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2023年05月

Posted on August. 30th, 2023, | By Estoolcarbide Rapid Manufacturing

The modern industry needs parts done very fast. Rapid prototypes or custom parts demand to rise higher every month. The clients want their orders faster and need the components to have more accuracy than before. One of the most widespread alloys for modern production is aluminum, seemingly the best material there can be. It is lightweight, strong, durable, and resistant to corrosion. That’s why new milling aluminum strategies are developed rapidly.

One of the modern successful CNC aluminum milling methods is called High-Speed Machining. The main difference compared to conventional milling is that the speeds of high-speed milling are considerably higher, and with them, the machinists can increase cutting feeds. As a result, HSM milling aluminum is very advantageous in a number of unexpected ways. Here is what you will gain by choosing? HSM strategies for aluminum instead of using conventional milling.

By increasing the cutting speed up to 3 times as fast as conventional aluminum milling, it is possible to increase the feeds up to 2 times ( in cases for softer aluminum alloys ). As far as we know, machining feeds are the parameters that define the productivity of the whole milling process. That being said, high-speed machining efficiency can be much compared to conventional milling. Aluminum machinability makes it possible to increase spindle revolution speeds up to 18000 rpm and more, thus making material removal rates scary.

Such material removal rates make aluminum machining services using HSM strategies for aluminum a very lucrative offer for automotive and aerospace industries. In the first case, automotive prototypes require a lot of material removal with preferably as few milling setups as possible. In the second case, there are a lot of long and large parts that have deep pockets ( they must be lightweight so they are mostly machined down to a set of intersecting ribs) and thin walls, in addition, aluminum alloys are what planes and rockets consist of up to 80%.

It has been proved that the temperature of the cut changes with the increase of the speed. At first, as the speed grows, so does the temperature. However, as we go further, the temperature starts to go down drastically until, at some point, it stops to matter. Increasing cutting velocity will only lower the temperature to a small degree. This transition is what signifies HSM. For example, when milling aluminum at 300-500 m/min, the temperatures may reach 600-800 degrees. However, if we increase the velocity up to 1200, the temperature goes down to less than 200 degrees, and it is a mere 150 degrees at 1800 m/min. From that point on cutting faster is pointless.

Just consider, a mere 150-200 degrees! No material property change in the area of the cut due to local thermal processing, no metal grain increase, and much smaller demands to cooling. A good advantage, I’d say.

It may seem strange because the speed of the cut is larger and so tool wear must be as well, but if we compare the amount of material that gets cut by the aluminum cutting tools at HSM with conventional milling rather than tool life in minutes, we’ll see that the difference is evident and speaks in High-speed milling aluminum favor. What’s the reason for a prolonged tool life? First, the cutting temperature is lower and that means tool material strength is higher. Then, chip width during high-speed milling is Carbide Steel Inserts much lower ( the tool turns faster and manages to cut off a thinner chip even despite increased feeds).

In addition, when machining aluminum, one of the main issues is that it is so soft, it sticks to the cutting edges of the tool during processing. This lowers tool sharpness and increases cutting forces hence decreases tool life. But that doesn’t happen at high speeds. Aluminum just leaves.

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We all think that higher feeds make the aluminum surface finish lower because the tool cutting edge travels further while the tool can make a turn and cut it off. Generally, this results in a wider chip, higher cutting force, and a worse surface finish. However, in HSM despite the feed being larges, the velocity of the tool is higher, so the chip is actually thinner than in conventional Tungsten Steel Inserts milling. In addition, vibration is lower because of a smaller cutting force.

One of the major problems when milling part cavities with end mills is concerned with manufacturing pocket angles. The end mill must turn 90 degrees in order to produce the pocket and at that moment, the material it has to cut doubles ( from both sides of the pocket). This results in a local increase in cutting force and is very bad for tool life and part precision. However, HSM aluminum milling has a number of predetermined tool path generation strategies that include a constant tool engagement angle. That means the tool gets gradually closer to the angle while machining all the material around it in a circular trajectory. That way, the cutting force remains constant and so does the precision. in addition, tool life is prolonged.

Some HSM strategies for aluminum machining don’t use coolants at all. I mean, machining at 200 degrees hardly requires any cooling of both the material and the cutter. However, some extremely precise operations still use coolants in order to increase part quality but the quantity of the coolant is much lower compared to conventional machining. Some aluminum high-speed milling processes use the so-called minimum quantity lubrication. The amount of coolant administered is just enough to make a thin film that lowers friction and offers some cooling.

