Introduction Recently, we tackled a challenging project involving a small, complex workpiece that required exceptional precision. This experience demonstrated our ability to overcome machining difficulties associated with thin-walled structures and intricate geometries. In this article,
we share the challenges we faced, our solutions, and how our expertise delivered outstanding results. Whether you’re looking for CNC machined parts, CNC machined products, or CNC machining aerospace parts, this case study highlights why we are a trusted partner in precision manufacturing.
Our Challenges in CNC Machining This Workpiece
- Structural Fragility and Dimensional Control: The workpiece, measuring just 19.08 mm x 71.50 mm, was machined from a solid bar. After material removal, its walls were reduced to a thin 1.5 mm thickness. This thinness compromised its strength, making it highly susceptible to vibrations and resulting in challenges with dimensional tolerances.
- Complex Right Angle Geometries: The design required precise right angles, which involved machining away residual R radii. Achieving sharp corners in tight areas where standard CNC machine tools couldn’t easily reach added another layer of complexity.
- Deep and Constrained Machining: A critical feature of this workpiece was a 44.50 mm-deep cylinder with dimensions of OD 7.86 mm x 10.55 mm. This cylinder also required an M4 x 0.7 threaded hole drilled to a depth of 5 mm, with concentricity maintained. With only 16.30 mm of available machining space, custom tools and precise calculations were required to avoid collisions and ensure accuracy.
How We Solved These CNC Machining Challenges
- Custom Tool Design and Optimization: For the deep cylinder machining, we designed custom CNC tools with an optimized length-to-diameter ratio. This minimized deflection and ensured the tool could reach the required depth while maintaining concentricity for the threaded hole.
- Precision CNC Path Calculations: We carefully calculated tool paths to maximize the limited machining space. Our engineers used advanced CAD/CAM software to simulate the machining process, ensuring collision-free operations and maintaining the tight tolerances required.
- Addressing Vibration Challenges: Using a 1 mm insert knife with precise cutting parameters (spindle speed of 2000 RPM and controlled pressure), we successfully minimized vibration during machining. This approach ensured the integrity of the thin-walled structure and prevented dimensional inconsistencies.
- Achieving Perfect Right Angles: With diamond-ground tools, we progressively machined the inner corners, reducing the residual R1 radius to the required R0.1. This allowed us to achieve sharp right angles and meet the client’s stringent design requirements.
Why Our CNC Precision Machining Stands Out
- Dimensional Accuracy: We successfully maintained the required tolerances across all features, including the concentric M4 thread and precise inner corner radii.
- Superior Surface Quality: The surface roughness of the finished framework measured Ra0.6, exceeding industry standards.
- Expertise in Deep Machining: Our custom solutions enabled us to machine a 44.50 mm-deep cylinder within a constrained space, demonstrating our advanced CNC capabilities.
- Trusted by Key Industries: Thin-walled and complex CNC machined parts like this are essential for industries such as aerospace, automotive, and consumer electronics. Whether machining aircraft parts, car parts, or components for smartphones and laptops, our expertise ensures high-quality results.
conclusion
Conclusion Through our mastery of CNC precision machining, we overcame the significant challenges presented by this thin-walled workpiece. Our ability to design custom tools, optimize machining paths, and control vibrations highlights our expertise in delivering exceptional results.
If you’re looking for a reliable CNC machine parts manufacturer or need custom-machined components for aerospace, automotive, or consumer electronics applications, trust us to bring your designs to life with precision and reliability. Reach out today to discuss how we can help with your CNC machining needs.
