| blob | 2f9eb8168371312ef55455ed30f650065269d76b |
1 author: 'ben lipkowitz'
2 license: 'GPL2+'
3 urls:
4 - 'http://heybryan.org/mediawiki/index.php/Skdb'
5 - 'http://fennetic.net/git/gitweb.cgi?p=skdb.git;a=blob_plain;f=materials.yaml'
6 - 'git://fennetic.net/git/skdb.git/'
7 source: manufacturing processes reference guide, 1993 first edition. todd, allen, and alting.
9 template: !process
10 name:
11 classification:
12 mechanism:
13 geometry:
14 tolerance:
15 surface finish:
16 consumables:
17 functionality:
18 parameters:
19 safety:
22 abrasive jet: !process #eventually this will be something like skdb.Shaping.Reducing.Mechanical
23 name: abrasive jet machining
24 mechanism: compressed air accelerates abrasive particles toward the workpiece
25 functionality:
26 - finishing
27 - hole drilling
28 - deburring
29 - prismatic geometry
30 - tapered geometry
31 machinability: !which workpiece material, machinability
32 removal rate:
33 typical: 0.003.. 0.0007in/min #what exactly does this refer to?
34 feasible: 0.0001 .. 0.002in/min
35 geometry:
36 primitive: cone #!geometry #what angle?
37 path:
38 - parallel to workpiece face
39 tolerance:
40 typical: +-0.005in
41 feasible: +-0.001in
42 surface finish: #arithmetic average
43 typical: 6..48 microinch
44 feasible: 4..64 microinch
45 consumables:
46 nozzle: &orifice
47 tungsten carbide:
48 life: 12..30hr
49 sapphire:
50 #this should work, but it doesn't?
51 # life: !range
52 # min: 300hr
53 abrasive: 1..25g/min
54 #this really should be something like "compressed air: 4.5..7cfm"
55 power: 0.5..4 hp #power = cfm * pressure is dependent on pressure and diameter
56 parameters: #"factors affecting process results"
57 pressure: 25..130psi
58 orifice diameter: 0.005..0.05in
59 nozzle distance: 0.03..0.6 in
60 nozzle angle:
61 workpiece size:
62 typical: 5..50 in^2
63 feasible: 0.2 .. 100 in^2 #workpiece size is only limited by enclosure
64 workpiece material: &machinability
65 #on a scale of 0 to 4 representing process quality and/or ease of use
66 #need to figure out a new unit 'stars' representing this
67 ceramic:
68 machinability: 2.25 .. 3.75 stars
69 germanium:
70 machinability: 2.2 .. 3.5 stars
71 glass:
72 machinability: 2.2 .. 3.8 stars
73 mica:
74 machinability: 1.9 .. 3.4 stars
75 silicon:
76 machinability: 2.3 .. 3.8 stars
77 steel:
78 machinability: 1.1 .. 2.5 stars
79 aluminum:
80 machinability: 0.4 .. 1.6 stars
81 abrasive material:
82 aluminum oxide:
83 functionality:
84 - cutting
85 - hard materials
86 diameter: 10 .. 50 microns
87 silicon carbide:
88 functionality:
89 - fast cutting
90 - hard materials
91 - ceramics
92 diameter: 25 .. 50 microns
93 glass beads:
94 functionality:
95 - deburring
96 - light cleaning #how do i parameterize this with dimensional units?
97 - polishing
98 diameter: 0.025 .. 0.05in
99 sodium bicarbonate:
100 functionality:
101 - cleaning
102 calcium compounds:
103 functionality:
104 - light cleaning
105 - light etching
106 magnesium compounds:
107 functionality:
108 - light cleaning
109 - light etching
110 safety:
111 - airborne dust
112 - flying particles
113 - abrasion
114 - toxic dust
116 arbor milling: !process
117 name: arbor milling #really this is just endmilling supported at both ends and you can stack cutters
118 classification: process, shaping, mass-reducing, mechanical, reducing, multi-point, milling
119 mechanism: rotating toothed cutter supported axially at both ends is fed into the workpiece at a controlled rate
120 geometry: #!geometry
121 primitive: revolute #like a candlestick. used to calculate swept volume of tool path
122 path:
123 - path perpendicular to axis
124 - axis parallel to workpiece opposite face
125 #cutters can be ganged.. where do i put this?
126 length:
127 typical: 0.2..5in
128 feasible: &width_of_cut 0.03..20in
129 radius:
130 typical: 1.5 .. 10in
131 tolerance:
132 typical: +-0.005
133 feasible: +-0.001
134 surface finish:
135 typical: 64..200 microinch
136 feasible: 32..500 microinch
138 unit power: !which workpiece material, unit power
139 consumables:
140 power: !formula unit power * removal rate
141 tool:
142 life: !which tool material, life
143 lubricant: !which lubrication, lubricant #how long does each lubricant last? where do i get this info?
144 functionality:
145 - roughing
146 - prismatic geometry
147 - !which tool material, functionality #hmm
148 machinability: !which workpiece material, machinability
149 effects:
150 - surface stress
151 - untempered martensitic layer 0.001in in heat treated alloy steels #blargh
152 parameters:
153 depth of cut:
154 typical: 0.05 .. 0.25in
155 feasible: 0.004 .. 1in
156 width of cut: *width_of_cut
157 rotation direction vs feed: #surely there's a name for this
158 #clockwise rotating cutter by default; a counterclockwise cutter reverses this
159 - conventional
160 - climb
161 feed per tooth: 0.005 .. 0.010in/tooth
162 surface speed: 30 .. 500 feet/min #see materials
163 lubrication: !which workpiece material, lubrication
164 workpiece hardness:
165 typical:
166 max: Rockwell C25 #joy~~ how about some real units
167 rigidity: #this includes the machine, workpiece, clamps, and tool bit rigidity
168 static: #mostly affects deflection or absolute uncompensated accuracy
169 dynamic: #affects maximum cutting rate vs surface finish, tool life, etc
170 tool geometry: !which workpiece material, tool geometry
171 tooth count:
172 typical: 10 .. 20 teeth/rev #i just made up these values
173 feasible: 1 .. 200 teeth/rev #ditto
174 tool sharpness: #units??
175 tool material:
176 high speed steel:
177 functionality:
178 - special geometry
179 - low production
180 carbide insert:
181 functionality:
182 - high production
183 ceramic insert:
184 functionality:
185 - high speed machining
186 - high production
187 - uninterrupted cuts
188 diamond insert:
189 functionality:
190 - high surface finish
191 - low tolerance
192 - nonferrous materials
193 workpiece material:
194 aluminum:
195 tool geometry: #!multipoint_rotating_cutter
196 teeth: !which tooth count #blarg
197 axial rake: 12 .. 25 deg
198 radial rake: 10 .. 20 deg
199 axial relief: 5 .. 7 deg
200 radial relief: 5 .. 11 deg
201 unit power: 0.3 hp/in^3
202 hardness:
203 typical: 70 .. 125 brinell
204 feasible: 30 .. 150 brinell
205 machinability:
206 typical: 2.6 .. 3.2 stars
207 feasible: 2.2 .. 3.7stars
208 lubricant:
209 - none
210 - mineral oil
211 - fatty oil
212 brass:
213 tool geometry:
214 axial rake: 12 .. 25 deg
215 radial rake: 10 .. 20 deg
216 axial relief: 5 .. 7 deg
217 radial relief: 5 .. 11 deg
218 unit power: 0.6 .. 1.0 hp/in^3
219 hardness:
220 typical: 60..100brinell
221 feasible: 50..240 brinell
222 machinability:
223 feasible: 2.1 .. 3.6 stars
224 typical: 2.6 .. 3.1 stars
225 lubricant:
226 - mineral oil
227 - specialty fluid #wtf??
228 cast iron:
229 tool geometry:
230 axial rake: 10 .. 12 deg
231 radial rake: 10 .. 20 deg
232 axial relief: 2 .. 4 deg
233 radial relief: 3 .. 7 deg
234 unit power: 0.6 .. 1.1 hp/in^3
235 hardness:
236 typical: 250..320 brinell
237 feasible: 110 .. 320brinell
238 machinability:
239 feasible: 2 .. 3 stars
240 typical: 2.3 .. 2.6 stars
241 lubricant:
242 - soluble oil
243 - chemical oil
244 - synthetic oil
245 - none
246 mild steel:
247 tool geometry:
248 axial rake: 10 .. 15 deg
249 radial rake: 10 .. 15 deg
250 axial relief: 3 .. 5 deg
251 radial relief: 4 .. 8 deg
252 unit power: 1.1.. 2.1 hp/in^3
253 hardness:
254 typical: 275..325 brinell
255 feasible: 85..560 brinell
256 machinability:
257 feasible: 2.1 .. 3
258 typical: 2.3 .. 2.6
259 lubricant:
260 - chemical oil
261 - syntheic oil
262 - soluble oil
263 stainless steel:
264 tool geometry:
265 axial rake: 10 .. 12 deg
266 radial rake: 5 .. 10 deg
267 axial relief: 3 .. 5 deg
268 radial relief: 4 .. 8 deg
269 unit power: 1.4 .. 1.5hp/in^3
270 hardness:
271 typical: 275..325 brinell
272 feasible: 135..430 brinell
273 machinability:
274 feasible: 0.3 .. 2.4 stars
275 typical: 0.8 .. 1.5 stars
276 lubricant:
277 - sulfurized mineral oil
278 - fatty soluble oil
279 - chemical oil
280 - synthetic oil
281 plastic:
282 tool geometry:
283 axial rake: 18 deg
284 radial rake: 15 deg
285 axial relief: 6 deg
286 radial relief: 8 deg
287 hardness:
288 unit power: 0.05hp/in^3
289 machinability:
290 feasible: 2 .. 3.8 stars
291 typical: 2.5 .. 3.2 stars
292 lubricant:
293 - mineral oil
294 - soluble oil
295 - cold air
296 - none
297 safety:
298 - 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
299 - hot chips #todo: calculate the energy in a typical hot chip
300 - sharp chips
301 - toxic fluids
303 band filing: !process
304 #there really wasn't much data on this
305 name: band filing
306 classification: shaping, mass reducing, mechanical, reducing, multi-point, filing
307 mechanism: a prismatic multipoint cutter mounted on a metal belt is fed into the work
308 geometry:
309 primitive: prism
310 path:
311 - under 90 degrees to previous segment #direction of cutting really depends on the tool bit geometry
312 - axis perpendicular to workpiece opposite face
313 tolerance:
314 surface finish: "fine"
315 functionality:
316 - irregular prismatic geometry
317 - deburring
318 - squaring edges
319 - finishing
320 consumables:
321 tool:
322 life:
323 parameters:
324 tool geometry: #this needs work, should conform to !multipoint_cutter eventually
325 - flat (square)
326 - triangle
327 - half oval
328 - half cylinder
329 tooth count: 10..24 teeth/in
330 safety:
331 - particulate material
332 - moving belt
334 band sawing: !process
335 name: band sawing
336 classification: shaping, mass-reducing, mechanical, reducing, multipoint, sawing
337 mechanism: a moving flexible tensioned metal loop with teeth is fed into the workpiece at a controlled rate
338 geometry:
339 primitive: rectangle
340 path:
341 - roll = 90 deg
342 - perpendicular to rectangle or tangent arc
343 - geometry must extend above and below workpiece
344 - !formula arc radius > something * blade width
345 tolerance:
346 typical: 0.05 .. 0.1 in
347 feasible: 0.02 .. 0.3 in
348 surface finish:
349 consumables:
350 tool:
351 lubricant:
352 functionality:
353 - narrow kerf
354 - single angle cuts
355 - !which tooth shape, functionality
356 - !which blade width, functionality
357 parameters:
358 teeth in contact with work: #!range #FIXME
359 min: 2 teeth #bleh
360 tooth count: 4..28 teeth/in
361 tooth shape:
362 precision:
363 functionality:
364 - finishing
365 buttress:
366 functionality:
367 - roughing
368 - parting
369 - high chip load
370 claw:
371 functionality:
372 - chip clearance
373 - fast cuts
374 blade width:
375 thin:
376 functionality:
377 - irregular prismatic shape
378 - curved cuts
379 thick:
380 functionality:
381 - straight cuts
382 - parting
383 blade thickness:
384 blade tension:
385 lubricant:
386 - none
387 - soluble oil
388 - cutting oil
389 safety:
390 - moving belt
391 - moving blade
392 - particulate material
394 internal broaching: &internal_broaching !process
395 name: internal broaching
396 classification: shaping, mass-reducing, mechanical, reducing, multi-point, broaching
397 mechanism: a tapered cutter is fed into a hole in one pass
398 geometry:
399 primitive: prismatic or helical
400 path:
401 - axis parallel to workpiece face
402 - helix angle < 20 deg #yah i made this up.. isnt a tap just a helical broach?
