Machining

Vertical milling:

How it works:

1. Material is clamped into place
2. Cutter is selected and RPM is chosen
3. The material always remains stationary while the machines cutting tool rotates
4. As the cutting moves, it presses against the workpiece and shapes the material

Advantages	Disadvantages
Visibility - can see machine work Can be CNC controlled and so automated Ease of use Very precise	Uses electricity/needs to be plugged in Expensive to buy machines

Uses: Cutting gears, produce slots, drilling

Horizontal milling:

How it works:

1. Material is clamped into place
2. Cutter is selected and RPM is chosen
3. The material always remains stationary while the machines cutting tool rotates
4. As the cutting moves, it presses against the workpiece and shapes the material

Advantages	Disadvantages
Runs faster than vertical milling Very precise Can run at a higher capacity than vertical milling Durable machine - can do many runs No parting lines from mould	Not good at doing radial cuts Machinery takes up lots of space compared to handheld version Uses electrcity/needs to be plugged in More expensive machinery than vertical milling

Uses: Cuttings gears, produce slots, drilling

Routing:

How it works:

1. Material is clamped into place
2. Cutter is selected and RPM is chosen
3. The material always remains stationary while the machines cutting tool rotates
4. As the cutting moves, it presses against the workpiece and shapes the material

Advantages	Disadvantages
Quick process Low skilled Can be done via CNC	Uses electrcity/needs to be plugged in Handheld router can be dangerous if used improperly

Uses: Cabinets, doors

Drilling:

How it works:

1. Drill bit is selected and holes are marked up
2. Drill bit is fixed in the chuck and tightened using a chuck key
3. The table is set at a certain height and the RPM of the drill is chosen
4. The hand wheel is lowered to drill the hole

Advantages	Disadvantages
Quick Low skilled Cheap Can be automated easily	Drill can overheat if drill bit isn't sharp or at correct rotational speed Wood can be burnt Hole finish can be poor

Uses: Drilling holes for products, seperating pop rivets

Turning:

How it works:

1. Begin by placing a circular, square or rectangular shaped peice of metal/wood into the lathes drive area
2. The metal/wood piece is typically secured using a pressure pad
3. Once in place, the lathe is activated to rotate and press the mould against the metal/wood piece
4. The rotational force of the lathe then deforms the metal/wood piece to achieve the same shape as the mould
5. When metal/wood spinning is performed by hand, a worker manually presses the mould against metal/wood piece

Advantages	Disadvantages
Complex designs/shapes can be made Energy efficient Good surface finish Can be computer controlled	Dangerous pieces can be ejected from machine potentially causing harm Some materials are very hard to turn

Uses: Table legs, table lamp, engine parts, handles

Note: Turning machines are different depending on the material being used.

Stamping:

How it works:

1. Process is usually done via a CNC
2. The CNC program moves the platen carrying the sheet metal
3. Once the sheet metal is under the stamp the die is punched against the sheet metal
4. The waste material is then recycled and the stamped metal is collected

Advantages	Disadvantages
Economical Can be done many times very quickly Highly automated	Residual cracks appear along the edges Hardening along the edges Burrs can be created if clearance is excessive

Uses: Shape sheet metal into shapes with holes, washers, cogs, tin can pull tabs

Pressing:

How it works:

1. Metal is rolled out and straightened
2. Metal is cut to required blank size
3. The blank metal is clamped over the die and held in the correct position using the back gauge
4. A hydraulically operated punch is then pushed into the sheet metal
5. Once the desired shape is formed the punch is retracted and the sheet component is ejected

Advantages	Disadvantages
High strength in pressed parts Can be mass produced	Expensive set up costs Large runs are needed to be economical Can make product heavy

Uses: Shaping metal, patterns on metal trolley bases

Topic test: