Month: November 2024

Lathes are incredibly versatile machines. They’ve been used in one form or another for thousands of years to make tools, furniture, parts, and more. Of course, the CNC lathes used in today’s machines shops are much more sophisticated than their ancient predecessors. Keep reading to learn more about these amazing feats of engineering.

How a CNC Lathe Works

There is a wide range of equipment available in a machine shop, but CNC lathes create unique shapes that can’t be easily made through other machining methods. CNC turning is unique to lathes and turning centers, creating shapes like cylinders, cones, disks, and other objects with axial symmetry.

The most basic parts of a lathe typically include a:

1. Headstock, main spindle, and chuck,
2. Tailstock,
3. Tool turret or tool holder, and
4. Machine bed.

While most modern CNC lathes will include a wide range of additional features, these 4 components are essential to even the simplest lathes. The headstock, main spindle, and chuck are used to grip the workpiece and provide the turning power. To provide support and stability, the tailstock supports the opposite end of the workpiece, which is most important for longer parts.

CNC lathes can support an assortment of specialized tooling for turning, and this is either attached independently between cutting operations to a tool holder or controlled by a tool turret. Depending on the number of machining axis a lathe has, its tooling can slide left, right, up, down, forward, or backward along the length of the machine bed to perform cutting operations.

What are CNC Lathes Used For?

Historically, lathes were used to make items like wooden handles for tools, legs for furniture and handrails, bowls and dishes, architectural pillars, and more. As lathes became more advanced and started to use electrical power, they could effectively produce parts more rapidly and from a wider range of materials, including metals. They could also do so with more precision than ever before.

Nowadays, the use of computer numerical control (CNC) in lathes makes turning operations faster and more precise than ever before. CNC lathes are well-suited to both custom, one-of-a-kind projects and mass production operations.

Applications for CNC lathes include:

• Fasteners, like bolts and screws
• Household goods, like furniture legs, decorative fixtures, and cookware
• Automotive parts, like bearings, wheels, and crankshafts
• Medical equipment, like surgical tools or prosthetics made from advanced materials
• Aerospace parts, like engine parts or components of landing gear

In summary, CNC lathes are used for precisely and efficiently producing a wide range of high-grade industrial and consumer products.

Precision Turning Services from Gensun

CNC lathes can create an impressive variety of parts for a wide range of applications. The experienced team at Gensun offers top-of-the-line CNC turning services to help make sure your next product design is consistently manufactured to meet tight tolerances at a competitive price.

Injection molding flash is a defect that occurs when molten plastic flows out of the mold during injection and solidifies. This defect lowers the quality of the molded part and can destroy the mold. As a result, it is important to know the causes of flashing, the right fixes, and defect prevention. This article talks about everything you need to know about plastic injection molding flash so that you can fix or avoid the defect.

What is Flash in Injection Molding?

An injection molding flash occurs when a thin film of plastic flows out of the mold cavity during the injection. It arises from several causes, such as high injection rate and pressure, and occurs majorly at the parting line (it can also emerge from other locations).

On escaping the mold cavity, the molten plastic solidifies outside, resembling flapping which can be aesthetically displeasing or non-functional. As a result, there is a need to remove them in high and low-volume injection molding or they can damage the mold.

What Causes Injection Molding Flash?

There are several reasons why you can experience plastic injection molding flash. Below are a few you should be wary of during part injection molding:

Parting Line Mismatches

The mold’s parting line is the line where the two halves of the mold meet. A mismatch in the parting line due to debris or bad design can prevent the complete sealing of the mold. As a result, molten plastic will be leaked during the injection.

Improper Venting

Improper venting can lead to the inability of air to escape the mold cavity during the injection. When this occurs, it can lead to the compressed trapped air increasing the injection mold pressure and forcing the molten material. Venting problems can also be due to old/worn-out vents, which may permit too little or too much air to escape.