So, it is quite evident that High-speed aluminum milling is an innovative and productive way to manufacture custom parts, prototypes, small batches, and other sets made of aluminum alloys. With high-speed machining, you will get better prices and will spend less time waiting for your order to be fulfilled.


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February 24, 2023

Mild steel is the steel that combines iron and carbon. Owing to iron presence it developed good magnetic properties. Mild is not alloy steel. Due to more carbon present its chemical composition is quite different from other elements or other steels as mild steel has a good surface quality and you can increase its surface hardness in different ways. Let’s learn more about this material.

Steel is mostly composed of iron. Depending on different amounts of carbon content, there are low-carbon steel (also called mild steel or plain carbon steel), medium-carbon steel, and higher carbon steel.

The following chart shows the differences and characteristics of the three steel types:

?

Carbon content (wt. %)

Microstructure

Characteristics

Examples

?

Low-carbon steel (Mild steel)

?

Less than 0.25

?

Pearlite, ferrite

Soft, cheap, very ductile, easy to machine and weld

AISI105, AISI 316L, Q195, Q215, Q235, 08F, 15Mn, 20Mn

?

Medium-carbon steel

?

0.25 to 0.60

?

Martensite

Reasonably?ductile, hard, strong and not easy to harden

AISI 409, 45#, 40CR, 20CR, SCM 435

?

High-carbon steel (carbon tool steel)

?

0.60 to 1.25

?

Pearlite

Very hard, strong, unyielding, hard to machine and weld

T7, T7A, T8Mn, T8MnA, AISI440C

From the above chart, mild steel is a steel type that contains 0.05%-0.25% carbon. Due to its malleability and ductility, the material is easy to form and Carbide Threading Inserts machine. Mild steel parts are generally very suitable for stamping, forging. Mild steel is widely used in tools, automotive body parts, construction, and infrastructure.

The manufacturing processes of mild steel (low-carbon steels) resemble that of other carbon steels.?These processes have been changing over time and are currently are more efficient?and cheaper?than before. In modern manufacturing?processes, three?major steps are involved in producing?mild steel out of pure iron or iron ore.

In this process, ?iron is mixed with coal and lime and heated in a blast furnace. ?Modern primary steelmaking uses?modern furnaces such as Basic Oxygen Furnace?or Electric Arc Furnace. The latter is generally used by manufacturers in developed?countries, and steel parts that come out of the Electric Arc Furnace?are of high quality.

The purpose of secondary steelmaking Carbide Inserts is to mainly reduce the carbon (less carbon) contents to the desired extent and add other alloying elements to improve the properties of the steel. This step is mainly controlling and monitoring the heat treatments and cooling of the furnace.

As soon as the steel in the furnace reaches the specific carbon content and mechanical properties are enhanced to a certain degree, the steel is to be poured into a mold, which is called casting and some say cast iron which is not right. . During this process, the liquid form of steel will be cured and formed into various geometries. These crystal structures cast steel will subsequently be cut into smaller shapes of parts.

The casted steel has plenty of defects and imperfections. A primary?forming process called hot-rolling is applied. After hot-rolling, the steel gains more strength, ductility, weldability, etc.

Generally speaking, there is a secondary forming process such as CNC-machining, cold-rolling, powder-coating, case-hardening, or electroplating?to further improve the mechanical and chemical?properties or aesthetics?of the mild steel parts. At these processes, a metallic coating, such as a zinc coating or any other type of carbon steel, is properly applied.

As you could judge from the chart above, mild steel has lower carbon content than other carbon steel. The mild steel has a mere carbon content of 0.25%.

Mild steel has great impact strength, great ductility and weldability, good malleability with cold-forming possibilities. With these properties, CNC-machining mild steel is easier than CNC-machining other types of steel.

The major disadvantage of mild steel is that it has a relatively low tensile strength, which means it’ll break more easily than other types of steel.

Fortunately, a heat-treatment process called carburizing can be used to improve tensile strength. Carburizing is a surface-hardening process that heats the mild steel to a certain temperature then cools down the steel, which makes the steel hardened on the surface when keeping the core of the steel soft and ductile.

