author: 'ben lipkowitz' license: 'GPL2+' urls: - 'http://heybryan.org/mediawiki/index.php/Skdb' - 'http://fennetic.net/git/gitweb.cgi?p=skdb.git;a=blob_plain;f=materials.yaml' - 'git://fennetic.net/git/skdb.git/' source: manufacturing processes reference guide, 1993 first edition. todd, allen, and alting. template: !process name: classification: mechanism: geometry: tolerance: surface finish: consumables: functionality: parameters: safety: abrasive jet: !process #eventually this will be something like skdb.Shaping.Reducing.Mechanical name: abrasive jet machining mechanism: compressed air accelerates abrasive particles toward the workpiece functionality: - finishing - hole drilling - deburring - prismatic geometry - tapered geometry machinability: !which workpiece material, machinability removal rate: typical: 0.003.. 0.0007in/min #what exactly does this refer to? feasible: 0.0001 .. 0.002in/min geometry: primitive: cone #!geometry #what angle? path: - parallel to workpiece face tolerance: typical: +-0.005in feasible: +-0.001in surface finish: #arithmetic average typical: 6..48 microinch feasible: 4..64 microinch consumables: nozzle: &orifice tungsten carbide: life: 12..30hr sapphire: #this should work, but it doesn't? # life: !range # min: 300hr abrasive: 1..25g/min #this really should be something like "compressed air: 4.5..7cfm" power: 0.5..4 hp #power = cfm * pressure is dependent on pressure and diameter parameters: #"factors affecting process results" pressure: 25..130psi orifice diameter: 0.005..0.05in nozzle distance: 0.03..0.6 in nozzle angle: workpiece size: typical: 5..50 in^2 feasible: 0.2 .. 100 in^2 #workpiece size is only limited by enclosure workpiece material: &machinability #on a scale of 0 to 4 representing process quality and/or ease of use #need to figure out a new unit 'stars' representing this ceramic: machinability: 2.25 .. 3.75 stars germanium: machinability: 2.2 .. 3.5 stars glass: machinability: 2.2 .. 3.8 stars mica: machinability: 1.9 .. 3.4 stars silicon: machinability: 2.3 .. 3.8 stars steel: machinability: 1.1 .. 2.5 stars aluminum: machinability: 0.4 .. 1.6 stars abrasive material: aluminum oxide: functionality: - cutting - hard materials diameter: 10 .. 50 microns silicon carbide: functionality: - fast cutting - hard materials - ceramics diameter: 25 .. 50 microns glass beads: functionality: - deburring - light cleaning #how do i parameterize this with dimensional units? - polishing diameter: 0.025 .. 0.05in sodium bicarbonate: functionality: - cleaning calcium compounds: functionality: - light cleaning - light etching magnesium compounds: functionality: - light cleaning - light etching safety: - airborne dust - flying particles - abrasion - toxic dust arbor milling: !process name: arbor milling #really this is just endmilling supported at both ends and you can stack cutters classification: process, shaping, mass-reducing, mechanical, reducing, multi-point, milling mechanism: rotating toothed cutter supported axially at both ends is fed into the workpiece at a controlled rate geometry: #!geometry primitive: revolute #like a candlestick. used to calculate swept volume of tool path path: - path perpendicular to axis - axis parallel to workpiece opposite face #cutters can be ganged.. where do i put this? length: typical: 0.2..5in feasible: &width_of_cut 0.03..20in radius: typical: 1.5 .. 