Clamping Pressure

Clamping pressure is the force required to keep the mold closed during the injection process. When there is a problem with the clamping pressure, even with a perfect parting line, the high injection pressure built up in the mold can cause it to be forced open. As a result, this can cause an injection molding flash.

Low Viscosity

Molten plastic with low viscosity flows out of the mold readily. Viscosity is how easily the molten material flows, depending on the operating temperature and pressure. Furthermore, the pressure and the temperature of the nozzle and barrel can increase the viscosity of the molten material and contribute to the formation of an injection molding flash. As a result, there is a high tendency for the error defect to occur.

Overfilling the Mold

Overfilling the mold with the material will naturally result in leakage due to increased injection pressure greater than the clamping pressure. These extra materials from the cavity will attach to the final product, creating flashes.

Ways to Fix Flash in Injection Molding Process

If you have experienced flash injection molding already, there are several ways to fix the defect. Below are the common solutions you can try:

1. Using Hot Air

In the occurrence of injection molding flash, you can melt the flash into the formed plastic using hot air. However, this is only suitable for removing thin and fine flashes. For coarse flashes, it may not be easy to melt back into the part’s surface, or it can compromise the final product’s appearance. Instead, you can use hot air as the secondary deflashing method after mechanically removing the flash.

2. Cryogenic Deflashing

Cryogenic deflashing is the most effective way to fix flashing in injection molding. It involves cooling down the part using liquid nitrogen to a temperature where the flash is easily removable. The process does not affect the finish of the parts. However, commercially available cryogenic deflashing machines are expensive.

3. Manual Deflashing

Manual deflashing is popular because of its versatility. It involves cutting the injection mold flash using equipment such as scissors, knives, and grinders. This removes flashes along the parting line of the final product.
Almost all engineering materials can be subjected to manual deflashing. Deflashing by hand produces the highest quality (although this depends on the operator) without putting the material under stress. Furthermore, it enables quick inspection during the deflashing process.

4. Using Open Flame

Occasionally, you can use an open flame for deflashing. However, this can alter the material’s surface, making it aesthetically devalued and more difficult for post-processing options such as painting.

How to Prevent Flash in Injection Molding?

Instead of fixing flash in injection molding, the better approach is to prevent its occurrence. Below are a few ways to prevent injection mold flash:

Proper Cleaning and Maintenance of Mold

Cleaning up mold is necessary to prevent injection molding flash. To do this, you can use a clean rag, mold cleanser, and compressed air to clean the surface of molds. Before the molding process, ensure to remove debris, plastic, and other contaminants that can prevent the mold from fully closing. Furthermore, examine the mold carefully for plastic fragments hiding behind slides and deep into the leader pins’ pockets.

Apply Enough Clamp Tonnage

The success of a molding process depends on the tonnage, point of force exertion, and the clamping mechanism. However, you should be careful because using too much force can damage the mold and the final part. To prevent flash and other damages, apply the correct clamp tonnage.

Design for Manufacturability (DFM)

DfM is an effective way of preventing flash injection molding. It is a set of design rules advocated by the industry so that you can manufacture parts at a low cost in the shortest time with the highest quality. With a properly done DfM, you can get various parameters such as ideal injection mold gate design, wall thickness, hole design, and mold parting line design to produce a flash-free part.

This is very important in prototype injection molding. However, note that the more the complexity, the need for features such as undercuts are used in undercut injection molding which can increase the injection mold cost.

Use a Flash-free Mold

Avoid flash in your molded parts by using a flash-free mold. The mold has high injection molding tolerance and is perfect where aesthetics and functionality are important. Though they guarantee the best results, many businesses may be unable to afford them.

Slow Down the Injection Rate

A high injection rate increases the pressure of injecting molten plastic. As a result, there is an increasing tendency for injection molding. Slowing down the injection rate will reduce the injection pressure. However, reducing the injection rate will also lengthen the cycle time.