Mild steel is widely used. Typical?applications include common hardware tools, cookware, medical instruments, machinery, construction, infrastructure, and so on.

Due to its?very little carbon?content, the mild steel doesn’t not rust, which makes cookware stay clean and sharp for a long time. Mild steel is more heat-resistant than other materials, can be used as a non-stick material, and is more healthy than aluminum cookware.

4. Pipelines

Because mild steel is extremely?ductile, pipes that are made of mild steel are very popular?when people make various kinds of pipes and poles. Mild steel could be used as food-safe materials, so it is ideal to transport water, beverage, and natural?gas in steel?pipes. Also due?to its low-carbon containment, pipes that are used outdoors don’t rust and cold weather through the harsh environment. Compared with plastic pipes, mild steel pipes are more environment-friendly?and last a lot longer. It also can be cut in a rectangular shape as well.

AISI 316L, which has a low carbon content?of only 0.03%, is typically mild steel that is very commonly used. During dealing with various companies?over the years, we have found that medical instruments companies love?using?the?material. To make prototypes or customize low-volume steel parts, CNC-machining is the generally?number one choice. CNC-machined 316L steel parts often need no surface treatment or any heat-treatment process. CNC mild steel parts can be used as final products, not only prototypes. Other common products such as fishing tools also use a lot of AISI 316L.

Why do people often complain?that steel is hard to be CNC-machined? The machinability of?steel mostly depends on its carbon content. High-carbon steels are difficult to machine mostly because of their unyielding?characteristics plus internal stress.

However?mild?steels are also difficult to machine because they are too soft. The chips that appeared during the CNC-machining process tend to stick and accumulate, this leads to more time for cleaning the chips and possibly damaging the cutting tools. The ideal amount of carbon content for easy machining is around 0.20%.

For instance, some mild steel is too soft and it causes chip-accumulation problems. There is one way we sometimes use: case hardening the soft steel first. Case hardening or surface-hardening makes the mild steel hardened on the outside which keep the steel soft on the inside, which makes the chip-accumulation problems go away, and because the core of the steel is still soft, when the external stress is produced during the machining process being applied on the material, the softness or ductility of the mild still will absorb the stress and make the part unable to break.

For the short-run production of mild steel parts, CNC machining is the way to go. The mild steel material used for CNC-machining is what we called” block material”, which has good quality and reasonably cheap price. CNC machining is very fast, compared to casting and molding. For casting and molding, the initial time and cost invested in making molds are of large amount. ?With short-run production or low-volume production of mild steel parts, the total cost is generally much cheaper than casting and molding, because you don’t have to make molds.

If large volumes of mild steel parts are?to be produced, the common method is called casting or molding (molten steel).?Metal injection molding?(MIM), which is similar to plastic injection molding, is the process of injecting a liquid form of metal into a mold, the liquid metal will be cured and solidified in the mold. After being ejected from the mold, steel parts are roughly formed. There are post-finishing processes to further improve the aesthetics?of molded parts.

Like plastic injection molding, when designing the MMI molds and parts, a designer has to consider?issues such as draft angles, de-molding, shrinkage, tolerances, etc.

Mild steel or low-carbon steel has a carbon content that’s less than 0.25. Due to its properties, mild steel is widely used in almost every industry. The common method to make mild steel prototypes or low-volume production-grade parts is by CNC machining. For larger volumes, metal injection molding is a more feasible way.

Estoolcarbide as a professional prototype and low-volume production service provider have many years of experience and expertise to machine different types of carbon steel, scrap steel, stainless steel, alloy steel and the same manner, etc. If you have a project related to the processing of mild steel, please get a quote.


