Intro

Question 1

The machining processes described in the first part involved material removal by mechanical means of chip removal, abrasion or microchipping. What are the reasons why these mechanical methods are not satisfactory, economical or possible?

Answer 1

• the strength and hardness of the workpiece material is very high, typically above 400HB
• material may be too brittle to be machines without damage- typically the case with highly heat treated alloys, glass, ceramics and powder metallurgy parts
• workpiece is too flexible or slender to withstand forces involved in machining or grinding, or the parts too difficult to clamp in fixtures and workholding devices
• part has complex shape
• has special surface finish and dimensional tolerance requirements
• the temp rise during processing and residual stress developed in the workpiece are not acceptable