10in tolerance: typical: +-0.005 feasible: +-0.001 surface finish: typical: 64..200 microinch feasible: 32..500 microinch unit power: !which workpiece material, unit power consumables: power: !formula unit power * removal rate tool: life: !which tool material, life lubricant: !which lubrication, lubricant #how long does each lubricant last? where do i get this info? functionality: - roughing - prismatic geometry - !which tool material, functionality #hmm machinability: !which workpiece material, machinability effects: - surface stress - untempered martensitic layer 0.001in in heat treated alloy steels #blargh parameters: depth of cut: typical: 0.05 .. 0.25in feasible: 0.004 .. 1in width of cut: *width_of_cut rotation direction vs feed: #surely there's a name for this #clockwise rotating cutter by default; a counterclockwise cutter reverses this - conventional - climb feed per tooth: 0.005 .. 0.010in/tooth surface speed: 30 .. 500 feet/min #see materials lubrication: !which workpiece material, lubrication workpiece hardness: typical: max: Rockwell C25 #joy~~ how about some real units rigidity: #this includes the machine, workpiece, clamps, and tool bit rigidity static: #mostly affects deflection or absolute uncompensated accuracy dynamic: #affects maximum cutting rate vs surface finish, tool life, etc tool geometry: !which workpiece material, tool geometry tooth count: typical: 10 .. 20 teeth/rev #i just made up these values feasible: 1 .. 200 teeth/rev #ditto tool sharpness: #units?? tool material: high speed steel: functionality: - special geometry - low production carbide insert: functionality: - high production ceramic insert: functionality: - high speed machining - high production - uninterrupted cuts diamond insert: functionality: - high surface finish - low tolerance - nonferrous materials workpiece material: aluminum: tool geometry: #!multipoint_rotating_cutter teeth: !which tooth count #blarg axial rake: 12 .. 25 deg radial rake: 10 .. 20 deg axial relief: 5 .. 7 deg radial relief: 5 .. 11 deg unit power: 0.3 hp/in^3 hardness: typical: 70 .. 125 brinell feasible: 30 .. 150 brinell machinability: typical: 2.6 .. 3.2 stars feasible: 2.2 .. 3.7stars lubricant: - none - mineral oil - fatty oil brass: tool geometry: axial rake: 12 .. 25 deg radial rake: 10 .. 20 deg axial relief: 5 .. 7 deg radial relief: 5 .. 11 deg unit power: 0.6 .. 1.0 hp/in^3 hardness: typical: 60..100brinell feasible: 50..240 brinell machinability: feasible: 2.1 .. 3.6 stars typical: 2.6 .. 3.1 stars lubricant: - mineral oil - specialty fluid #wtf?? cast iron: tool geometry: axial rake: 10 .. 12 deg radial rake: 10 .. 20 deg axial relief: 2 .. 4 deg radial relief: 3 .. 7 deg unit power: 0.6 .. 1.1 hp/in^3 hardness: typical: 250..320 brinell feasible: 110 .. 320brinell machinability: feasible: 2 .. 3 stars typical: 2.3 .. 2.6 stars lubricant: - soluble oil - chemical oil - synthetic oil - none mild steel: tool geometry: axial rake: 10 .. 15 deg radial rake: 10 .. 15 deg axial relief: 3 .. 5 deg radial relief: 4 .. 8 deg unit power: 1.1.. 2.1 hp/in^3 hardness: typical: 275..325 brinell feasible: 85..560 brinell machinability: feasible: 2.1 .. 3 typical: 2.3 .. 2.6 lubricant: - chemical oil - syntheic oil - soluble oil stainless steel: tool geometry: axial rake: 10 .. 12 deg radial rake: 5 .. 10 deg axial relief: 3 .. 5 deg radial relief: 4 .. 8 deg unit power: 1.4 .. 1.5hp/in^3 hardness: typical: 275..325 brinell feasible: 135..430 brinell machinability: feasible: 0.3 .. 2.4 stars typical: 0.8 .. 1.5 stars lubricant: - sulfurized mineral oil - fatty soluble oil - chemical oil - synthetic oil plastic: tool geometry: axial rake: 18 deg radial rake: 15 deg axial relief: 6 deg radial relief: 8 deg hardness: unit power: 0.05hp/in^3 machinability: feasible: 2 .. 3.8 stars typical: 2.5 .. 3.2 stars lubricant: - mineral oil - soluble oil - cold air - none safety: - rotating parts #if this were a high speed rotating part we'd calculate the energy, but the danger is mostly from being crushed by the torque - hot chips #todo: calculate the energy in a typical hot chip - sharp chips - toxic fluids band filing: !process #there really wasn't much data on this name: band filing classification: shaping, mass reducing, mechanical, reducing, multi-point, filing mechanism: a prismatic multipoint cutter mounted on a metal belt is fed into the work geometry: primitive: prism path: - under 90 degrees to previous segment #direction of cutting really depends on the tool bit geometry - axis perpendicular to workpiece opposite face tolerance: surface finish: "fine" functionality: - irregular prismatic geometry - deburring - squaring edges - finishing consumables: tool: life: parameters: tool geometry: #this needs work, should conform to !multipoint_cutter eventually - flat (square) - triangle - half oval - half cylinder tooth count: 10..24 teeth/in safety: - particulate material - moving belt band sawing: !process name: band sawing classification: shaping, mass-reducing, mechanical, reducing, multipoint, sawing mechanism: a moving flexible tensioned metal loop with teeth is fed into the workpiece at a controlled rate geometry: primitive: rectangle path: - roll = 90 deg - perpendicular to rectangle or tangent arc - geometry must extend above and below workpiece - !formula arc radius > something * blade width tolerance: typical: 0.05 .. 0.1 in feasible: 0.02 .. 0.3 in surface finish: consumables: tool: lubricant: functionality: - narrow kerf - single angle cuts - !which tooth shape, functionality - !which blade width, functionality parameters: teeth in contact with work: #!range #FIXME min: 2 teeth #bleh tooth count: 4..28 teeth/in tooth shape: precision: functionality: - finishing buttress: functionality: - roughing - parting - high chip load claw: functionality: - chip clearance - fast cuts blade width: thin: functionality: - irregular prismatic shape - curved cuts thick: functionality: - straight cuts - parting blade thickness: blade tension: lubricant: - none - soluble oil - cutting oil safety: - moving belt - moving blade - particulate material internal broaching: &internal_broaching !process name: internal broaching classification: shaping, mass-reducing, mechanical, reducing, multi-point, broaching mechanism: a tapered cutter is fed into a hole in one pass geometry: primitive: prismatic or helical path: - axis parallel to workpiece face - helix angle < 20 deg #yah i made this up.. isnt a tap just a helical broach? tolerance: typical: +-0.002in feasible: +-0.0005 surface finish: typical: 16..63 microinch feasible: 8..125 microinch consumables: tool: power: !formula drive efficiency * hardness / chip load #see graph, normalize so that 80% * 100brinnel/(0.01in/tooth) = 0.25 hp/(in^3/min) ... or something like that requirements: #do i even need this? - pre-existing hole functionality: - heat treated parts - low production - roughing - finishing - internal prismatic geometry - low angle internal helical geometry - keyways - !which tool material, functionality machinability: !which workpiece material, machinability effects: - welding tool and workpiece - work hardening parameters: diameter: typical: 0.125 .. 6 in feasible: 0.04 .. 12 in surface speed: !which material, surface speed rigidity: alignment: lubricant: !which workpiece material, lubricant feed per tooth: !which workpiece material, feed per tooth tool geometry: !which workpiece material, tool geometry hardness: !which workpiece material, hardness tool material: high speed steel: functionality: - low production - irregular internal prismatic geometry - irregular internal helical geometry workpiece material: aluminum: feed per tooth: 0.005..0.007in/tooth lubricant: - kerosene - mineral oil - sulfurized mineral oil tool geometry: rake: 10 .. 