How to Process the Right Angle on Machined Parts

In mechanical processing, the right angle, as a fundamental and crucial geometric shape, has its processing techniques directly impacting product quality and production efficiency. Below is a detailed elaboration and comprehensive consideration of traditional processing methods and unique processes (such as Electrical Discharge Machining, EDM) in the context of right-angle processing:

I. Traditional Processing Methods

1. Turning: Turning involves the removal of material through the interaction of a rotating workpiece and a linearly moving cutting tool. When processing right angles, right-angle chucks or high-precision angle plates are often utilized to secure the workpiece, ensuring the accuracy of the processed angle. This method is particularly suitable for processing right-angle end faces on rotary symmetrical parts, such as shafts, featuring high efficiency and stability.
2. Milling: Milling is significant in right-angle processing due to its flexibility and efficiency. Utilizing right-angle milling cutters (90° main cutting edge angle) allows for precise control over the cutting path, creating features like square shoulders and grooves with right angles. By programming multi-axis control of milling machines, precise right-angle structures can be machined onto complex curved surfaces, catering to diverse processing needs.
3. Shaping and Slotting: Shaping and slotting involve gradually removing material through the repetitive insertion and withdrawal of cutting tools. They are particularly suitable for workpieces requiring high precision and numerous right-angled areas. Strict control over the tool's feed rate and cutting depth is crucial during this process to ensure precision and surface quality.
4. Grinding: Grinding utilizes the high-speed rotation and friction of grinding wheels or belts to refine workpiece surfaces, making it suitable for precise processing and polishing of geometric shapes like right angles. While grinding may be relatively slow and costly, it achieves exceptional precision and surface finish, making it an indispensable step in precision mechanical processing.

II. Special Process – Electrical Discharge Machining (EDM)

EDM, a non-contact processing technique, removes material through the high-temperature erosion caused by electrical discharge. It is ideal for processing high-hardness, high-toughness materials, and complex-shaped workpieces with right angles. Its high processing accuracy, excellent surface quality, and independence from material hardness provide effective solutions for scenarios where traditional methods falter. However, EDM's relatively slow processing speed and high equipment costs necessitate careful consideration based on specific processing requirements.

III. Selection of Processing Methods and Precautions

When selecting a right-angle processing method, comprehensive consideration should be given to the workpiece's material properties, dimensional requirements, precision standards, and the limitations of processing equipment. Precise measurement and calibration are essential for high-precision right-angle processing to ensure dimensional accuracy. Additionally, strict adherence to mechanical processing safety regulations is crucial to maintain the safety and stability of the processing process.

In conclusion, the processing methods for right angles in mechanical processing are diverse, with traditional techniques and unique processes, each having its strengths. In practical applications, the selection of processing methods should be flexible based on specific circumstances to achieve efficient and precise right-angle processing, meeting the demands of various fields for mechanical processing products.