Other Injection Molding Defects

Aside from flash, other defects can occur during injection molding. Below are the common injection molding defects you can experience:

1. Weld lines

A weld line develops when two or more flow fronts come together but do not meld completely because of partial solidification. This defect occurs due to the temperature and pressure not being high enough, causing premature solidification. To prevent weld lines, increase the pressure and temperature. Also, adjust the wall thickness to provide a different fill time.

2. Surface Delamination

Surface delamination occurs when the surface of the molded component comes off. Although it can happen anywhere on the molded part, the defect frequently happens in the gate area.

Contaminated material is the major cause of surface delamination. Additionally, the surface of a material can peel off layer by layer when excessive moisture heats up and produces steam. To prevent surface delamination, ensure the material is free of any impurities or incompatible polymers.

3. Jetting

Jetting occurs due to uneven solidification as the initial plastic entering the cavity starts hardening up before the cavity gets filled up. This forms a skin of cooled plastics. Reducing injection pressure and increasing the temperature of the material will delay the early solidification of the initial jet of the material.

4. Cracking

Cracking is commonly seen at the weld line area but sometimes on the entire surface. The primary cause of cracking is stress and deformation brought on by the external environment, cold mold surfaces, and low injection rates. Increase the injection speed and mold/operational temperature to prevent fracture or surface breakdown.

5. Flow Lines

Flow lines occur as a wavering or ring-shaped pattern on the plastic part that can affect the part’s function or aesthetic. These patterns usually develop due to changes in the plastic cooling rate as it flows through the mold in various directions. You can prevent flow lines by increasing the injection rate and molding pressure and ensuring that the plastic resin cools before filling the cavity.

Conclusion

Mold flash is a defect that lowers product quality and destroys the mold. There are several causes of flashing. Therefore, this article talked about the causes, solutions, and how to prevent injection molding flash. Hope this article will solve your questions. If you would like to learn more about rapid injection molding, please contact WayKen.

FAQ

What is the most effective way to stop flash in injection molding?

The most effective remedy is to slow the injection rate to reduce the injection pressure and molten plastic viscosity. Another would be to increase the clamping pressure.

Which is better between hot air and cryogenic deflashing?

It depends on the type of mold flash. Both are suitable for large mold flashes, although cryogenic deflashing has advantages as it does not use heat. However, hot air can melt the flash to its original part, making it suitable for small and fine flashes.

What is the major cause of mold flash?

The major cause is the molten plastic leakage along the mold’s parting line due to high injection pressure and a weakly designed parting line.

Computer Numerical Control (CNC) machining is the type of manufacturing in which parts are made with the help of numerical codes. There are a lot of advantages of CNC machining like it increases the speed of parts production and reduces a lot of manufacturing time in case of the production of identical parts.

It also reduces human errors during manufacturing as it is being controlled by the computer. CNC machining is also preferred for the production of complex parts with precision.

3D printing differs from CNC operations as it is an additive type of manufacturing. For the production of plastic and lower quality materials, 3D printing is preferred. However, when you are required to cut the products with precision and a high number of identical products is required then CNC machining is preferred instead of 3D printing.

The products of various materials can be made with the use of CNC machines i.e. metals, alloys, and plastics. The cost of 3D printing services is not preferred for mass production. The cost required to manufacture products using CNC technology depends on different factors.

In this article, different factors are discussed that are affecting the CNC machining cost. It will help you to calculate the CNC machining costs and provide tips to reduce them.

9 Factors affecting the calculation of CNC machining cost

CNC machining costs may vary depending upon different factors as discussed below:

1. CNC Machine costs

Machining cost changes with the change of type of the machine. Mainly, there are two types of machines that are being used for manufacturing parts using CNC machining i.e. 3 axis and multi-axis machines.

The machine cost is also dependent on various factors like the size & weight of the machine, speed, power, and machine configuration.

The machining cost is calculated per hour and the approximate cost of 3 axis CNC machining is around 40$ per hour while for CNC turning machines it is about 35$ per hour. The hourly rate of CNC machining using multi-axis machines is comparatively more ranges between 75$ and 125$.

