Wasting Techniques – Consider a range of products to determine the methods of ‘wasting’ applied to achieve the required ‘forms’.

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The term wasting is used to describe those processes that produce waste by cutting bits out or cutting bits off. For example, sawing will produce saw dust. Waste is not always something that is discarded, it is increasingly more cost effective and responsible to look at the waste material as a recyclable commodity.


wasting processes include


Planing


Chiselling


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Sawing


Filing


Drilling


Centre lathe turning


Wood turning


Milling


Screw cutting


The action of cutting is in fact the same for all wasting processes. It can be linked to driving a wedge into the material causing the waste to split off. Tool cutting angles are important, tools work by tearing and then cleaning up the surface of the material that they are cutting. This is achieved by a combination of rake, cutting and clearance angles.


Looking around the home it may be seen that many items in which are formed have been wasted in order to require these forms. For example products such as bowls, dishes, spindles, legs and lamps which have been created using wood lathes. There is a very wide range of wood turning tools including scrapes, gouges and chisels. The tools are hand held against a rest that must be adjusted close to the work and at a height that suits the tool being used.


Almost any shape can be cut out of a solid mass of any material by some technique. If designers choose to use such a method in order to create their product, then their role is to facilitate the task so that it becomes cost effective. Every effort must be made to minimise the amount of material which needs to be removed and to simplify its removal. This means, were possible, designing around standard sections, conventional machinery, standard tooling and work holding assemblies. The design of special jigs and fixtures as part of the production process is quite common, but there must be a very clear justification.


When shapes are produced by removing material from a solid mass this is generally known as a ‘wasting technique’. In many cases it may be possible to use or recycle the material removed, but certainly the swarf produced from machining steels is difficult to reprocess. Wasting should not, however be thought of only in terms of the cutting of metals. Wood and plastics can be machined, clay jiggered, ceramics strickled, stone carved and metals can be shaped by electrical, chemical and sintered carbides as well as on the most brittle metals.


The problems associated with designing for a wasting technique can be considered in two areas firstly, how the material is going to be removed, and secondly, how the work piece is to be held, the tool manipulated and provided with power. These latter problems relate to the design of jigs, fixtures and machines. Although special jigs and fixtures might well be made up in order to produce quite a small quantity of components, building a special machine of any complexity can only be justified for very high production volumes. It is clearly essential for designed to develop an awareness of the capabilities of existing machines.


The methods available for removing materials can be categorised into four groups mechanical, electrical, chemical and thermal methods. Mechanical methods are by far the most common. Electrical methods find applications in working difficult materials and chemical methods in dealing with large components. Methods relying entirely on hear are used to cut shapes from metals and plastics are important production processes.


There are three main types of machine for shaping materials by wasting


Lathes


Milling machines


Drills


Lathes The centre lathe spins the work around and a tool or cutter is brought up to it. The process is called turning.


• Parallel turning produces cylindrical forms.


• Facing produces a flat surface.


• You can also use a centre lathe can to cut a screw or a thread.


Some centre lathes are controlled by a computer. This gives greater accuracy and enables boring, repetitive work to be done by machine. A system controlled by someone typing figures into a computer is called a CNC system (computer numerically controlled).


You can use a wood turning lathe for turning a spindle or making a bowl. Again, the work spins round and you shape the wood with a chisel.


Milling machines


In a milling machine or mill the cutter spins round, and you move the work past it. There are horizontal mills and vertical mills. CNC milling machines are widely used in industry.


Drills


You use the pillar drill for drilling accurate holes.


Many factories use multi-axis machines. These might have a selection of cutters and drills which can be used in turn, so that the work can be shaped in a number of ways in one machine. Usually these are controlled by computers. This is called CAM (computer aided manufacturing). If this is linked to CAD (computer aided designing), the whole system is called CAD/CAM.


Additional methods of wasting metals


• Eroding - Very accurate wasting can be done through spark erosion. This is also suitable for wasting very hard metals.


• Ultrasonic machining - Very accurate and suitable for very hard materials such as glass, ceramics and precious stone.





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