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【introduction】The construction of flexible electronic devices with certain functions and structures provides a variety of possibilities for human life in the future, such as wearable electronic products, implantable chips, sensing skin, flexible robots, and so on. With the deepening of the research on luminescent materials, these creative products are moving from the laboratory to people’s lives. For example, a clothing containing a light-emitting element, a detector built by an optical signal, a chip capable of releasing a drug through an optical signal, a chip that participates in a signal transmission, and the like. Early research, mainly using screen printing technology, to achieve a large-scale manufacturing of AC flexible luminescent materials. Nowadays, with the advent of 3D printing technology, flexible materials with more complex structures are also produced.The researchers have designed a novel structure of light-emitting devices, which are mainly composed of four parts, namely, a pair of parallel stack or side by side distribution of the electrode, light-emitting layer, dielectric layer and a controllable electrode layer. The control of the electrode layer is achieved by selecting a different polarizing material or an electroconductive tungsten carbide inserts thin film. This new structure is not only simple, but also conducive to large-scale manufacturing, more importantly, compared with the traditional sense of the light-emitting devices, a pair of opposing electrodes are no longer stacked with each other, but side by side distribution. It is because of this structural advantage, the researchers have designed different types of devices. For example, this flexible material is mounted on an umbrella, and when the water falls on an umbrella, the umbrella glows, which also makes it possible to build a remote detector that utilizes optical signal changes.Figure 1. Comparison of conventional sandwich configurations of light emitting devices (denoted as S-ELS) and polarized electrode bridge light emitting devices (denoted PEB-ELS)a) Schematic diagram of the structure of a conventional sandwich device (S-ELS)b) Schematic diagram of Tungsten Steel Inserts polarization electrode bridge light emitting device (PEB-ELS)c) Flexible display of PEB-ELS;d) The backside of the PEB-ELS is enlarged with an electrode width of 0.45 mm and a pitch of 0.40 mm.e) the water shines on the PEB-ELS;f) Comparison of changes in AC voltage before and after water dumping.Figure 2. Effect of bridging material, voltage and frequency on PEB-ELS performancea) PEB-ELS positive partial magnification, electrode width of 1.5 mm, spacing of 0.4 mm;b) the addition of different bridging liquid, the light in the dark situation;c) the relationship between the luminous intensity and the type and concentration of the bridged liquid at a voltage frequency of 2 kHz;d) the effect of substrate impedance on the luminous intensity, insert the picture shows the relationship between liquid contact time and luminous intensity;e) the relationship between the luminous intensity and the voltage frequency when the voltage is constant;f) Draw a Picasso painting on PEB-ELS with a pencil.Figure 3. Polarized electrode bridge experiment.a-b) bridging the experimental diagram, the first PEB-ELS is divided into two parts, and then use the hydrogel as a polarized bridge, the two parts connected to test;c) half of the PEB-ELS infiltrated in the two beakers;d) Transparent polyacrylamide hydrogel for bridging, 5 cm long, 1.6 cm wide, 0.3 cm thick;e) After the two beakers are connected with a hydrogel, the voltage is applied and the PEB-ELS emits light;f) Place the hydrogel directly on PEB-ELS and the material glows.Figure 4. Preparation and performance testing of rainwater sensorsa-b) rainwater sensor preparation diagram;c-d) rainwater sensor of the physical map, white and dark;e) hand as bridge electrode, PEB-ELS light;f) When the water is frozen, the emission intensity of PEB-ELS is weakened.【summary】This study presents a new, low-cost, flexible, light-emitting device that can be mass-produced. In this paper, the luminescence performance of the device is studied, and the relationship between the luminescence performance and the bridging material and the applied voltage is discussed. And then made it based on the optical signal sensor. When the umbrella is wet or touched by hand, the contact surface will light. Not only that, this new type of light emitting device can also be used to write, when writing with a pencil, the corresponding area can also light. This also provides a new possibility for the future development of touch display technology.
Source: Meeyou Carbide


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Because the wear resistance and toughness of cemented carbide tool materials are not easy to take into account at the same time, users can only choose suitable tool materials from many cemented carbide grades according to the specific processing objects and processing conditions. This brings the choice and management many inconveniences. In order to further improve the comprehensive cutting performance of cemented carbide tool Cast Iron Inserts materials, current research hotspots mainly include:

By refining the grain size of the hard phase, increasing the surface area between the hard phase crystals, and enhancing the bonding force between the grains, the strength and wear resistance of the cemented carbide tool materials can be improved. When the WC grain size is reduced to sub-micron or less, the hardness, toughness, strength, and wear resistance of the material can be improved, and the temperature required to achieve complete densification can also be reduced.

The grain size of ordinary cemented carbide is 3-5μm, the grain size of fine-grained cemented carbide is 1-1.5μm (micron level), and the grain size of ultra-fine-grained cemented carbide can reach 0.5μm or less (subs-micron, nano-level). Compared with ordinary cemented carbide with the Carbide Turning Inserts same composition, ultra-fine grained cemented carbide can increase its hardness by more than 2HRA, and its bending strength can be increased by 600-800MPa.