Due to the involvement of more complex parts, CNC milling is more expensive than other types of machining operations. The machining expenditures increase with the increase in axes of the milling machines. For example, in the case of 5 axis machining, it costs more as compared to 3 axis machines.

2. Machining time

The time required for complete machining of any CNC machined part also plays a vital role in the calculation of the CNC machining cost. It is the rule of thumb, that the more time taken for machining more will have the cost of the machining which add up to the basic setup cost.

Software like CAM, which requires a 3D CAD design model, can provide the estimation of the time required for the completion of the project. A project with a high level of complexity requires more hours to complete.

3. Labor

One of the advantages of CNC machining, as compared to manual machining, is that it reduces the number of laborers that are involved in manufacturing. The primary cost of the labor is of the expert designer who designs the 3D CAD design model for the machining which increases with the complexity of the desired product.

This cost remains the same even you are required to manufacture more parts which reduce the per part machining price. Then, the additional cost is of the labor who operates the CNC machine which also increases with the increased hours required for complete machining of the part.

The extra cost is added to the labor cost if manual work is done to assemble, finish, and post-process the parts. The extra labor cost is also added if the finished product is being delivered from the machine shop to the client at a different location.

4. Shape complexity and dimensions

The machining cost is also increased with the increase in complexity of the CNC machined parts. The parts with higher complexity may require more process operations, different tools, and more production time.

The part features like sharp internal corners, deep cavities, or thin wall increases the CNC machining cost. The designs with simple features are easy to manufacture and also save manufacturing time.

The parts with larger dimensions require more raw material and time to manufacture, so their cost will be higher as compared to the smaller parts.

5. Material costs

The material costs are also imperative in calculating the cost of CNC machining. The price of the final product made by a CNC machine depends upon the type of materials of which you are required to make the product. You may be required to make part of plastic or metal materials.

As the plastic materials are cheaper and of less durability, the machining cost of plastic or aluminum material is less as compared to stainless steel. As in CNC machines, the material is removed from the solid blocks to make the 3D object. so, the required raw material will be more than the material of the final product.

The machinists buy the materials in the form of solid blocks and calculate the expense of the product per block. The most commonly used metals in CNC machining are Aluminum, Stainless Steel, and Brass.

Due to the economical prices and excellent machinability of aluminum, most machinists use aluminum in CNC machines.

Stainless Steel and brass result in more cost due to poor machinability relative to aluminum. The titanium alloy is the most expensive of all these metals so the machining cost of this metal will be the highest because it may require some special tools to manufacture the parts.

In case of the plastics, the price of the bulk material is less, tools required also cost less and less time is required to machine the plastics like Nylon, Delrin, and ABS.

6. Surface finishing

In the case of some products, surface finishing is required which also results in an increase in the price of the final products. In order to improve the aesthetic of the final product and remove any scratches made during the machining process, you may require to provide a good finish like polishing.

Other finishing processes may also include coating, anodizing, painting, chroming, blacking, galvanizing, brushing, and water transferring. The inclusion of any of these finishes will add the extra cost to the price of the final product.

7. Tooling cost

In some cases of manufacturing, standard tooling is not useful so custom tooling is required which also increases the manufacturing cost using CNC machines.

8. Tolerances

In manufacturing the products with tight tolerances, the cost will also increase because fabricating parts with tight tolerances requires complex machinery. Sometimes you may be required to make holes or cavities with tight tolerances which may develop burrs on the surface and will spend more time to reduce it.

9. Quantity

The volume of the order tremendously affects the cost of the final product. It is true that the overall cost will increase with the increase of required finished parts but the cost per part will decrease.

3 Tips to Save CNC Machining Cost

Before the start of the project, it is calculated how much will be the CNC machine cost. While manufacturing the parts with the CNC machining process, one should try to minimize the machining cost.

