As with Protolabs&#; milling centers, CNC turning on high-speed lathes are able to complete many complex parts in a single operation. Live tooling and Y-axis capabilities mean it&#;s possible to turn a bolt, mill the wrench flats, then drill a cross hole for a safety wire. More complex examples might include a hydraulic piston with alignment slots on one end, a fitting with spanner wrench holes on its face, or a shaft with an external keyway. In some cases, it&#;s even possible to &#;turn&#; a part that&#;s more orthogonal than it is round.
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With this milling and live tooling background in mind, here are five elements to consider when designing complex parts:
1. Hole Placement
The minimum size for on-axis and axial holes on Protolabs&#; CNC lathes is 0.04 in. (1mm), with a maximum depth of 6x the diameter. Radial holes (those drilled from the side of the part) should be at least 0.08 in. (2mm) in diameter. Holes that go all the way through turned or milled parts are usually okay (especially on hollow or tube-shaped parts), but depending on the part size, hole diameter, and material, the cutting tool might not have enough reach. Protolabs will machine from each side when possible, but be sure to check your design analysis for potential constraints.
2. Deep Features
External grooves on a turned part cannot exceed 0.95 in. (24.1mm) in depth, or be narrower than 0.047 in. (1.2mm). All other slot-like milled features generally read from the same playbook as drilled holes in terms of size, but a good rule of thumb is to keep the depth less than 6x the feature width. Also, be sure to leave at least 0.020 in. (0.5mm) wall thickness on the adjacent material. Large flats and other milled surfaces&#;mill or lathe&#;depend entirely on the part geometry relative to the available cutter size. Deep ribs and grooves can be challenging though, wherever they&#;re made. It is possible to cut heat sink-like features on a turned or milled part, but this depends on the actual part geometry and available tools. Again, check your DFM analysis carefully, and don&#;t be afraid to test our software, or contact an applications engineer instead.
Designers frequently add threaded features to milled and turned parts. Threading options differ for milled and turned parts, so check
hereto ensure the right process is selected.
Considering threading for your machined part? You might also think about using an insert. Coil inserts (shown here), and key inserts, provide longer service life than bare threads, especially in soft materials like aluminum or plastic.
3. Better Threads
There&#;s a great deal of overlap in threading capabilities between Protolabs&#; turning and milling centers. Generally speaking, Protolabs can thread from #4-40 (M3 x 0.5) up to about 1/2-20 (M10 x 1.25) depending on the type of machine and the feature placement, although some exceptions exist. Check out the threading guidelines for precise measurements and details. While you&#;re there, be sure to read the section about the proper way to model threads, and how this relates to internal vs. external and milled vs. turned part features. You might also think about using an insert. Coil and key inserts provide longer service life than bare threads, especially in soft materials like aluminum or plastic, and are easy for you to install.
4. Texting Can Be Costly
Complex aerospace and medical parts often require permanent marking of part numbers and company names. Recessed text may look nice, but it&#;s also one of the more time-consuming of all machining operations, and is downright prohibitive as production quantities rise. It&#;s usually better to electrochemically etch or laser-mark parts, but if you must have engraved text, keep it short and sweet with simple, clean fonts. We recommend for soft metals and plastic Arial Rounded MT font 14 point 0.3mm deep, for hard metals Arial Rounded MT font 22 point 0.3mm deep.
5. Radii: Watch the Corners
One common mistake on any machined part is the call out of sharp internal corners. For example, the turning tools typically used for finishing at Protolabs have a 0.016 in. (0.032mm) nose radius, so any mating parts should be designed with this in mind. Milling cutters go down to 0.040 in. (1mm), which means any pockets will contain internal corner radii a little more than half that. That&#;s pretty sharp, but remember that milling with a tool that small takes a long time, and will be limited to a pocket no more than 0.375 in. (9.52mm) deep. The best bet is to relieve internal corners or allow for as large an internal radius as possible on mating part designs.
A final word of caution: Failing to apply good design for manufacturing practices makes challenging machining operations even more challenging, and therefore costly. Paying a bit more might be less of a concern on prototypes, but can be a real game changer when demand ramps up and parts move into production quantities. As always, when in doubt about any complex part or part feature, feel free to contact Protolabs with any questions at 877-479- or [ protected].
Rapid prototyping is a manufacturing process that employs specialized production techniques to create high-fidelity physical prototypes. Designers generally use prototypes for evaluating design, testing functionality, controlling quality, iterating concepts, and improving the design. By delivering quick and economic models, prototypes provide valuable insights into a product concept. And they can be critically evaluated before mass production proceeds. What&#;s more, rapid prototyping is extremely fast because the process doesn&#;t require hard tooling.
