Design Manufacturing Engineering Techniques

1. MACHINING

2.  Drilling is a process of producing round holes in a solid
material or enlarging existing holes with the use of
multi- tooth cutting tools called drills or drill bits.
Various cutting tools are available for drilling, but the
most common is the twist drill.
 Reaming is a process of improving the quality of
already drilled holes by means of cutting tools
called reamers. Drilling and reaming are performed on
a drilling press, although other machine tools can also
perform this operation, for instance lathes, milling
machines, machining centers.

7.  Milling is the cutting operation that
removes metal by feeding the work
against a rotating, cutter having single or
multiple cutting edges. Flat or curved
surfaces of many shapes can be
machined by milling with good finish and
accuracy. A milling machine may also be
used for drilling, slotting, making a
circular profile and gear cutting by
having suitable attachments.

9.  a. Slab Mills
For heavy cutting of large and flat surfaces.
 b. Side and Face Cutters
This type of cutters has cutting edges on the periphery
and sides of the teeth for cutting shoulders and slots.
 c. Slitting Saws
For cutting deep slots or for parting off.

10.  a. End Mills
Commonly used for facing, slotting and profile milling.
 b. Rough Cut End Mills
For rapid metal removal.
 c. Slot Drills
For producing pockets without drilling a hole before
hand.
 d. Face Milling Cutters
For heavy cutting.

11.  Milling Processes
 Milling is a metal removal process by means of using a
rotating cutter having one or more cutting teeth
 Cutting action is carried out by feeding the workpiece
against the rotating cutter.

12. Up-cut milling Down-cut milling

13.  Plain Milling
 Plain milling is the milling of a flat surface with the axis
of the cutter parallel to the machining surface. It can be
carried out either on a horizontal machine or a vertical
machine as shown in figure

14.  End Milling is the milling of a flat surface with the axis
of the cutter perpendicular to the machining surface as
shown in figure

15.  Gang milling is a horizontal milling operation that
utilises three or more milling cutters grouped together
for the milling of a complex surface in one pass. As
illustrated in figure different type and size of cutters
should be selected for achieving the desire profile on
the workpiec

16.  Straddle Milling In straddle milling, a group of
spacers is mounted in between two side and face
milling cutters on the spindle arbor as shown in figure .
for the milling of two surfaces parallel to each other at a
given distance.

18.  Routing is a linear manufacturing
process.
 Reserve to wood work to make grooves,
rebates and moldings
 A rotating arm with changeable tools and
heads to create the desired profile