Optimum CNC machining is important for keeping components in
the best possible shape over time. Poor machining design causes CNC components
to wear out prematurely.
By avoiding design mistakes, you can delay repair needs at
your industrial or manufacturing facility as long as possible. The following
are eight design flaws to avoid for optimum CNC machining.
1. Excessively Small Features
Small features in your CNC design like micro-holes that are
under a couple of millimeters in diameter create problems because they make it
more difficult for equipment to execute accurate machining. Small features also
add to machining time.
You, therefore, should avoid small features in all CNC
machining designs at your facility except where they're absolutely necessary.
2. Deep Cavities
Another CNC machining design characteristic that creates
problems is deep cavities. Deep cavities in the workpiece are likely to
increase the occurrence of tool breakage. Broken tools increase the cost of
production due to the resulting repair and replacement expenses.
When it comes to milling cavities, the depth should not
exceed a few times the diameter of the tool for optimum design.
3. Tight Part Tolerances
Tighter part tolerances increase the costs of CNC machining
operations for several reasons. First off, they require the need for special
measurement tools. At the same time, they increase fixturing needs and the
amount of scrap that CNC machining work produces.
The function, form, and fit of individual parts all need to
result in an acceptable dimension range that is not excessively narrow.
Ideally, you shouldn’t specify tolerances if possible if you want to keep
machining labor costs down and speed up the machining process.
4. Improper Material for the Application
One of the most important considerations to take into
account when optimizing machining design is which material is used for the
workpiece.
You should consider numerous factors in choosing your
material, including chemical resistance, thermal stability, rigidity, and heat
responsiveness needs. A last consideration that is especially important is the
material thickness you need.
5. Excessively Thin Walls
CNC machining operations generally proceed with difficulty
if the walls of the workpiece are particularly thin. Thin walls complicate the
process because they require multiple passes and low cut depths that will take
more time and be more cumbersome.
Another issue with thin walls is that they are likely to
vibrate excessively, and vibration tends to decrease the accuracy of the
machining process.
6. Long Thread Lengths
As thread lengths get longer, the connection they provide
does not get any stronger. In fact, once threads exceed a certain length they
will no longer strengthen the connection at all.
Keep thread lengths shorter whenever possible to optimize
the fastening mechanism of your CNC machining design.
7. Embossed Text
You might need to add text to your machined parts. If you
do, you should incorporate engraved text into your design rather than embossed
text.
Engraved text is preferable from a design standpoint because
embossed text requires more material to be removed from the workpiece. The
engraved text will be able to put into machined parts more efficiently than
embossed text can.
8. Drilled Holes
Holes that need to be put into machined parts should be
interpolated using an end mill. Drilling holes is less efficient because a
drill provides less flexibility regarding hole sizes.
Also, using an end mill rather than a drill offers the
advantages of improved surface finishes and the ability to multitask with the
end mill to machine both slots and pockets in addition to creating holes.
Quad Fluid Dynamics, Inc. offers CNC component repair
services that help clients address component repair from design flaws. Contact
us at Quad Fluid
Dynamics, Inc.
to learn more about the CNC machining services we
offer.