CNC Machining is one of the most effective means for rapid prototyping. The process allows you to take advantage of the CNC to deliver high-quality prototypes in a quick turnaround period. Here are more reasons why CNC machining should be your preferred technique for making rapid prototypes.
1. Speed
CNC Machines have greatly improved since their inception in the s. The addition of computerized controls has greatly accelerated the capacity of CNC machines to deliver higher quality at improved speeds.
As rapid prototyping demands genuine models with fast turnaround times, CNC machining is one of the most preferred methods in the industry for obvious reasons. From setup times to actual execution, CNC machines will translate 3-dimensional CAD/CAM models into G-code software and then commence milling to produce the final part in several hours.
Automating the CNC milling technique also means almost zero downtime during the production process. Moreover, CNC machines can operate continuously, enabling lights-out manufacturing&#;where machines function unattended during off-hours. Their capability maximizes productivity, especially when used in prototyping where time is critical. Manufacturers can make several prototypes at the same time or one after another. This speeds up development because they don&#;t need constant monitoring.
Additionally, CNC technology enables quick adjustments to the machining process when needed. Design changes are common in prototype making, and you can easily implement these alterations using CAD software. The new design can be re-cut to produce a new G-code with little or no intervention. So, this lets you recalibrate machining parameters instantly. This flexibility is ideal for prototyping since it often means trying different ideas to find the best solution. Such services also include simulated CNC tools that allow engineers to model and check tool paths before implementation to mitigate mistakes and achieve the best machining processes.
Overall, the combination of automation, continuous operation, and flexible programming capabilities of CNC machining makes it appropriate to offer high speed and efficiency in the fabrication of rapid prototypes. The advantages of fast reaction to design changes and the flexible organization of the production processes not only increase efficiency but also guarantee the standard quality of prototypes.
2. Tooling &#; CNC Machines will run without tooling and dies
For manufacturing techniques like pressure die casting and injection molding, there is usually a need for a rigid die from steel alloys, and the cost will be high. These dies can take weeks to manufacture based on the complexity of the design and the desired shape. Also, errors in the details of these dies will automatically be reflected in their copies.
CNC machining, on the other hand, requires no fixed tooling. The process only requires a CAD/CAM design, computer software, and some CNC cutters to execute production. Because of this, CNC machining is considerably faster, cost-efficient, and more accurate for rapid prototyping. However, tools may required for production in large batches. So, it&#;s crucial to understand their significance and workability.
2.1. What Makes Tooling Essential?
2.2. Types of Tools Used In CNC Machines to Produce Quality Prototypes
CNC machining tools are usually manufactured from a combination of materials. Each material has the desired characteristics that can improve efficiency and tool longevity.
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High-speed steel is popular for its toughness and durability. Design manufacturers commonly use it for drill bits and end mills. As it handles high speeds well and works effectively on materials like steel and aluminum.
Carbide tools possess high wear resistance, high heat conductivity, and are thermally stable. They are heatproof and can last for a long time. These tools are suitable for use on materials such as stainless steel and titanium materials. They can be used in tough conditions.
Cobalt alloy in high-speed steel improves the heat material treatment properties. This material is perfect for roughing due to its machining strength. It incorporates the properties of strength with heat resistance. This makes it suitable for use on difficult-to-cut materials.
Ceramic tools are very hard and best suited for use with brittle material. They are good on cast iron and are capable of withstanding high temperatures. Nevertheless, ceramics are very fragile materials and therefore not suitable for use in most applications.
PCD tools are extremely hard. So they are ideal for cutting non-ferrous materials such as aluminum and any composite materials. These tools are especially helpful when manufacturers produce a large number of similar products.
Cermet tools consist of the desirable properties of ceramics and metals. These materials provide good wear resistance and a high level of toughness for finishing operations. These tools are useful in hard steels and nonferrous materials. They contribute to improving the total CNC machining performance flexibly.
3. Accuracy and Precision
No other manufacturing process in the industry can match the accuracy and precision offered by CNC machines. In modern production hubs, the CNC is the most effective way of achieving the highest level of accuracy with tolerances in the neighborhood of 0.05mm, give or take.
CNC machines also offer highly scalable and repeatable accuracy. So, helps ensure all produced prototypes look and function almost identically. The tolerances achievable with CNC machines are so precise that they are suitable for nearly all commercial applications in which they might be used.
