title = "Machining Overview: Processes and Selection Criteria"

content = """
Machining encompasses a broad family of manufacturing processes that remove material from a workpiece to achieve a desired shape, dimension, and surface finish. At Ridgecrest Metalworks, machining operations transform forged, cast, or rolled metal stock into finished components meeting precise dimensional and surface specifications.

The primary machining processes include turning (workpiece rotates against a stationary cutting tool), milling (rotating cutter moves against a stationary or fed workpiece), drilling (rotating tool creates cylindrical holes), grinding (abrasive wheel removes small amounts of material at very high surface speeds), and finishing operations such as honing, lapping, and superfinishing.

Process selection depends on several factors. Part geometry is the primary driver: rotational symmetry favors turning; flat and prismatic features favor milling; holes favor drilling or boring; very tight tolerances and fine finishes require grinding or honing. Material machinability influences process selection and parameter setting—free-machining steels (sulfurized grades like 12L14) cut easily with high speeds and long tool life; stainless steels, titanium, and hardened materials require lower speeds, more rigid setups, and appropriate tooling.

Required tolerance and surface finish determine the number of operations. Rough machining removes the bulk of material quickly with high material removal rates and lower precision. Semi-finish operations refine dimensions. Finish operations achieve final tolerance (±0.001 inch or tighter) and surface finish (Ra 16–63 microinch or better). Grinding and honing achieve the finest tolerances and finishes.

Workholding is critical to machining accuracy. Parts must be located (positioned) and clamped rigidly without distorting the workpiece. Standard workholding includes vises, chucks, collets, fixtures, and face plates. Setup time is a major component of machining cost for small runs.

At Ridgecrest, process planning (routing) specifies the sequence of machining operations, tooling, speeds, feeds, and inspection points for each part number. Floor operators follow the route card but are expected to recognize when deviations (tool wear, raw material variation, setup error) require supervisor notification. Correct sequencing—roughing before finishing, holding datum surfaces through the process—is essential to meeting final part specifications.
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