Designing Underguts and Internal Features for CNC Machining
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- Source:Orbis Parts
CNC machining is renowned for its precision and ability to create complex geometries from a block of solid material. However, certain features, like undercuts and internal cavities, present unique challenges that require thoughtful design to be manufactured successfully and costeffectively. Mastering the design of these features is key to unlocking the full potential of CNC for your components.
cnc machining center Understanding the Challenge
An undercut is a recessed feature that is not accessible directly from the primary tool approach directions. Internal features, such as enclosed cavities or internal threads, share a similar accessibility problem. Standard cutting tools, like end mills, move linearly and cannot magically cut around corners. Designing such features without considering tool access leads to impossible machining or exorbitant costs for specialized tooling and complex setups.
Key Design Strategies for Success
1. Standardize Tooling with TSlots and Dovetails: Instead of custom undercut profiles, use standard Tslot or dovetail cutters. These cutters have welldefined geometries, and designing your undercut to match their profile eliminates the need for expensive, custommade tools. This significantly reduces cost and lead time.
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2. Incorporate Adequate Access and Clearance: The most common rule is to design undercuts with sufficient clearance for a tool to enter and exit without collision. Ensure the opening is wider than the undercut's depth to allow a standard tool to reach the recess. For internal pockets, the depth should be reasonable, and corner radii should be as large as possible to allow for larger, more robust tools.
3. Design for Internal Threading: For internal threads, the primary consideration is tool access. The thread length should not exceed 1.5 times the hole diameter for sizes below M6, and 23 times for larger diameters. This ensures the tap has sufficient clearance to cut the threads properly without breaking. Always include an unthreaded length at the bottom of the blind hole for chip evacuation.
4. Utilize MultiAxis Machining: 5axis CNC machines can tilt the cutting tool, providing new angles of attack for complex internal features. This can sometimes eliminate the need for an undercut cutter altogether or simplify the machining of deep, internal cavities. While 5axis machining has a higher hourly rate, it can be more economical for complex parts by reducing setups and secondary operations.
Benefits for Your Project
A design optimized for undercuts and internal features is not just manufacturable; it's economical and robust. It leads to:
Reduced Costs: Eliminates custom tooling and minimizes machining time.
Faster Lead Times: Simplifies the machining process.
Higher Quality: Prevents tool deflection and breakage, ensuring better surface finish and dimensional accuracy.
By partnering with a knowledgeable manufacturing provider, you can seamlessly integrate these design principles. Our expertise ensures your designs with complex internal features are not only feasible but are produced with optimal efficiency, directly contributing to the success and growth of your product development.