For Instance; CNC Milling is a prominent precision technique in manufacturing. It can deliver tolerances of ±0. inches, and ± 0. mm with high-quality tools and proper setup. The process employs tools typically mounted on spindles. These tools move in different axes to cut material from a stationary workpiece, to create formidable shapes and features.
CNC Milling is widely exploited in the aerospace and automotive sectors. These sectors require precise machining components for improving fuel efficiency and parts longevity. Furthermore, it can also deliver uniform or evenly finishes, with Ra values of 32µin or better, while necessary for parts that have to be functional and cosmetic in equal measures.
CNC turning also stands as one of the most vital processes to create complex parts with symmetrical features. The process usually produces a dimensional accuracy of ± 0. inches (± 0.005 mm). In CNC turning, the workpiece turns around an axis while a cutting tool is held still and interacts with the material. This approach leads to small surface roughness and equal cross-sectional area, meaning that dimensional variation is reduced. The process is effective in delivering a high surface finish, often delivering Ra values of 16 µin or better, and is appropriate for high tolerance components such as shafts, gears, and other rotary parts.
Electrical Discharge Machining (EDM) can be employed where higher accuracies are necessary. EDM can be accurate within ±0.001 inches (±0.025 mm), making it ideal for designing complicated shapes and difficult-to-cut materials. This process conducts electric sparks to cut the material and allow for shape carving while avoiding mechanical stresses that are integral to most cutting processes. The tight tolerance design provided by EDM is most beneficial to industries for instance in the aerospace and medical equipment industries where components manufactured must meet certain performance specifications.
Verifying that the required tolerances are met determines the accuracy of CNC machining. There are different ways of determining the accuracy of a machined part through measurement. Coordinate Measuring Machines (CMMs) are used for making accurate three-dimensional measurements and are crucial to quality assurance in manufacturing industries.
Rapid and accurate surface measurements can be obtained from laser scanning technologies while for in-process checks conventional instruments such as gauges and calipers are used. Most CNC systems come with some in-process measurement features that enable them to monitor the operations of the machine and make corrections should there be a deviation. Preliminary findings also indicated concerns regarding the possible future need for expensive recalibration of the CNC machinery to maintain the effectiveness of the processes in place.
Here&#;s a brief table that includes various technical aspects of several rapid prototyping machining methods:
Rapid Prototyping Technology
Accuracy
Prototype Types
Applications
Technical Aspects
CNC Milling ±0. in (±0. mm) Complex shapes and features Aerospace, automotive Uses rotating cutting tools; can machine various materials; ideal for high-speed production. CNC Turning ±0. in (±0.005 mm) Symmetrical parts like shafts and gears High-tolerance components Workpiece rotates; suitable for cylindrical shapes; minimizes surface roughness. Electrical Discharge Machining (EDM) ±0.001 in (±0.025 mm) complicated shapes, intricate designs Aerospace, medical equipment Uses electrical sparks to erode material; effective for hard materials; avoid mechanical stress.4. Control and Modifications
Simply altering a few lines in the software program can modify an entire manufacturing process to match new specifications in just a few seconds. The G-code program enables highly interactive and controlled prototyping, allowing users to run multiple design iterations by merely refining and tweaking certain specifications without incurring additional costs. This is a great advantage over conventional manufacturing and prototyping techniques, where modifications may require new dies or expensive modifications to existing ones.
5. Material Variety
CNC machines are for the most part unselective machines. This means they will cut and mill various types of material for production. As long as the material is strong enough and not to deform under pressure.
CNC machining is suitable for rapid prototyping as it allows many developers to run multiple prototypes of their parts from various materials. This way, the same design can be made from several materials to evaluate the option with the best-fit mechanical, functional, and physical properties for its end use. With only small modifications to the feed parameters and running speed, the same design can be run across several materials to get the perfect prototype and ideal product.
You can use CNC machining effectively with various materials, allowing you to create different prototype parts. Here are some common materials and the prototype parts they often make:
These materials enable versatility in application that makes CNC machining suitable for prototyping across many industries.
Premium Parts CNC Machining Services in China
Premium Parts is your go-to source for all CNC prototype needs. At Premium Part, we offer high-quality CNC machining services for different industries. Our expertise ranges across several services, and we can generate exceptional quality products with a quick turnaround. We can work with an extensive range of materials and produce both low and mass manufacturing volumes. Our highly experienced team will deliver best-in-class manufacturing quality and standards.
Contact us to discuss your requirements of CNC Machining Services for Prototypes and Production Parts. Our experienced sales team can help you identify the options that best suit your needs.