How deep can you cnc
How deep can you cnc
(OP)
I am not sure if this is possible, but I am attempting to design this part with 0.125" radius inside total depth of 60mm. It is aluminum. I ran a check in solidworks and it mentions a depth error. Without EDM is there a way to cnc this part. The center wall is 1.5mm thick also. The part is 1" x 2.5" x 2.4" depth. The holes would go right through the part. Is this possible
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RE: How deep can you cnc
RE: How deep can you cnc
RE: How deep can you cnc
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RE: How deep can you cnc
Alternatives are probably numerous and depend on what your application, dimensional tolerances, and production volume will allow. More information about how the part would be used and how many would be made would probably help get better suggestions.
RE: How deep can you cnc
"Art without engineering is dreaming; Engineering without art is calculating."
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RE: How deep can you cnc
How high of volume part is this? Impact extrusion may be worth checking into, as well as diecasting.
It is better to have enough ideas for some of them to be wrong, than to be always right by having no ideas at all.
RE: How deep can you cnc
Comprehension is not understanding. Understanding is not wisdom. And it is wisdom that gives us the ability to apply what we know, to our real world situations
RE: How deep can you cnc
Even drilling the corners, you're going to get a lot of chatter from a depth like that trying to mill it.
It is better to have enough ideas for some of them to be wrong, than to be always right by having no ideas at all.
RE: How deep can you cnc
RE: How deep can you cnc
Does the part have to be done by CNC?
The corners may be doable with a broach.
The ultra deep radii may be doable by using a very slow feed, making the part much more expensive than it would be with more reasonable dimensions. Maybe this is acceptable to you.
If your radius is .125", the CNC people will not use a Ø.250" cutter. They will use something smaller, so that they can feed all the way through the radius.
Have you talked to a machine shop yet. If they come back and say they can do it, somehow, you should be fine!
--
JHG
RE: How deep can you cnc
If CNC is an absolute must, hog out with a larger bit, and then carefully plunge cut the corners from both ends with a Ø1/4 slot drill. Clean up the run-outs with same or end mill.
RE: How deep can you cnc
RE: How deep can you cnc
It's only 60 mm - just over 2 in deep "pockets" - so do the pocket next. Flat bottom, to the right depth. You have room now, so use a shorter end mill that's fairly rigid: may a 1/2 inch dia. Go the the exact depth across the floor.
Change tools to a finishing 1/4 inch dia ball end mill; but "aim" the tool so it is angled down and into the 4x corners at a 45 degree down angle, 45 degree sideways angle. Trim the 4x corners with the 0.250 ball bit so you are cutting from the top down cutting a radius in the radius in the corners with a rigid tool.
RE: How deep can you cnc
John Acosta, GDTP S-0731
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RE: How deep can you cnc
If I had only ~6,000 rpm available, I might hog out the pocket with big indexable 2flute drills of a diameter nearly the smaller pocket side dimension, then broach the remainder of the pocket and the corners.
OR just let the CNC owner decide how to make the moderately deep through pockets with moderately difficult corner radii. There are a near infinite number of ways to do it with canned cycles, and shortest cut time may not be optimal for cost, considering cutter and machine availability, chip removal, presence or absence of an attendant, etc.
I.e., just send it out for quotes, with a full set of dimensions and tolerances please, and see what you get back.
Mike Halloran
Pembroke Pines, FL, USA
RE: How deep can you cnc
If the internal finish is important and you need the 60mm pocket depth then another option would be to split the part in two (or 3) and then vacuum braze them together.
Wave guides are made this way sometimes.
The 60mm depth requirement is somewhat confusing if the holes go all the way through...if you could post another picture showing that detail it might help everyone understand your requirement better.
TobyK
RE: How deep can you cnc
Mike Halloran
Pembroke Pines, FL, USA
RE: How deep can you cnc
Regards,
Terry