Commonly used methods of grain refinement mainly include physical vapor deposition, chemical vapor deposition, plasma deposition, and mechanical alloying. Equal Channel Angular Extrusion (ECAE) is a very promising method of grain refinement, which is to put the powder in a mold and extrude it in a direction different from (not opposite to) the extrusion direction, and the cross-sectional area during extrusion is unchanged. The powder crystal grains processed by the ECAE process can be significantly refined.

Because the above-mentioned grain refining process method is still not mature enough, the nano grains are easy to grow into coarse grains during the cemented carbide sintering process, and the general growth of the grains will cause the material strength to decrease. A single coarse WC grain is often An important factor causing material fracture. On the other hand, the price of fine-grained cemented carbide cutting tools is relatively expensive, which also restricts its popularization and application.

On the cemented carbide substrate with better toughness, by CVD (chemical vapor deposition), PVD (physical vapor deposition), HVOF (high velocity oxy-fuel thermal spraying) and other methods, a thin layer of wear-resistant metal compound can be applied. Combine the strength and toughness of the substrate with the wear resistance of the coating, thereby improving the overall performance of cemented carbide tools.

1. Coated cemented carbide tools have good wear resistance and heat resistance, and are especially suitable for high-speed cutting; due to their high durability and good versatility, they can be effectively reduced when used in small batches and multi-variety flexible automated processing. The number of tool changes improves the processing efficiency.

2. The coated carbide tool has strong anti-crescent wear resistance, stable cutting edge and groove shape, reliable chip breaking effect and other cutting performance, which is beneficial to the automatic control of the machining process.

3. The body of the coated cemented carbide tool has high dimensional accuracy after passivation and refinement treatment, which can meet the requirements of automatic machining for tool change positioning accuracy.

The above characteristics determine that the coated carbide cutting tools are particularly suitable for automatic processing equipment such as FMS and CIMS (Computer Integrated Manufacturing System). However, the use of coating methods still fails to fundamentally solve the problem of poor toughness and impact resistance of cemented carbide base materials.


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May 27, 2023

As product designers and manufacturers, both of us are always looking for ways to speed up the manufacturing process and make it easier and cheaper. This is where DfM comes in.

Design for Manufacturing, or DFM, is crucial for producing high-quality products and low manufacturing costs. It is a process that enables designers and engineers to optimize a product design for efficient production.

By considering manufacturing methods and constraints during the design phase, DfM can help avoid costly changes and delays in production.

This blog post will explore some of the most critical aspects of DFM, including DFM for different rapid prototyping processes, and provide tips for implementing it into your product development cycle.

Contents hide I What is DFM (Design for Manufacturing)? II Why is Design for Manufacturing Important? III Design For Manufacturing vs. Design For Assembly IV General DFM Principles & Rules V DFM For Different Rapid Prototyping Processes VI Get DFM For Your Project At Estoolcarbide

Design for Manufacturing, or DFM, is a process by which you can design and create products that are easy to manufacture. It’s an integral part of the overall product design process because it helps you ensure that your product will be cost-effective, efficient to produce, and according to international quality standards.

When designing a product, you must consider how it will be manufactured. You have to consider the product dimensions and shape, the materials used in production, and the labor cost and other costs associated with producing your product.

You can use various DFM processes in the rapid prototyping, including CNC machining, rapid injection molding, vacuum casting, and 3d printing, to see if your great ideas and ambitions can be turned into reality or not.

DFM helps you make sure your design is ready for mass production by considering all of these factors before production.

Ensure product works as intended

The primary goal of Design for Manufacturing (DFM) is to ensure that your product will look good and functional. If you don’t consider manufacturing issues during the design phase, you may find yourself with a product that doesn’t work in its intended environment (or at all) after assembly.

This happens when designers don’t think about how their product will be manufactured when they’re designing it. For example, suppose there are multiple parts or pieces involved in construction. In that case, these components need to fit together seamlessly during assembly so that everything fits together smoothly without any gaps or overlaps between pieces which could cause problems later on down the road.

Make product cost-effective

Design for Manufacturing (DFM) is vital because it ensures that your product can be made as effectively and efficiently as possible. It also helps you determine how to best use the materials available to you to create a product that’s both cost-effective and sustainable.

