DFMA for Turning

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Design recommendations

 Standard tool geometry should be incorporated at diameter transitions, grooves and chamfer areas.

It is preferred to keep the parts as short as possible to minimize the work deflection from the cutting tool.

 Irregular and interrupted cutting actions are to be avoided.

 When casting or forgings are designed with large shoulders or other areas to be faced, the surface should be 2 to 30 from the plane normal to the axis of the part. It provides edge relief to the cutting tool.

Sharp corners are to be avoided. The radius should be large and conform to standard tool nose radius specification. If possible leave the radius dimension to the discretion of the manufacturer. Provision of sharp corner and burrs are hazardous to the function of the part. These can be minimized by putting chamfers or curved surfaces at the intersection of the other surfaces. 

Clamping and locating region should be free from parting line, draft angles and forging flash. 

In case the part is to be tracer-turned, the turned contour should be designed for easy tracing with a minimum number of changes of stylus and cutting tool. Creating grooves with parallel or steep sidewalls are not possible in one operation. Undercuts should also to be avoided.

Dimensional control in turning

Achieving close dimensional limits in turning operation are inversely related to the size and length of work piece. If the dimensions are high the variations are more. 

Various factors which affect the proper working of the machine are machine vibration, deflection, thermal distortion and wear of the functional part. Other factors on this line part deflection, tool wear, measuring-tool accuracy and operator skills are other factors. 

Surface finish  is dependent upon the above factors. Further, surface finish is also directly related to the feed rate. 

DFMA for Turning - Boothroyd - Dewhurst DFMA Software Case Study

https://www.dfma.com/support/Downloads/MachiningFull.pdf