Tips for Design Cost Effective Machined Parts
In designing complex machined parts, excellent communication and collaboration between customers and the manufacturers are crucial to achieving quality, minor errors can lead to unnecessary costs, and post-production adjustments can be very devastating.
Creatingway as one excellent CNC machining Manufacturer to you, We will share these deign of cost effective machined parts below.
More tips for design cost effective machined parts
Drawings and Prints
More time needs to be spent on drawing what you need on the part for a cost effective machined part; the drawing should show all the part components since it acts as a communication device between the machinist who think visually and you. The drawing can he hand drawn, or a CAD may be used. To ensure this phase success,
Ensure the text on your drawing or print is readable
Avoid using bright colors such as yellow, light blue which can be hard to read, use the color that even after the print is scanned or faxed, the content can be visible and readable.
Label all parts with unique names and numbers
Proper naming and labeling will allow easy identification of part components and avoid mixing up the machinist.
Specify the material you want
As mentioned above, materials are of different types, the cost, has different lead time and more, on submitting your print ensure you specify on the material that you want.
Indicate any material finishes
Avoid the assumption that the machinist will make the finish; it is relevant to explain how you want the surface to be; the engineer can make the surface smoother than you wanted.
Communicate the purpose
It is advisable that you communicate the intended purpose of the part, what the part will be used for’ so as the machinist can have the context of the part.
Ensure print completeness
Ensure all dimensions, estimates, surfaces, edge breaks and any other part requirement are included to ensure quality and cost effectiveness.
Provide the dimensions
If possible is advisable to provide both 2D and 3D prints, do not fake the dimensions, ensure accurate dimensions and geometry and also need to be consistent. Decimal places need to be carefully considered to avoid making costly parts due to high spec tolerances.
Designing for machining for Design Cost Effective Machined Parts
Visualizing how the part can be correctly machined makes complications on along the way minimal, and the cost effectiveness can be easily achieved. This can be accomplished by:
Taking into account endmill radii
Design using EM standard sizes, this implies that you avoid sharp, square, inner corners, any pocketing corner should be round, and for a sharp mating part, the inside corner should be trimmed to avoid destroying the arrangement.
2.Account for endmill length to diameter
Endmills are known to work best when stiff, deep pocket with small radii should be avoided as the deeper it is, the more it gets harder and more time is also spent. A deep pocket can cause the part to break easily and make the finish surfacing poor. Therefore is advisable to limit pockets depth to smaller diameter as possible
3. Do not specify too deep holes
A hole 1 to 3 times the diameter can offer maximum strength, deeper than three will not only add on cost but will be unnecessary.
4. Make corners larger than EM Diameter
Modern mills can easily curve and make arcs with no regards to the endmill diameter; larger edges reduce the surface contact and therefore reducing the chances of chatter.
5. Limiting machining risk factors
Machining simple parts is less costly compared to one complex part, this is due to the risk and the workforce involved, and if an error occurs, the whole part needs to be redone therefore complicated part are charged more, it is logical to deal with multiple small parts which are cost effective.
Setup and Fixture Design Cost Effective Machined Parts
Chances of error in machining should be minimized to zero; several factors need to be considered which include:
Using vise fixturing
This method has been the most common since it does not require the part to have two parallel sides for a firm grip, the tool is capable of opening up to about 9inches making it possible to hold parts of a bigger size.
2.Use of Soft Jaws
For more complex parts with no parallel edges, soft jaw Fixturing should be used, however, this technique is slightly expensive since it does require additional machining steps, but it’s worth it when no other option is available.
3.Avoid multiple setups
Avoiding multiple setups if possible, least expensive part are the once that can be machined with a single setup since no time is wasted in re-setups. The part only needs to be flipped over and repositioned.
4. Use of tapes
For cost effective machining parts, thin pieces can be taped, mostly plastics. Mostly this should be applicable if the tape can hold the piece firmly and the tape is adhesive enough. Lowering the machining cost is crucial having covered the various techniques in different machining phases.
Finally, we need to get reasonable material to design for production
To achieve quality, the material to be used should be selected wisely, and the following should be considered
The price of the equipment
The overall cost of the material should be reasonable enough, that which will provide quality and save more.
The delivery of the materials
Different materials have different lead time when a delay occurs; the overall time used to make the part is also extended resulting in an extra cost. welcome visit our material sheet guide for details, any special material needs, we outsource them in open marketing.
Creatingway always is willing to share more design of cost effective machined parts information to our customers and partner for cost reduction, welcome visit us and get us more improvement, so we can continuously research and develop more new products and machining process.
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