403 tolerance:
404 typical: +-0.002in
405 feasible: +-0.0005
406 surface finish:
407 typical: 16..63 microinch
408 feasible: 8..125 microinch
409 consumables:
410 tool:
411 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
412 requirements: #do i even need this?
413 - pre-existing hole
414 functionality:
415 - heat treated parts
416 - low production
417 - roughing
418 - finishing
419 - internal prismatic geometry
420 - low angle internal helical geometry
421 - keyways
422 - !which tool material, functionality
423 machinability: !which workpiece material, machinability
424 effects:
425 - welding tool and workpiece
426 - work hardening
427 parameters:
428 diameter:
429 typical: 0.125 .. 6 in
430 feasible: 0.04 .. 12 in
431 surface speed: !which material, surface speed
432 rigidity:
433 alignment:
434 lubricant: !which workpiece material, lubricant
435 feed per tooth: !which workpiece material, feed per tooth
436 tool geometry: !which workpiece material, tool geometry
437 hardness: !which workpiece material, hardness
438 tool material:
439 high speed steel:
440 functionality:
441 - low production
442 - irregular internal prismatic geometry
443 - irregular internal helical geometry
444 workpiece material:
445 aluminum:
446 feed per tooth: 0.005..0.007in/tooth
447 lubricant:
448 - kerosene
449 - mineral oil
450 - sulfurized mineral oil
451 tool geometry:
452 rake: 10 .. 15 deg
453 clearance: 1 .. 3 deg
454 hardness: 30 .. 150 brinell
455 machinability:
456 typical: 2.8 .. 3.2 stars
457 feasible: 2.2 .. 3.7 stars
458 brass:
459 feed per tooth: 0.004..0.005in/tooth
460 lubricant:
461 - water
462 - soluble oil
463 - mineral lard oil
464 tool geometry:
465 rake: -5 .. 5 deg
466 clearance: 1 .. 3 deg
467 hardness: 40 .. 200 brinell
468 machinability:
469 typical: 2.7 .. 3.2 stars
470 feasible: 2.1 .. 3.6 stars
471 cast iron:
472 feed per tooth: 0.002..0.005in/tooth
473 lubricant:
474 - water
475 - soluble oil
476 - sulfurized mineral oil
477 tool geometry:
478 rake: 6..15 deg
479 clearance: 2 .. 3 deg
480 hardness:
481 typical: 120 .. 320 brinell
482 feasible: 110 .. 400 brinell
483 machinability:
484 feasible: 2 .. 3 stars
485 typical: 2.3 .. 2.5 stars
486 mild steel:
487 feed per tooth: 0.003..0.004in/tooth
488 lubricant:
489 - water
490 - soluble oil
491 - sulfurized mineral oil
492 - mineral lard oil
493 tool geometry:
494 rake: 15..20 deg
495 clearance: 1..3 deg
496 hardness:
497 typical: 100..275 brinell
498 feasible: 85 .. 375 brinell
499 machinability:
500 feasible: 2.1 .. 3 stars
501 typical: 2.3 .. 2.5 stars
502 stainless:
503 feed per tooth: 0.002..0.003in/tooth
504 lubricant:
505 - water
506 - soluble oil
507 - sulfurized mineral oil
508 - mineral lard oil
509 tool geometry:
510 clearance: 0.5 .. 3 deg
511 rake: 8 .. 18 deg
512 hardness:
513 typical: 135 .. 375 brinell
514 feasible: 135 .. 440 brinell
515 machinability:
516 feasible: 0.3 .. 2.4 stars
517 typical: 0.7 .. 1.5 stars
518 plastics:
519 machinability:
520 feasible: 2 .. 3.7 stars
521 typical: 2.5 .. 3.2 stars
522 safety:
523 - reciprocating cutter
524 - hot chips
525 - sharp chips
526 - toxic fluids
527 - flying broken cutter
529 external broaching: !process
530 name: external broaching
531 classification: shaping, mass-reducing, mechanical, reducing, multi-point, broaching
532 mechanism: a tapered cutter is fed across a workpiece in one pass
533 similar: *internal_broaching
534 functionality:
535 - heat treated parts
536 - low production
537 - roughing
538 - finishing
539 - prismatic geometry
540 - low angle external helical geometry
541 - gear teeth
542 - irregular prismatic geometry
543 - slot cuts
544 - !which tool material, functionality
545 parameters:
546 width:
547 typical: 0.075 .. 10in
548 feasible: 0.02 .. 20in
549 tool material:
550 high speed steel:
551 functionality:
552 - low production
553 - irregular prismatic geometry
554 carbide insert:
555 functionality:
556 - high production
557 - prismatic geometry
558 - high hardness
560 superfinishing: !process #somehow i think there isnt quite enough info here
561 name: superfinishing
562 classification: shaping, mass-reducing, mechanical, reducing, abrasive #is this right?