Creating a product that can be manufactured efficiently means that it will be easier for your manufacturer to produce it at a reasonable cost, which means you’ll be able to offer your product at an affordable price point. The more affordable the product is, the more people will want it—and the higher demand there is for your product, the more money you’ll make!

Get product sustainable

Designing for manufacturing also helps you ensure that all of your products are made using sustainable materials. This is important because it will help you reduce waste and save money in the long run by cutting down on production costs. If your manufacturer uses less material than necessary, they’ll have less waste, and waste costs money!

Make the manufacturing process more straightforward

With the DFM process, the manufacturing operations won’t be more expensive or complicated than it needs to be. It also means that it can be done quickly and at a low cost if the design changes later.

Increase product quality

DFM helps you avoid problems with quality control. Because you’ve made sure your product can be manufactured in a way that’s easy to check for defects, you’ll have fewer defective products going out into the world.

Consequently, you can save time and money by making fewer mistakes during production, and it will further increase the efficiency of your manufacturing process.

Optimize manufacturing speed

Design for the Manufacturing process can speed up the whole manufacturing process, as it makes a part fit for its manufacturing equipment.

For example, if the part fits appropriately into the machine’s dies, cutting tools can do their jobs more efficiently and produce a finished part in less time.

Let the production process be simple and automated

DFM process can make the part easy to manufacture, increasing a product’s automation potential, as there is less need for human oversight.

A simple design alteration can help in simplifying assembly steps, as a result. For example, you may reduce the number of machines used in the production process and eliminate the need for various setups.

Design for Manufacturing and Design for Assembly are two terms that are often confused with one another, but they’re very different things.

Design for Manufacturing (DFM) is designing a product so it can be made cost-effectively. Whereas, Design for Assembly (DFA) is the process of designing a product so it can be easily assembled by the manufacturing companies and/or consumers.

Design for manufacturing focuses on reducing the cost of production by minimizing waste or rework while also maximizing efficiency and throughput.

The goal of DFM is to make sure that each piece fits together correctly and minimizes time spent on quality control while keeping costs low.

On the other hand, Design for Assembly focuses on making sure that assembly is quick and easy to assemble products quickly without errors or confusion. It reduces labor costs by making it easier to assemble components without wasting time or materials.

The goal of DFA is to make assembly easy enough that people who aren’t trained professionals can assemble the product without causing damage or confusion about how everything goes together.

The fundamental principles that should be considered for design for manufacturing (DFM) are as follows:

Process

The right Manufacturing process is essential in product development. When choosing a process, a company should consider several factors – the product’s cost, material, volume, surface finish, post-processing needs, and tolerances – and then select the most appropriate one. It is crucial to finalize the process as soon as possible because other factors highly depend on it.

Design

When designing products, you must ensure that your ideas can be manufactured. You need to know how much your product will cost and how long it will take the manufacturer to produce it. DFM tools can be used in the early design phases to help predict whether a design is practical. Besides, it also helps in reducing the cost and lead times.

Material

During the product development process, you must consider the material you’re using, its grade, and its form. Different materials require different manufacturing processes. You must choose the raw material and shape in the early stages of the development process. This choice depends on your expectations for the product.

The following factors will guide you toward the best material choice for your needs:

Surface finish (includes anodizing, polishing, plating, coating and etc);Opacity (how much light passes through);Flammability (how easily a material burns);Strength (how much weight something can carry);Thermal/electrical resistance (how hot or cold something gets before it changes shape or melts);Machinability (how easy it is to cut with machines).

Service environment

To create a product that functions well, it is crucial to consider the environmental factors of the product’s intended use. When building a product used in extreme temperature conditions, for instance, the specifications will be different from those of a product used in dusty conditions. The difference depends on the intensity and effect these environmental factors have on the product.

Testing

You must always keep testing and compliance requirements in mind while carrying out design for manufacturing activities so that they can prevent any hiccups later on. It will never reach the market when a product is manufactured after significant cost reduction but cannot be passed by certifications.

Regardless of the type of product, the following general rules will be helpful to you in the DFM process:

Minimize your part count by combining parts into a single component whenever possible. There are benefits to using fewer parts in manufacturing and logistics, including decreased cost and improved efficiency. This will also reduce assembly difficulty, make inspection and testing more effortless, and minimize upfront tooling costs.