There are some fixed requirements from the client which can’t be modified but still, there are different methods to reduce the machining cost as follows:

1. Quantity

A lot of machining costs can be saved if you are required to make parts in larger numbers. The cost per unit part will be decreased because you have to design the identical part once. In this case, you are required to repeat the machine setup for each part which also results in a decrease in production cost.

2. Be wise in Material Selection

In order to reduce the cost of the product, special attention should be paid to the selection of materials. Materials with good mechanical properties will have lower processing costs. Keeping in mind the function of the product, you must choose the best available material that is easy to process. There is a difference in price between plastic and metal materials. Of course, you can follow the needs of your project and let your manufacturer give you more advice on material selection.

3. Design Optimization

If some features of the product don’t affect the functionality, the design should be optimized to avoid machining those features which will reduce the production cost.

(1) Consider Hole sizes and profiles

When fabricating your CNC parts, you should ensure that your part features (e.g., holes, contours, slots, threads, etc.) can be made with standard toolings commonly available. Custom hole and thread sizes will need special tools, which can be quite expensive. There are many references about standard sizes used in the machining industry available on the internet.

(2) Avoid thin walls and deep cavities for your part design

Thin-walled parts and deep cavities are very challenging to achieve through machining, and they are usually prone to dimensional inaccuracies. These part features tend to cause vibration on the part and sometimes lead to the scrappage of parts.

(3) Avoid requiring very tight tolerances as much as possible

Parts with tighter tolerances are significantly harder to achieve, hence making them expensive. Only control a dimension if it is essential to the part’s overall functionality. One great piece of advice we can give you is to design your part to have one common reference point or datum. This will both help you and the machinist. First, you, to minimize the dimensional controls you need to put on a part, and second, the machinist, to lessen the inspection time, which also reduces costs.

(4) If complexity is inevitable, convert one piece of that complicated part into modular components instead

When one part gets too complex, it is advisable to split one whole part into multiple components to be assembled. This will make machining much easier and simpler. It significantly reduces set-up time, lessens machining operations, and optimizes machining time. This is a strategy commonly used by designers to promote a part’s manufacturability and lessen its fabrication cost.

Looking for more tips to save the cost of CNC machining? Let’s check this video.

FAQs

Q: Is CNC machining expensive?

A: The product made by CNC machining will be less expensive if it is manufactured in a larger number. For example, you are asked to make a product for which the machine setup cost is $500. The raw material for one product costs 10$.

The overall machining cost of the one will be 510$. But if you have to make 50 identical parts then the cost per part will be 20$. With the increase in the number of required parts, the cost will be decreased as machine setup costs will not be changing.

Q: How do you effectively reduce CNC machining costs?

A: The cost of CNC operations can be minimized by optimizing the design without affecting the complete functionality of the product. It can be done by adding radius in internal vertical edges of the part, limiting the depth of the cavities, increasing the thickness of the walls, properly limiting the length of the threads, optimizing the tapped holes, by splitting the complicated parts into simpler separate parts, by choosing only essential surface finishes, and minimizing the number of the machine setups for operations.

Conclusion

There are various approaches to manufacture our desired products like 3D printing and CNC machining. Every customer has a desire to get an affordable product from the manufacturing company. The different factors, to calculate the machining cost and reduce money spent on the product, are discussed in this article.

By adopting above mentioned tips, WayKen follows DFM and is committed to providing cost-effective CNC machining solutions which an average of 30% lower quotes than competitors. Please feel free to get an instant quote!

Undercut injection molding is a process used to create parts with complex shapes and features that prevent removing the part from the mold without any damage. Undercut features in injection molding generally increase any design’s overall complexity and associated costs. For these reasons, it is better to avoid them whenever possible.

In this article, we will explore in detail when will undercuts occur in injection molding and various methods used to create undercuts.

What Situations Make Undercuts Injection Molding Necessary?

There are many scenarios where undercut injection molding becomes necessary, but here are some common ones.