563 mechanism: abrasive surface and oil act as hydrodynamic bearing; surface asperities contact abrasive and are cut
564 geometry:
565 primitive: cylinder or sphere or cone or plane
566 path:
567 - colinear with workpiece face axis #superfinishing just makes a cylinder "more cylindrical" etc
568 tolerance: -0.0002 .. -0.0008in
569 effect: removes smeared surface layer
570 surface finish:
571 typical: 2 .. 8 microinch
572 feasible: 0 .. 30 microinch
573 rate: 10..40 in^2/min
574 consumables:
575 abrasive:
576 functionality:
577 - high precision
578 - wear resistance
579 - bearing surfaces
580 parameters:
581 periodicity: #how the heck do i represent this
582 surface speed: 50 .. 60 feet/min
583 pressure: 10 .. 40 psi
584 lubricant:
585 - oil
586 - water
587 workpiece surface finish: 30..200 microinch #i made this up.. chrysler recommends rough grinding prior to surface finishing
588 safety:
589 - abrasive fluid
590 - rotating parts
592 gas cutting: !process
593 name: gas flame cutting
594 classification: shaping, mass-reducing, thermal, torch cutting, gas cutting
595 mechanism: ferrous workpiece is heated and then oxidized. gas flow then blows the liquid metal out of the cut
596 geometry:
597 primitive: cylinder
598 path:
599 - parallel to workpiece face
600 diameter: 1/16 .. 1/4 in #kerf
601 tolerance:
602 typical: +- 1/8 in
603 feasible: +- 1/32 in
604 surface finish:
605 typical: 250..1000 microinches
606 feasible: 100..1100 microinches
607 consumables:
608 fuel consumption: !which fuel, fuel consumption
609 oxygen consumption: !which fuel, oxygen consumption
610 torch tip:
611 functionality:
612 - straight cuts
613 - parting
614 - roughing
615 - irregular prismatic geometry
616 - angular cuts
617 - ferrous materials > 3/8 inch thickness
618 effects:
619 - distortion
620 - annealing
621 - microcracks
622 - residual stress
623 - surface embrittlement
624 - oxidation
625 heat affected zone: #no mention?
626 parameters:
627 workpiece thickness:
628 typical: 0.125 .. 12in
629 feasible: 0.05 .. 60in #wow
630 oxidizer pressure: 20 .. 50 psi
631 fuel pressure: 3 .. 7 psi
632 feed rate: !which fuel, feed rate
633 temperature: tempf(1400)..tempf(1600)
634 tip style: !which fuel, tip style
635 fuel:
636 acetylene: #how do i say acetylene is the preferred fuel? least heat dispersion
637 tip style:
638 - one-piece straight tip
639 - one-piece divergent tip
640 feed rate: 2.6 .. 20 in/min
641 removal rate: 120 in^3/hr
642 fuel consumption: 25 ft^3/hr
643 oxygen consumption: 155 ft^3/hr
644 propane:
645 tip style: two-piece recessed tip
646 feed rate: 2.5 .. 30 in/min #typo?
