The three basic categories of material removal processes are:
1. Machining : Processes in which a cutting tool is used to remove material from a workpiece, typically in the form of chips. Examples include turning, milling, drilling, and grinding.
2. Abrasive Processes : Processes that remove material through the action of hard, abrasive particles. Examples include grinding, honing, lapping, and abrasive jet machining.
3. Nontraditional Machining: Processes that remove material using various forms of energy (other than mechanical) such as electrical, chemical, thermal, or a combination of these. Examples include electrical discharge machining (EDM), laser cutting, and chemical machining.
Machining is commercially and technologically important for several reasons:
1. Precision and Accuracy: Machining can produce parts with very tight tolerances and fine finishes, which is crucial for many applications, especially in the aerospace, automotive, and medical device industries.
2. Versatility: Machining can be used on a wide range of materials, including metals, plastics, ceramics, and composites. It can also create a variety of shapes and features that are difficult or impossible to achieve with other manufacturing processes.
3. Complex Geometries: Machining allows the production of complex geometries and intricate details that are essential for many engineering components.
4. Prototyping: It is often used in prototyping because it allows for rapid iteration and testing of designs before committing to mass production methods.
5. Surface Finish: Machining processes can achieve superior surface finishes, which are important for both functional and aesthetic purposes.
6. Economic Viability for Small Batches: For low-volume production runs, machining is often more cost-effective compared to other manufacturing processes like casting or molding, which have higher initial setup costs.
7. Repair and Maintenance: Machining is essential for the repair and maintenance of equipment and machinery, enabling the replacement or reworking of worn or damaged parts.
8. Tool and Die Making: Machining is critical in the production of tools, dies, and molds used in various manufacturing processes, including injection molding and stamping.