1. Custom Inserts

Using the undercut injection molding process, you can create custom inserts that fit into larger parts. Machinists often use this insert type in medical devices or products that need an exact fit. You can also use undercut inserts as an alternative to screws or rivets when attaching two pieces.

2. Side Holes

Undercut injection molding can create side holes that are difficult to produce using traditional methods. Machinists often use side holes for mounting components or attaching them to other pieces of equipment. You can also use them for aesthetic purposes, such as adding a design element or venting heat inside the product.

3. Vertical Threads

Vertical threads are another common use for undercut injection molding. These threads are commonly found on bolts and screws, but you can also use them as part of an assembly where multiple parts need to thread together to work properly together as one unit.

4. Barb Fittings

In the case of barb fittings, the male parts need to be undercut to form a lip, holding the female mating part of the barb fitting.

5. Interlocking Features

If you are designing an interlocking feature, such as a tongue and groove, you must undercut one side of the tongue so you can mate the side with the groove on another.

Challenges Faced With Undercuts in Injection Molding

The major challenges of injection molding undercut result from the design, choice of materials, and aesthetic requirements of the machined part.

1. Lack of Draft

The more complicated the arrangement is, the more issues you’ll find with the undercut design. Everything begins there. It would be best to control draft angles, cavity angles, and other complex angles for the greatest performance. To reduce the possibility of any ejection process difficulties, you must make the coating on the hand load of the proper substance.

2. Difficulty in Pulling Materials from Mold

It might be difficult to include undercut characteristics in some materials. For example, some materials, including plastics with glass filling, are more challenging to remove from the mold. According to the general rule of thumb, the harder the material is, the more difficulties you’ll have in extracting it. Therefore, use as much draft as possible while employing these tougher materials. Additionally, the solution you may employ to maximize your undercut molding depends on the material’s general flexibility and elasticity.

3. Aesthetic Consideration

The project’s aesthetic demands may provide another significant obstacle. For example, the undercut design option you can employ will have certain restrictions if you work with a component where you don’t want a noticeable parting line on injection molded parts or any other aesthetic concern. You’ll consequently have to cope with extra difficulties.

Different Ways to Use Undercut Successfully in Molded Parts

Success with undercuts necessitates small mold alterations and a high level of competence. Some of the designs that can assist minimize mold flaws and wear include the following.

1. Use Hand-Loaded Inserts

Machinists employ hand-loaded inserts when it is necessary to include an undercut in machining for challenging features like a lip with a sharp angle. They also come in handy when an additional feature like an awkwardly placed hole makes it impossible to use a standard solution such as a bumpoff.

To make use of a hand-loaded insert, the operator inserts one or more metal pieces into the mold before injecting the plastic. The number and position of the pieces depend on how many undercuts the machined piece needs. These metal pieces effectively create a cavity as they prevent the plastic from flowing into the spaces they occupy.

Once the operator opens the mold after the item has been created, they have to recover the hand-loaded insert physically. The disadvantage is that it increases the injection molding cost and cycle time as the operator must load and unload each cavity individually.

2. Part Lines Placement

Moving the mold’s parting line to overlap an undercut is sometimes the simplest way to deal with undercuts. The rationale is that when the feature is split in half by the parting line, the operator can release the component from the mold without needing an undercut. Machinists can zigzag the parting line using his method to align with different features, eliminating the need for undercuts. There are, however, limitations to this method. These range from the geometry and the flow properties of the plastic.

3. Insert Bumpoffs

Bump-offs are a good choice when working with flexible and elastic fabrics. The process only differs from the standard injection molding process by adding a single insert. The operator removes this insert first after the completion of the procedure. The vacuum it leaves behind gives the component some ‘wiggle room.’ Once removes the insert, they can take the part out of the mold. The “wiggle room” allows the machinist to bend the part slightly while taking it out of the mold, even with the presence of the undercut.

While bump-offs may appear to be relatively straightforward from the outside, using them necessitates careful consideration of several things. First, the part must be elastic enough not to break when the machine operator bends it. Also, the operator must ensure that the lead angle ranges from 30 to 40 degrees.