Orient the parts correctly as it will facilitate handling. If possible, orient them vertically. Use gravity to your advantage. Design each part to be symmetrical; this way, you won’t have to use sensors or other mechanisms to orient the parts during assembly. If you can’t make a part symmetrical, make it asymmetrical and add external guiding features so that it can be installed correctly.

Designers should try to design multi-functional parts that can serve multiple purposes simultaneously. If the company has multiple products or product lines, it will be more cost-effective to design parts that can be used in more than one product.

Consider the design features that facilitate alignments, such as chamfers, tapers, and moderate radius sizes. It can help you avoid costly assembly errors and damage to your parts or equipment.

To create a more complex design, consider using modular assemblies. This will allow you to change individual components and capabilities without redoing the entire product.

Save money, time, resources, and hassle by using standard components. These standardized parts are more accessible to source, cheaper, and quicker to incorporate into the design and lower the BOM.

It’s important to know what kind of finish you want. Adding a finish might make the part more durable, but it will also make the part cost more money. Therefore, to control or reduce cost, determine which dimensions of the part are genuinely critical and which can be less precise, and give more margin on dimensions that aren’t important.

Design parts to fit into fixtures and machine tools to be fixtures and used on automated assembly lines. It would be very difficult for machine tools and assembly stations to accurately position your part for subsequent operations without these features.

Different processes offer different trade-offs in terms of design for manufacturability. For example, injection molding, urethane casting, CNC machining, and 3d printing all have different DFM considerations. Let’s read on more.

For products that will be cast using the urethane casting process, DFM is particularly important in ensuring that the design can be produced without any defects. Injection molding is another manufacturing process where DFM can be very useful in achieving a high quality final product.

In both urethane casting and injection molding, careful attention to detail is required in the design phase to avoid potential problems later on.

DFM in Urethane Casting and Injection Molding

One primary difference between urethane casting and injection molding is that urethane casting typically has lower molded-in stress than injection molding. This is due to the difference in how the two processes produce parts.

Urethane casting involves pouring the liquid urethane into a mold, where it then cures to form the part.

On the other hand, injection molding involves injecting the molten urethane into a pre-made mold cavity. Because of this, injection molded parts tend to have higher molded-in stress than those produced by casting.

Besides, they also have the following differences that need to be considered in the DFM.

The other difference is the complexity of the model. You can usually do it in urethane casting if it’s a simple, one-piece model. If it’s more complex or has many parts, you’ll need to use an injection molding process instead.

Silicone molds used in urethane casting are less durable than molds used in injection Molding, typically made from steel or aluminum.

The cost of creating a urethane casting mold is significantly lower than the cost of creating an injection mold. Molds for urethane casting can be tooled in days, while it can take longer to get injection molds production-ready.

Injection molding requires stricter wall thickness and undercut tolerances than urethane casting.

Key Considerations DFM for Urethane Casting and Injection Molding

Tolerances

Tolerance is the first thing to watch out for during the manufacturing design process. Tolerance refers to the amount of error that a product can tolerate, and it’s often expressed in mils (thousandths of an inch).

Injection-molded parts must be manufactured within extremely tight tolerances to fit together seamlessly. Urethane casting can be more forgiving, but it’s still essential to maintain high precision throughout manufacturing.

So you need to choose the proper manufacturing process. If you’re creating a product with tight tolerances and significant features, you can go for Injection molding. Carbide Steel Inserts Else urethane casting is more economical.

Undercuts

The undercut is one of the significant considerations during the design for manufacturing of the part.

A component has a hole or cavity inside it that prevents you from inserting any tool (like an awl or screwdriver) into that area without damaging its surface or edges.

Undercuts make it difficult for manufacturers to assemble products without damaging them during the assembly process–which is why they’re so important!

Besides, the impact of undercut varies according to the manufacturing process. In the injection molding process, the impact is more as its mold is usually made from steel or aluminum, which is not flexible.

The impact is considerably lower in Urethane casting due to flexible silicone molds that can be bent and stretched while tooling to release the Carbide Stainless Steel Inserts part.

Wall thickness

Another concern is wall thickness—the distance from one side of an object to another (think of a cube). Wall thickness can affect how well your part functions and its durability, so it’s essential to keep tabs on how thick each piece will be before you start producing prototypes.

