for tool access! –a short endmill used inside a deep narrow pocket might CRASH!) –Don’t cut into the vise or clamps!

14. Mill: Part in Vise

15. To make it faster (& less annoying) Minimize number of fixtures –Every time you take the part out of the vise you have to re-reference it – wastes time! Include features for easy fixturing & referencing Image from: http://www.wmccm.co.uk/WMCCM/DesktopDefault.aspx?tabindex=0&tabid=2049

16. Process Planning

17. From 2.008 Process Planning lecture, SP03

18. Process Planning From 2.008 Process Planning lecture, SP03 Look for departmental resources TOMORROWMachine shop resources Buy material Make material correct size

19. Detailed Process Planning for Manufacturing Choose material and order it Make material correct starting size/shape –Watch for tolerances when ordering – parts aren’t always exact size or perfectly square Plan what cuts/features to make first, second, third based on complexity, yield of process, etc. - SKETCH –If something is likely to not work, don’t do that step last!

20. Detailed Process Planning for Manufacturing, Continued… Determine when to check for quality/accuracy in the process –Easier to measure twice and cut once than the other way around! For any hand-machining operations, mark the parts in an OBVIOUS way! –ei, an X on the part that you don’t want, scribble where you want material removed

21. Optimizing your Process Plan Fewer steps = better Make a flowchart

22. How Its Made Examples

23. Resources Machinery’s Handbook Manufacturing textbooks (Kalpakjian) Your local machinist MIT shops –MIT departmental shops –Edgerton Student Shop (on Vassar Street) –MIT Hobby Shop