Materials, surface treatment and machining

Choosing steel, stainless, aluminium and engineering plastics; heat and surface treatment; choosing machining methods and designing parts that are manufacturable at the right cost.

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1. Materials #11: Aluminum A5052, A6061 and A7075 — Choosing by Machining, Welding and Strength — Compare aluminum grades A5052, A6061 and A7075 by machining, welding, bending, strength and corrosion, with a comparison table, T6/H32 temper and a checklist.
2. Materials #10: SUS303 vs. SUS304 – Which Stainless Should You Choose for a Machine Part? — SUS303 or SUS304? Compare machinability, welding, bending and corrosion resistance, with a checklist to choose the right stainless for a machine part.
3. Materials #09: SS400 vs. SS400-D – Pick the Wrong Steel and the Part Bows After Machining — Hot-rolled SS400 vs. cold-drawn SS400-D: surface, tolerance, residual stress, bowing after machining and how to choose the right steel for a machine part.
4. Materials #12: SKD11 and SKH51 — Choosing Steel for Wear-Resistant Parts — Compare tool steels SKD11 and SKH51 by hardness, wear resistance and hot hardness, with a comparison table, heat treatment, toughness, coating and a checklist.
5. Machine Design #63: Heat Treatment and Hardness — Do Not Stop at One HRC Number — MINATA guide to heat-treated part design: function, process, tolerance, inspection, failure modes, and maintenance evidence for dependable machines.
6. Materials #13: Anodizing, Plating or Powder Coating — Choosing by Environment and Tolerance Stack — Compare anodizing, plating and powder coating by base material, coating thickness (tolerance effect) and environment, with tables and a checklist.
7. Manufacturing Engineering #02: CNC Milling, Turning or Wire EDM — Choosing by Shape and Tolerance — Compare CNC milling, turning and wire EDM by geometry and achievable tolerance (IT6–IT9), with a comparison table, a drawing-reading example and a checklist.
8. Manufacturing Engineering #03: Laser, Plasma or Waterjet Cutting — Choosing by Material and Thickness — Compare laser, plasma and waterjet cutting by material, thickness, edge quality and heat-affected zone, with a comparison table, hidden costs and a checklist.
9. Manufacturing Engineering #04: Machining, Casting or Welded Fabrication — The Break-Even by Volume — Compare machining from solid, casting and welded fabrication by cost structure and break-even volume, with a comparison table, casting types and a checklist.
10. Machine Design #61: Blind Holes, Relief Grooves, and Square Corners — Design for the Real Tool Path — MINATA guide to machined feature design: function, process, tolerance, inspection, failure modes, and maintenance evidence for dependable machines.

Calculators and lookup tables

• Common Material Selection
• Hardness Conversion HRC / HV / HB
• Thermal expansion & shrink-fit calculator
• Workpiece weight calculator
• Cutting speed ↔ spindle speed
• Feed rate & machining time
• Cutting power & MRR
• Beam deflection & stress calculator
• Bolt Tightening Torque
• Bolt torque ↔ clamp force

Downloads

• Steel, Stainless and Aluminium Material Lookup Tables
• Bill of Materials (BOM) Template (部品表)

All articles in this topic (40)

• Materials #01: Alodine (Chromate Conversion) Surface Treatment for Aluminum Parts
• Materials #02: Alumite (Anodizing) Surface Treatment for Aluminum Parts
• Materials #03: Choosing a UV Silicone Adhesive that Meets UL94 V-0
• Materials #04: A Summary of STKR Square Steel Tube Standards
• Materials #05: What Is Nitriding (窒化処理)? Common Treatment Types in Machine Parts
• Materials #06: Choosing Stainless Steel for Machined Parts – Don't Default to SUS304
• Materials #07: What Is PEEK Plastic? When to Use It in Machine Parts
• Materials #08: Thermal Expansion Coefficient – How to Calculate and Design Notes for Machines
• Materials #09: SS400 vs. SS400-D – Pick the Wrong Steel and the Part Bows After Machining
• Materials #10: SUS303 vs. SUS304 – Which Stainless Should You Choose for a Machine Part?
• Materials #11: Aluminum A5052, A6061 and A7075 — Choosing by Machining, Welding and Strength
• Materials #12: SKD11 and SKH51 — Choosing Steel for Wear-Resistant Parts
• Materials #13: Anodizing, Plating or Powder Coating — Choosing by Environment and Tolerance Stack
• Manufacturing Engineering #01: The Role of 生産技術 in a Manufacturing Company
• Manufacturing Engineering #02: CNC Milling, Turning or Wire EDM — Choosing by Shape and Tolerance
• Manufacturing Engineering #03: Laser, Plasma or Waterjet Cutting — Choosing by Material and Thickness
• Manufacturing Engineering #04: Machining, Casting or Welded Fabrication — The Break-Even by Volume
• Manufacturing Engineering #05: How the Tolerance You Write Decides the Machining Cost — From IT7 to IT9
• Machine Design #06: Aluminum Extrusion Frame vs. Welded Steel Frame for Machine Bases
• Machine Design #24: What Is an Undercut? How to Recognize, Machine and Avoid Cost Increases
• Machine Design #27: 6 Sheet Metal Detail Design Mistakes When Cutting and Bending
• Machine Design #53: Plastic Parts — Design for Manufacturing, Assembly, and Long-Term Durability
• Machine Design #54: Choosing Aluminum for Parts and Frames — Do Not Call Every Grade “Aluminum”
• Machine Design #61: Blind Holes, Relief Grooves, and Square Corners — Design for the Real Tool Path
• Machine Design #62: Minimum Wall Thickness After Machining — Thinner Is Not Always Lighter or Cheaper
• Machine Design #63: Heat Treatment and Hardness — Do Not Stop at One HRC Number
• Machine Design #64: Surface Treatment — Select It by Function, Environment, and Tolerance Stack
• Machine Design #86: Standard Material Names — One Material Should Not Have Five Names
• Machine Design #87: Directional Materials — Face, Back, and Grain Must Follow the Part
• Machine Design #90: Matched Machining — When Two Parts Are Accurate Only If Made Together
• Machine Design #91: Matched-Set Parts — Do Not Replace Half of the Accuracy
• Machine Design #92: Split Parts — Accuracy Lives in the Joint Face and Tightening Method
• Machine Design #93: Draft Angle for Plastic Parts — Easy Release Must Preserve Function
• Machine Design #94: Plastic Wall Thickness — Uniformity Matters More Than Being Thick
• Machine Design #95: Plastic Ribs and Bosses — Add Stiffness Without Creating Sink Marks
• Machine Design #96: Inserts in Plastic Parts — Design the Small Joint for Heat and Force
• Machine Design #111: Welding, Bolting or Adhesive — Choosing the Joint by Load and Serviceability
• Device Selection #21: Aluminum Extrusion — Series 20, 30, 40 or 50 by Load
• Device Selection #23: Plate and Frame Material — Aluminum, Steel or Engineering Plastic
• Technical Japanese #15 — Mechanical Vocabulary: Materials, Machining, Welding and Surface Treatment

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