We list some product
design rules for general machining operations:
- Sharp inside and
outside corners should be avoided.
- The part should
be easily clamped.
- The machined surfaces
should be accessible.
- Materials that are
easily machined should be specified.
- Design should be
as simple as possible.
We also list some additional
design recommendations that are particularly applicable for milling
- Standard cutter shapes
and sizes should be used.
- When a small, flat
surface is required, as for a bearing surface or a bolt head seat
for a hole, spotfacing should be used. It is quicker and more
economical than face milling.
- When outside surfaces
intersect and a sharp corner is not desirable, a bevel or chamfer
is preferred to rounding.
- If using a casting
as the workpiece, Avoide milling at parting lines, flash areas,
and weldments to extend the cutter life.
- Designs that require
the fewest separate operations are the most economical.
- If design has no narrow
features, it allows for the use of large tools. This permits higher
material-removal rates, more efficient use of machine horsepower,
and lower dynamic operating conditions.
- The number of setups
should be reduced to minimize cost.
- A minimum separation
between features and pockets should be maintained -This helps
prevent thin walls of material that might deform or break when
subject to machining forces.
- Deep features should
be avoided to prevent tool deflections.
- Tolerances and surface
roughness should be as lax as permissible.
- Special features,
such as corner rounding, tapers, and fillets, should be avoided
-All these require special tooling and increase the time and cost
to make a part.