15 deg clearance: 1 .. 3 deg hardness: 30 .. 150 brinell machinability: typical: 2.8 .. 3.2 stars feasible: 2.2 .. 3.7 stars brass: feed per tooth: 0.004..0.005in/tooth lubricant: - water - soluble oil - mineral lard oil tool geometry: rake: -5 .. 5 deg clearance: 1 .. 3 deg hardness: 40 .. 200 brinell machinability: typical: 2.7 .. 3.2 stars feasible: 2.1 .. 3.6 stars cast iron: feed per tooth: 0.002..0.005in/tooth lubricant: - water - soluble oil - sulfurized mineral oil tool geometry: rake: 6..15 deg clearance: 2 .. 3 deg hardness: typical: 120 .. 320 brinell feasible: 110 .. 400 brinell machinability: feasible: 2 .. 3 stars typical: 2.3 .. 2.5 stars mild steel: feed per tooth: 0.003..0.004in/tooth lubricant: - water - soluble oil - sulfurized mineral oil - mineral lard oil tool geometry: rake: 15..20 deg clearance: 1..3 deg hardness: typical: 100..275 brinell feasible: 85 .. 375 brinell machinability: feasible: 2.1 .. 3 stars typical: 2.3 .. 2.5 stars stainless: feed per tooth: 0.002..0.003in/tooth lubricant: - water - soluble oil - sulfurized mineral oil - mineral lard oil tool geometry: clearance: 0.5 .. 3 deg rake: 8 .. 18 deg hardness: typical: 135 .. 375 brinell feasible: 135 .. 440 brinell machinability: feasible: 0.3 .. 2.4 stars typical: 0.7 .. 1.5 stars plastics: machinability: feasible: 2 .. 3.7 stars typical: 2.5 .. 3.2 stars safety: - reciprocating cutter - hot chips - sharp chips - toxic fluids - flying broken cutter external broaching: !process name: external broaching classification: shaping, mass-reducing, mechanical, reducing, multi-point, broaching mechanism: a tapered cutter is fed across a workpiece in one pass similar: *internal_broaching functionality: - heat treated parts - low production - roughing - finishing - prismatic geometry - low angle external helical geometry - gear teeth - irregular prismatic geometry - slot cuts - !which tool material, functionality parameters: width: typical: 0.075 .. 10in feasible: 0.02 .. 20in tool material: high speed steel: functionality: - low production - irregular prismatic geometry carbide insert: functionality: - high production - prismatic geometry - high hardness superfinishing: !process #somehow i think there isnt quite enough info here name: superfinishing classification: shaping, mass-reducing, mechanical, reducing, abrasive #is this right? mechanism: abrasive surface and oil act as hydrodynamic bearing; surface asperities contact abrasive and are cut geometry: primitive: cylinder or sphere or cone or plane path: - colinear with workpiece face axis #superfinishing just makes a cylinder "more cylindrical" etc tolerance: -0.0002 .. -0.0008in effect: removes smeared surface layer surface finish: typical: 2 .. 8 microinch feasible: 0 .. 30 microinch rate: 10..40 in^2/min consumables: abrasive: functionality: - high precision - wear resistance - bearing surfaces parameters: periodicity: #how the heck do i represent this surface speed: 50 .. 60 feet/min pressure: 10 .. 40 psi lubricant: - oil - water workpiece surface finish: 30..200 microinch #i made this up.. chrysler recommends rough grinding prior to surface finishing safety: - abrasive fluid - rotating parts gas cutting: !process name: gas flame cutting classification: shaping, mass-reducing, thermal, torch cutting, gas cutting mechanism: ferrous workpiece is heated and then oxidized. gas flow then blows the liquid metal out of the cut geometry: primitive: cylinder path: - parallel to workpiece face diameter: 1/16 .. 