4. Side Actions

In cases where having an undercut is unavoidable, a side-action feature can help to keep the part functional. A side-action core is an insert that is introduced before the plastic is injected into the mold. When the operator injects the material into the mold, it cannot fill the volume occupied by this insert. The machinist then slides the insert out after the completion of the molding.

However, unlike the case with bump-offs where the machinist removes the insert before the part, they remove the side action cores after taking out the part. Side actions also work best with rigid materials that do not adhere easily to the surface of the mold. One disadvantage of side actions is that each insert has to be specifically designed, making the procedure more complex.

5. Make Use of Shutoffs

Machinists use sliding shutoffs when a feature, such as a hook sticking out from the side of a molding, cannot be easily made by another method. You insert a sliding cutoff through the hole in the main component’s wall to produce the undercut and the hook. The other half of the mold will create the remaining hook feature.

The problem with sliding shutoffs is that they must be exceedingly tight. This is because you cannot allow the plastic to develop past the feature’s shape if you need to use them as two mating sections of a tool. If not, it will cause substantial friction whenever you open and shut the tool.

In addition, you must draft each of those surfaces by about three degrees to prevent mold damage, which would quickly result in molded parts with an unacceptable finish. This is necessary because full metal-to-metal contact won’t occur until the mold is fully closed and a mechanical seal forms between the two faces.

Applications of Undercut in Injection Molding

Undercut injection molding is widely used in numerous sectors due to its capability to turn out products with undercut characteristics. We have selected a handful of these industries and explained them below.

Consumer Electronics

In this application, we use other methods to form features such as buttons and flanges that are difficult to achieve. Undercuts are also used to create cavities for electronic components in consumer electronics like mobile phones and laptops.

Medical Devices

Using other methods like injection molding or machining, you can use undercuts to create complex geometries that you cannot easily manufacture. In medical devices like syringes and catheters, undercuts create grooves along their length, allowing them to function properly.

WayKen Helps You Solve the Undercutting Problem Effectively

The undercut injection molding process can be complicated and requires a lot of experience to execute properly. At WayKen, no matter undercut injection molding or undercut in machining, we can handle all your undercuts requirements and deliver the best results consistently.

WayKen also provides high-quality rapid tooling and prototype injection molding services designed to get your product developed quickly and efficiently. Contact us for an instant quote and get DFM to help you optimize your part design and minimize any complexities.

Conclusion

There are numerous reasons for utilizing undercuts in your design process. First, identifying your components’ moldability is vital when designing any part for Injection Molding. Whether a straight wall design or an undercut, you must build the geometry to precise specifications to allow the plastic to flow properly and produce a part with minimal defects.

FAQ

What are undercuts in injection molding?

An undercut in molding is a depression or protrusion in a form that prevents it from being withdrawn from a one-piece mold. Undercuts on molded components prevent the part from being discharged straight from an injection molding machine. They can be either internal or external undercuts, with external undercuts on the outside of the component and interior undercuts on the inside.

What is the undercut process?

When extracting the component from the mold, you need some mechanisms to adjust the portion of the mold that touches the undercut to take part from the mold since the part is not directly detachable without the device. This is the Undercut procedure.

What is a “parting line” in injection molding?

The parting line denotes the direction of the mold’s line of the draw or the point at which the machinist separates the two halves of the mold without causing harm to the part. The separating line is usually down the center of the part. However, this changes depending on the part shape.

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Conclusion

The JINPENG Cargo Electric Tricycle provides a convenient, safe and safe mode of transportation. This tricycle redefines perfection with its high-transparency headlamps, safety signals, foam-cushioned seats, and adjustable cargo space. Put your faith in JINPENG’s dedication to innovation and select a tricycle that puts comfort, safety, and versatility first. With the JINPENG Cargo Electric Tricycle, you can travel with safety and enjoyment, and we’ll be by your side on all the roads you take.