647 removal rate: 130 in^3/hr
648 fuel consumption: 11 ft^3/hr
649 oxygen consumption: 167 ft^3/hr
650 natural gas:
651 tip style: two-piece recessed tip
652 feed rate: 3 .. 20 in/min
653 removal rate: 130 in^3/hr
654 fuel consumption: 20 ft^3/hr
655 oxygen consumption: 167 ft^3/hr
656 MAPP gas:
657 tip style:
658 feed rate: 14 .. 30 in/min
659 removal rate: 90 in^3/hr
660 fuel consumption: 15 ft^3/hr
661 oxygen consumption: 120 ft^3/hr
662 workpiece material:
663 carbon steel:
664 machinability:
665 typical: 3.3..3.7 stars
666 feasible: 3..4 stars
667 cast iron:
668 machinability:
669 feasible: 0.5..1.5 stars
670 typical: 0.8..1.2 stars
671 galvanized steel:
672 machinability:
673 feasible: 0 .. 1 stars
674 typical: 0.3 .. 0.6 stars
675 free machining steel:
676 machinability:
677 feasible: 0 .. 1 stars
678 typical: 0.3 .. 0.6 stars
679 safety:
680 - hot parts
681 - toxic fumes
682 - sparks
683 - ultraviolet radiation
684 - flammable gases
685 - compressed gases
686 - smoke
687 - open flame
688 - explosive mixture
690 laser cutting: !process
691 name: laser beam cutting
692 classification: shaping, mass-reducing, thermal, high energy beam machining
693 mechanism: focused coherent light heats workpiece to melting or vaporization, then shielding gas blows the melted material out of the cut
694 geometry:
695 primitive: hyperboloid
696 path:
697 - parallel to workpiece face
698 diameter: !which beam, diameter #hmmm. beam has no choices, i.e. this varies continuously
699 tolerance:
700 typical: +- 0.001in
701 feasible: +- 0.0005in
702 surface finish:
703 typical: 125..250 microinch
704 feasible: 100 .. 300 microinch
705 consumables:
706 cutting gas:
707 power: !which workpiece material, power
708 functionality:
709 - drilling
710 - straight cuts
711 - irregular prismatic geometry
712 - !which lasing material, functionality
713 effects:
714 - hardening
715 - annealing
716 - change in grain size
717 parameters:
718 beam:
719 focal length: 1.5 .. 3 in #this varies significantly with material thickness
720 diameter:
721 typical: 0.004 .. 0.0125 in
722 feasible: 0.0002 .. 0.2 in
723 workpiece thickness:
724 feasible: 0.004 .. 6 inch
725 typical: 0.02 .. 0.5 inch
726 cutting gas:
727 oxygen:
728 compressed air:
729 nitrogen:
730 argon:
731 feed rate: !which workpiece material, feed rate #over typical thickness range, feed rate
732 workpiece reflectivity:
733 workpiece thermal conductivity:
734 workpiece material:
735 aluminum:
736 power: 1000 .. 10000 W
737 feed rate: 30 .. 800 in/min
738 machinability:
739 typical: 2.9..3.5 stars
740 feasible: 0.2 .. 3.8 stars
741 stainless:
742 power: 250 .. 1000 W
743 feed rate: 20 .. 750 in/min
744 machinability:
745 typical: 2.6..3.2 stars
746 feasible: 0.6 .. 3.6 stars
747 mild steel:
748 power: 400 .. 500 W
749 feed rate: 40 .. 177 in/min
750 machinability:
751 feasible: 2.5 .. 3.8 stars
752 typical: 2.9 .. 3.3 stars
753 wood:
754 power: 50 .. 650W
755 feed rate: #45 .. 180 in/min #this is wrong, 180 refers to 0.25" thickness, paper must be faster
756 machinability:
757 feasible: 2.3 .. 3.9 stars
758 typical: 2.9 .. 3.5 stars
759 titanium:
760 power: 210 .. 250 W
761 feed rate: 40 .. 300 in/min
762 plastic:
763 feed rate: #25 .. 60 in/min #this is also wrong
764 power: 50 .. 100W #i made this up
765 machinability:
766 feasible: 2.1 .. 3.6 stars
767 typical: 2.6 .. 3.3 stars
768 lasing material:
769 CO2:
770 functionality:
771 - scribing
772 - engraving
773 Nd:
774 functionality:
775 - high energy pulse
776 - low repetition speed #(1 KHz)#huh?