1/4 in #kerf tolerance: typical: +- 1/8 in feasible: +- 1/32 in surface finish: typical: 250..1000 microinches feasible: 100..1100 microinches consumables: fuel consumption: !which fuel, fuel consumption oxygen consumption: !which fuel, oxygen consumption torch tip: functionality: - straight cuts - parting - roughing - irregular prismatic geometry - angular cuts - ferrous materials > 3/8 inch thickness effects: - distortion - annealing - microcracks - residual stress - surface embrittlement - oxidation heat affected zone: #no mention? parameters: workpiece thickness: typical: 0.125 .. 12in feasible: 0.05 .. 60in #wow oxidizer pressure: 20 .. 50 psi fuel pressure: 3 .. 7 psi feed rate: !which fuel, feed rate temperature: tempf(1400)..tempf(1600) tip style: !which fuel, tip style fuel: acetylene: #how do i say acetylene is the preferred fuel? least heat dispersion tip style: - one-piece straight tip - one-piece divergent tip feed rate: 2.6 .. 20 in/min removal rate: 120 in^3/hr fuel consumption: 25 ft^3/hr oxygen consumption: 155 ft^3/hr propane: tip style: two-piece recessed tip feed rate: 2.5 .. 30 in/min #typo? removal rate: 130 in^3/hr fuel consumption: 11 ft^3/hr oxygen consumption: 167 ft^3/hr natural gas: tip style: two-piece recessed tip feed rate: 3 .. 20 in/min removal rate: 130 in^3/hr fuel consumption: 20 ft^3/hr oxygen consumption: 167 ft^3/hr MAPP gas: tip style: feed rate: 14 .. 30 in/min removal rate: 90 in^3/hr fuel consumption: 15 ft^3/hr oxygen consumption: 120 ft^3/hr workpiece material: carbon steel: machinability: typical: 3.3..3.7 stars feasible: 3..4 stars cast iron: machinability: feasible: 0.5..1.5 stars typical: 0.8..1.2 stars galvanized steel: machinability: feasible: 0 .. 1 stars typical: 0.3 .. 0.6 stars free machining steel: machinability: feasible: 0 .. 1 stars typical: 0.3 .. 0.6 stars safety: - hot parts - toxic fumes - sparks - ultraviolet radiation - flammable gases - compressed gases - smoke - open flame - explosive mixture laser cutting: !process name: laser beam cutting classification: shaping, mass-reducing, thermal, high energy beam machining mechanism: focused coherent light heats workpiece to melting or vaporization, then shielding gas blows the melted material out of the cut geometry: primitive: hyperboloid path: - parallel to workpiece face diameter: !which beam, diameter #hmmm. beam has no choices, i.e. this varies continuously tolerance: typical: +- 0.001in feasible: +- 0.0005in surface finish: typical: 125..250 microinch feasible: 100 .. 300 microinch consumables: cutting gas: power: !which workpiece material, power functionality: - drilling - straight cuts - irregular prismatic geometry - !which lasing material, functionality effects: - hardening - annealing - change in grain size parameters: beam: focal length: 1.5 .. 3 in #this varies significantly with material thickness diameter: typical: 0.004 .. 0.0125 in feasible: 0.0002 .. 0.2 in workpiece thickness: feasible: 0.004 .. 6 inch typical: 0.02 .. 0.5 inch cutting gas: oxygen: compressed air: nitrogen: argon: feed rate: !which workpiece material, feed rate #over typical thickness range, feed rate workpiece reflectivity: workpiece thermal conductivity: workpiece material: aluminum: power: 1000 .. 10000 W feed rate: 30 .. 800 in/min machinability: typical: 2.9..3.5 stars feasible: 0.2 .. 3.8 stars stainless: power: 250 .. 1000 W feed rate: 20 .. 750 in/min machinability: typical: 2.6..3.2 stars feasible: 0.6 .. 3.6 stars mild steel: power: 400 .. 500 W feed rate: 40 .. 177 in/min machinability: feasible: 2.5 .. 3.8 stars typical: 2.9 .. 3.3 stars wood: power: 50 .. 650W feed rate: #45 .. 180 in/min #this is wrong, 180 refers to 0.25" thickness, paper must be faster machinability: feasible: 2.3 .. 