The thickness of the part must be consistent from one end to another so that the material doesn’t weaken or warp as it cools down during casting or cooling down after injection molding.

In terms of the manufacturing process, CNC machining is a more complex processing method. DFM helps a lot to simplify the process and ensure that all parts are machined correctly.

Why is DFM important in CNC Machining?

In CNC machining, DFM is the process of measuring and monitoring the dimensional accuracy of the part being produced. It is an integral part of controlling variation in the manufacturing process.

Following are the key factors why DFM matters in CNC machining:

Design for manufacturability helps ensure that a manufacturer can make your parts or that your product’s design is manufacturable. This can be the case even if the design has some unique characteristics that have not been seen before in CNC machining, as long as these characteristics do not compromise the product’s performance or other important factors. So, with DFM, design drawings, and CNC prototyping, the designers ensure that the design can be turned into reality or not!

DFM brings together all elements of a product’s design, including parts layouts, heat transfer analysis, and parts design. This makes it easier to identify defects and avoid them during production.

If you don’t have Design for Manufacturing, your production will be delayed while people try to figure out whether or not the products are good. But if you do have DFM, you’ll have fewer mistakes and save production time and money.

DFM Tips for CNC Machined Parts

When selecting a material for CNC parts, consider the strength and hardness of the material and its compatibility with the machining process.

It’s essential to make sure that the parts of your CNC machine are accessible. If the machine can’t reach its parts, production efficiency will decrease, and manufacturing costs will rise.

All CNC drills have a circular shape, making it difficult to achieve sharp internal corners. Therefore, it is better to avoid sharp inside corners whenever possible.

To machine a hole in metal, use a drill bit or an end mill tool.

When using a CNC machine to make thin-walled products, you need to be careful. The product walls will be weaker and more likely to warp or soften than usual. Consequently, reducing the product reliability and quality. Therefore, try keeping the wall thickness above 0.02″.

Tight tolerances are essential for some parts, but using tight tolerances can increase costs when they’re not needed.

When deep pockets are an integral part of your product, the best approach is to either reduce their depth or increase their width.

Design your parts for functionality rather than appearance to lower cost and minimize the lead time for CNC machining services. Consider simplifying or eliminating any features that aren’t critical to the part’s function.

To save costs and time on machining, it’s best to design chamfers rather than fillets as exterior features on your CNC machined parts.

When designing components for an assembly, we recommend leaving 0.1″ (2.54 mm) clearances between parts to ensure a proper fit.

DFM is especially important when it comes to 3D printing, as the technology is widely used, and there are many details that should attend.

What is DFAM (Design for Additive Manufacturing)?

DFAM is a design philosophy that focuses on creating products that are easy to 3D print. This means using materials that are compatible with the additive manufacturing process, designing parts that can be printed without supports or rafts, and making sure that the design of your product doesn’t require any complicated support material or post-processing after it’s printed.

Designing for additive manufacturing can help you save time and money by making it possible to print larger quantities of your product faster and with lower material costs and usage.

How to Design for 3D Printing Manufacturing?

If you want your 3D printed product to be successful, you must take the time to design for 3D printing manufacturing. This means making sure that your design is adaptable and flexible enough to be manufactured with relative ease.

There are opportunities to reduce lead times and manufacturing costs both in your product and your production line. By streamlining your processes and making improvements where possible, you can minimize waste and save time and money.

Here are some tips on how to design for 3D printing manufacturing:

Please make sure all parts are removable or interchangeable to be easily replaced by the manufacturer as necessary.

Include as few moving parts as possible—this will ensure that the product will last longer in the field, which will help boost sales!

Pay attention to the types of materials used in manufacturing; if possible, choose durable or reusable materials so they can easily be recycled or reused when necessary.

Ensure your design is optimized for the most efficient use of materials. For example, if you have a product with many small parts, it could be cheaper to print them in two or three larger parts instead of printing each part individually using more material.

Try 3D printing the product in different orientations to see which one gives you the strongest result with the least amount of support material.

Ensure that the wall’s thickness of the 3D printed part is in the right proportion to your printer’s bead thickness. This will optimize build times, reduce material cost and usage, and increase product quality and durability.

Ensure your part height is a whole multiple of your printer’s Z thickness. It will reduce manufacturing costs and time.


The Carbide Inserts Blog: http://wide.blog.jp/
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