Section 02 / 18
Processes
Turning, milling, hole-making, grinding and every finishing and non-traditional method, each opened with a 3D model and tied to its cutting data.
- Live
- 12
- Pages planned
- 105
- Subsections
- 8
- Release phase
- Phase 1 first three months
Live pages
- 02 TurningTurning operationsWhat turning is and how DIN 8589-1 groups it; the operations a lathe performs, each with its feed direction, tool and typical problem; the entering angle and the chip it cuts; constant cutting speed with a speed limit; boring-bar overhang; and starting feeds from two tool makers.
- 02 TurningInternal turning and the L/D of the boring barWhy boring is harder than external turning, how a boring bar deflects (δ = F·L³/3EI) and why overhang counts three times and diameter four, the longest overhang for steel, heavy-metal, carbide and damped bars maker by maker, bar size and clamping length, centre height, insert geometry for low radial force, chip evacuation and the remedies for chatter.
- 02 TurningThread turningCutting a thread on a lathe with a threading insert: feed equal to the lead and the spindle encoder, full-profile, partial-profile and multi-tooth inserts, radial, flank, modified-flank and alternating infeed, the depth of each pass (ISCAR’s constant chip area, the √N rule, Mitsubishi’s table), the helix angle and the 1.5° shim, cutting speed, the G76 cycle and the usual faults.
- 02 TurningParting off and groovingCutting a part off the bar and cutting grooves on a lathe: the tools, why the cutting speed runs out at the centre, how much the makers cut the feed there, where to stop, the pip, centre height and overhang, chips and coolant in a narrow slot, and how to cut wide, deep and face grooves.
- 02 MillingClimb vs conventional millingWhy the direction of cutter rotation relative to the feed matters: chip thickness at entry and exit, forces that pull or lift the work, backlash, surface finish, when conventional milling is still the better choice, and where to place a face mill.
- 02 MillingFace millingWhat face milling is and which edges do what; the entering angle and what it does to the chip, the forces, burrs and breakout, maker by maker and with their different angle conventions; cutter diameter against the width of cut and where to put the cutter; pitch; wiper inserts and spindle tilt; cutting power from Mitsubishi’s worked example; and the common faults with their remedies.
- 02 MillingTrochoidal millingOpening a slot wider than the cutter in advancing loops, at a large depth and a small width of cut: why makers recommend it, the widths and depths they give, how much the engagement changes around the loop, radial chip thinning and the feed that makes up for it, what the machine and the CAM have to do, and the drawbacks.
- 02 Hole-makingTappingCutting and forming internal threads with a tap: the four tap types and where each sends the chips, the DIN 2197 chamfer forms, tap classes ISO 1–3 and the X classes, cutting speeds by maker, feed as pitch times speed, rigid against floating tapping with the CNC cycles, torque and power, and why taps break.
- 02 Hole-makingTap drill sizes for metric threadsWhich drill to use before tapping: the d − P rule and the DIN 336 / ISO 2306 table, why the hole has to fall inside the 6H minor-diameter limits, how much larger a hole a forming tap needs, and what "thread percentage" means.
- 02 Hole-makingReamingBringing a drilled hole to size and finish with a reamer: what reaming corrects and what it cannot, reamer types and the DIN standards, flute direction by hole and material, leads and back taper, stock allowance by diameter from four makers, the reamer’s own tolerance by ISO 522, cutting data, holders and coolant, and the usual faults.
- 02 Hole-makingThread millingCutting a thread with a milling cutter on a helical path: one pitch per orbit, multi-tooth and single-profile cutters, why it is chosen over tapping, climb milling and the G02/G03 and Z directions, tangential entry and cutter compensation, the feed correction between edge and tool centre, cutter size limits, radial passes, cutting data and the usual faults.
- 02 Grinding and finishingHoning and plateau honingHow honing corrects a bore: the kinematics and the crosshatch angle, what honing can and cannot fix, abrasives and bonds, plateau honing and its Rk targets from three sources, and how hydraulic cylinder tubes are finished by honing or by skiving and roller burnishing.
Section map
The subsections of this section and the number of pages planned in each. Pages go live in section order, all on the same template.
- 2.1Turning4/16
- 2.2Milling3/18
- 2.3Hole-making4/15
- 2.4Grinding and finishing1/19
- 2.5Gear manufacturing0/10
- 2.6Broaching, planing, sawing0/6
- 2.7Non-traditional methods0/11
- 2.8Hybrid and special methods0/10
In production 12 of 105 planned pages are live. The figure on each subsection is pages live / pages planned.