3.9 stars typical: 2.9 .. 3.5 stars titanium: power: 210 .. 250 W feed rate: 40 .. 300 in/min plastic: feed rate: #25 .. 60 in/min #this is also wrong power: 50 .. 100W #i made this up machinability: feasible: 2.1 .. 3.6 stars typical: 2.6 .. 3.3 stars lasing material: CO2: functionality: - scribing - engraving Nd: functionality: - high energy pulse - low repetition speed #(1 KHz)#huh? Nd-YAG: functionality: - very high energy pulse - engraving - trimming #wtf does this mean safety: - coherent infrared radiation - hot parts - toxic fumes - dust - compressed gases mig: !process name: MIG welding classification: shaping, joining, thermal, welding, electric arc, gas metal mechanism: a wire electrode surrounded by inert gas is heated to melting by an electric arc passing through it geometry: primitive: sphere post-operation: fillet edges diameter: !formula electrode rate*pi*(electrode diameter)^2/traverse rate #TODO unit check this formula tolerance: surface finish: typical: 250..1000 microinches feasible: 100..1100 microinches consumables: gas: !which shielding gas, flow rate electrode: !which weld geometry, feed rate power: !formula current * voltage functionality: !which shielding gas, functionality effects: - hardening - reduced fatigue strength - shrinkage - annealing - warpage - bad appearance - cracks - porosity - reduced corrosion resistance weldability: !which workpiece material, weldability parameters: workpiece thickness: feasible: 0.02..2.5in typical: 0.125..1in electrode material: #usually similar to workpiece material filler material: manganese silicon: shielding gas: carbon dioxide aluminum: shielding gas: helium or argon steel: shielding gas: carbon dioxide powder core: functionality: - specialized welding applications oxidizer: functionality: - rusty surfaces - semikilled steel - rimmed steel #what's this? workpiece material: mild steel: weldability: feasible: 2.4..3.7 stars typical: 2.8..3.3 stars cast iron: weldability: feasible: 1.3..3.1 stars typical: 2.1..2.5 stars stainless: weldability: feasible: 2.3..3.7 stars typical: 2.7..3.2 stars aluminum: weldability: feasible: 2.8..3.9 stars typical: 3.2..3.7 stars copper: weldability: feasible: 2.0..3.6 stars typical: 2.6..2.95stars magnesium: weldability: feasible: 2.6..3.6 stars typical: 3.2..3.5 stars titanium: weldability: feasible: 1.2..3.1 stars typical: 1.9..2.5 stars shielding gas: #gases can be mixed.. how to represent this? argon: functionality: - lower voltage - high quality - easy starting - stable arc helium: functionality: - high speed - small heat affected zone carbon dioxide: functionality: - good penetration - low cost - high speed weld geometry: #hmmm. i know it's in a book, but this is all wrong lap: traverse rate: 60ipm electrode rate: 234ipm electrode diameter: 0.0625in current: 380A butt: traverse rate: 7ipm electrode rate: 400ipm electrode diameter: 0.045in current: 275A tee: traverse rate: 16ipm electrode rate: 300ipm electrode diameter: 0.045in current: 200A edge: traverse rate: electrode rate: electrode diameter: corner: traverse rate: 10ipm electrode rate: 30..160ipm electrode diameter: 0.030in current: 80..85A circumferential corner: traverse rate: 45ipm electrode rate: 500ipm electrode diameter: 0.045in current: 280..300A circumferential modified butt: #wtf is this traverse rate: 46.6ipm electrode rate: 340..380ipm electrode diameter: 0.030 current: 170..190A current: voltage: traverse rate: !which weld geometry, traverse rate electrode rate: !which weld geometry, electrode rate electrode diameter: !which weld geometry, electrode diameter safety: - UV radiation - hot parts - smoke - sparks - metal fumes