777 Nd-YAG:
778 functionality:
779 - very high energy pulse
780 - engraving
781 - trimming #wtf does this mean
782 safety:
783 - coherent infrared radiation
784 - hot parts
785 - toxic fumes
786 - dust
787 - compressed gases
790 mig: !process
791 name: MIG welding
792 classification: shaping, joining, thermal, welding, electric arc, gas metal
793 mechanism: a wire electrode surrounded by inert gas is heated to melting by an electric arc passing through it
794 geometry:
795 primitive: sphere
796 post-operation: fillet edges
797 diameter: !formula electrode rate*pi*(electrode diameter)^2/traverse rate #TODO unit check this formula
798 tolerance:
799 surface finish:
800 typical: 250..1000 microinches
801 feasible: 100..1100 microinches
802 consumables:
803 gas: !which shielding gas, flow rate
804 electrode: !which weld geometry, feed rate
805 power: !formula current * voltage
806 functionality: !which shielding gas, functionality
807 effects:
808 - hardening
809 - reduced fatigue strength
810 - shrinkage
811 - annealing
812 - warpage
813 - bad appearance
814 - cracks
815 - porosity
816 - reduced corrosion resistance
817 weldability: !which workpiece material, weldability
818 parameters:
819 workpiece thickness:
820 feasible: 0.02..2.5in
821 typical: 0.125..1in
822 electrode material:
823 #usually similar to workpiece material
824 filler material:
825 manganese silicon:
826 shielding gas: carbon dioxide
827 aluminum:
828 shielding gas: helium or argon
829 steel:
830 shielding gas: carbon dioxide
831 powder core:
832 functionality:
833 - specialized welding applications
834 oxidizer:
835 functionality:
836 - rusty surfaces
837 - semikilled steel
838 - rimmed steel #what's this?
839 workpiece material:
840 mild steel:
841 weldability:
842 feasible: 2.4..3.7 stars
843 typical: 2.8..3.3 stars
844 cast iron:
845 weldability:
846 feasible: 1.3..3.1 stars
847 typical: 2.1..2.5 stars
848 stainless:
849 weldability:
850 feasible: 2.3..3.7 stars
851 typical: 2.7..3.2 stars
852 aluminum:
853 weldability:
854 feasible: 2.8..3.9 stars
855 typical: 3.2..3.7 stars
856 copper:
857 weldability:
858 feasible: 2.0..3.6 stars
859 typical: 2.6..2.95stars
860 magnesium:
861 weldability:
862 feasible: 2.6..3.6 stars
863 typical: 3.2..3.5 stars
864 titanium:
865 weldability:
866 feasible: 1.2..3.1 stars
867 typical: 1.9..2.5 stars
868 shielding gas: #gases can be mixed.. how to represent this?
869 argon:
870 functionality:
871 - lower voltage
872 - high quality
873 - easy starting
874 - stable arc
875 helium:
876 functionality:
877 - high speed
878 - small heat affected zone
879 carbon dioxide:
880 functionality:
881 - good penetration
882 - low cost
883 - high speed
884 weld geometry: #hmmm. i know it's in a book, but this is all wrong
885 lap:
886 traverse rate: 60ipm
887 electrode rate: 234ipm
888 electrode diameter: 0.0625in
889 current: 380A
890 butt:
891 traverse rate: 7ipm
892 electrode rate: 400ipm
893 electrode diameter: 0.045in
894 current: 275A
895 tee:
896 traverse rate: 16ipm
897 electrode rate: 300ipm
898 electrode diameter: 0.045in
899 current: 200A
900 edge:
901 traverse rate:
902 electrode rate:
903 electrode diameter:
904 corner:
905 traverse rate: 10ipm
906 electrode rate: 30..160ipm
907 electrode diameter: 0.030in
908 current: 80..85A
909 circumferential corner:
910 traverse rate: 45ipm
911 electrode rate: 500ipm
912 electrode diameter: 0.045in
913 current: 280..300A
914 circumferential modified butt: #wtf is this
915 traverse rate: 46.6ipm
916 electrode rate: 340..380ipm
917 electrode diameter: 0.030
918 current: 170..190A
919 current:
920 voltage:
921 traverse rate: !which weld geometry, traverse rate
922 electrode rate: !which weld geometry, electrode rate
923 electrode diameter: !which weld geometry, electrode diameter
924 safety:
925 - UV radiation
926 - hot parts
927 - smoke
928 - sparks
929 - metal fumes