When designing and manufacturing new parts, there are many factors to keep in mind to make the project a success. The company hopes that new parts can be designed and manufactured as efficiently as possible to keep production costs optimal. In order to achieve this, designers need to optimize the digital model of the new machining center and lathe to machine parts.
Each part has features essential to its operation, but other aspects of the design may need to be simplified or omitted. In some cases, designers include unnecessary features and geometric figures out of habit or because they do not realize how this will affect the complexity of production. This article will delve into such issues and how part designers can simplify manufacturing by optimizing CNC milling and turning designs.
Potential design issues
CNC machines make a wide range of parts, from plastic toys to aircraft landing gear components. Companies use CNC machining for manufacturing because it allows them to create complex geometries and shapes in a precise manner. However, different machines and tools have some limitations, which may surprise designers if they are not prepared.
CNC milling tools have a cylindrical design like drills, and their shape limits the geometric shapes they create. Designers who use large tools to create sharp corners may get design for manufacturability (DFM) feedback that the function is not manufacturable as designed.
When machining parts, milling tools also have depth and direction limitations. Designers who create overly complex internal geometries may mark their parts as DFM errors.
The tools of CNC lathes can only run within a specific range of motion. For parts with more complex geometries, the machining shop will use lathes with powered tools or multiple machining operations.
To avoid such problems, please optimize the design to improve manufacturing efficiency.
Seven keys to optimize CNC milling and turning design
Designers should consider the following seven points to ensure that the design has the best compatibility with CNC milling and lathes before submitting for manufacturing:
Integrate your tool and artifact settings
Every time a CNC machine requires a new tool or a machinist must reposition the workpiece in the workpiece fixture or milling machine, production slows down. Although this extra time may not be a problem when producing limited prototype parts, it may end up spending a lot of time and money in the mass production process.
Limit cavity depth
The designer should limit the cavity depth to four times the diameter of the cutting tool. The greater the depth, the more time and cost required for special tools or more expensive processes. Avoid sharp inner corners
The milling tool will leave a fillet in the cavity equal to the diameter of the tool. Smaller tools can reduce these diameters, but this increases the time required for machining. For manufacturing efficiency, it is best to design rounded inner corners with a larger radius to minimize the number of tool changes.
Use standard tolerances whenever possible
It is best to limit the number of tight tolerances in the design and specify only those required for key features. Each unique tolerance specified in the design increases manufacturing time and cost.
Combine standard size holes
Non-standard features, such as holes less than 2.5 mm in diameter, will increase the time required to manufacture parts. If possible, it is best to use standard-sized holes to reduce time and cost in the design (unless non-standard features are required).
Avoid thin walls as much as possible
In order to avoid vibration and integrity problems during the processing of parts, please avoid cavities separated by thin walls. Metal walls are thinner than 0.8 mm, plastics are thinner than 1.5 mm, and the processing speed is slower, which reduces accuracy and increases production time.
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Keep threaded holes shallow
The machine shop found threaded holes to be challenging, so designers should minimize their use. When threaded holes are required, keep the thread length to a minimum. The bolt only needs to turn three turns to hold it firmly, and a deeper screw will make the tap face a greater risk of breakage during processing.
You can also help optimize CNC milling and turning designs by choosing materials wisely. Material properties, such as hardness and weight, need to be balanced with its workability. For example, the machine shop can cut aluminum faster than harder metals, making it a more effective choice. However, depending on the application of the part, aluminum may not be the best choice.
A certified machining shop can advise on design decisions and optimize parts for CNC machining.
What can you expect from your mechanical workshop to help design optimization
The CNC machining shop wants the design to be as successful as its customers. They use automation tools and manufacturing expertise to help design optimization:
DFM feedback: A reputable machining shop will provide you with manufacturability design feedback, highlighting any problem areas in the part that are difficult to manufacture. Consultation with your suppliers will help you make better decisions to balance your design priorities and manufacturing costs.
Online parts ordering system: Many machining shops now use online parts requesting systems for their customers. The customer uploads the CAD model to the evaluation system, which will provide immediate feedback on the manufacturability of the part. If the store finds a problem with the design, or if the parts are acceptable, the customer can make changes and complete the order. This method saves a lot of time from the old and more traditional paper parts request process. In addition, the automatic evaluation system will point out problems that the designer can correct before submitting the part for production.
Engineering representatives: Some mechanical workshops use sales representatives with engineering knowledge to help their customers make the best design choices. You can optimize your design by answering key questions before submitting parts for production, from material selection to documentation requirements.