3D printing is one of the most rapid developments in recent years compared to traditional processing methods, and it is becoming more convenient and cost-effective. It has many key factors. Such as material factors, printing technology, resolution of the model file, wall thickness, etc. The wall thickness is often the initial stage of the design and should be the most necessary factor to consider, as you will only find out after the print is completed that an unsuitable wall thickness will frustrate you.

What is the wall thickness?

Wall thickness is a very important concept in 3d printing, wall thickness is the distance between the inner and outer surface of the model, the minimum wall thickness directly determines the strength of the printed item, and even determines whether the item can be printed. A reasonable wall thickness can be used for many benefits, including optimizing the structure, saving costs, avoiding various accidents, etc. It can not only show your design perfectly but also make it perform better in the work.

Why should You consider the right wall thickness?

Thick wall thickness is undoubtedly the better choice for parts in some particularly high-strength operating environments. However, reducing the wall thickness seems to be more cost-effective and the benefits of a lighter wall thickness can be even more pronounced when the function and strength of the part are not compromised. For example：

1. Save time and costs for printing, allowing for faster cooling and achieving higher output ratios.

2. Warpage from the cooling process is largely avoided.

3. The lighter weight allows for easier transportation and management.

Noteworthy, The wall thickness of the part is not the thinner the better, but the best choice is to reduce the unnecessary wall thickness according to the structure and shape of the different requirements, taking into account the difficulty of printing and the requirements of the part while ensuring its functionality.

The consequences of unsuitable wall thickness

3D printed parts often have thin walls that bend and parts that warp, either because the walls are too thin or because support structures are not used to keep the part in place during the printing process. Since printers work layer by layer, it is important to make sure that the layers are in stable contact with each other and have additional support during the printing process, just like building a building, we need concrete to be tightly bonded and reinforcing steel to support it.

(1) Warping

Warping refers to the printing process, the bottom corners of the object appear upward curved, the light will make the object deformation, and the heavy will make the object fall off on the way to print so that the print completely failed. The cause of warping is due to the shrinkage of the print material when it cools down after coming out of the high heat nozzle, and if the shrinkage around the large object is larger when printing, it will appear deformation. ABS material is more severe than PLA shrinkage, so the printing of large objects with ABS is a very difficult thing.

(2) Curling

Curling is a common problem in the 3D printing process, which is due to the principle of thermal expansion and contraction of the printing material, making the model and the printing platform in contact with the bottom edge is more likely to warp, or even off the platform, the lighter the impact on the printing effect, causing deformation of the bottom of the model, the heavier it will lead to print failure.

Choose the uniform wall thickness

Uniform wall thickness is very necessary for the cooling process of 3D printing. By joining parts with a large difference in thickness in certain excessive parts, then this part is likely to warp, crack, kettle, or even affect the whole during the cooling process. To avoid the effects due to stress and shrinkage, a consistent and uniform wall thickness is the best choice, even if a consistent wall thickness cannot be guaranteed, then a gradually excessive wall thickness is a good approach.

4 Factors to be considered in designing wall thickness

(1) Material

Each material has its inherent properties, there are fragile, there are strong, there are glossy, there are rough, there are light, there are heavy, and so on. Different materials have different design principles

Different materials use different printing technology, ABS / PLA using FDM; nylon, aluminum using SLS; resin using SLA or DLP. various printing technology to create the surface effect varies, there is a point of different printing technology printers print size space is not the same, the print post-processing methods are different, some complex, some simple 

(2) Product working environment and function

Is the product’s working environment high temperature, high humidity?

Whether the product will be exposed to sunlight and wind for a long time?

Does the product need to work in a high-load environment?

Does the product need to be transparent or have good optical properties?

Does the product need a specified color, whether it is the color of the material itself or achieved by spray painting?

 (3) Design of the product

The shape and size of the product, reinforcements, rounded corners, bevels, and transitions are all referenced by the wall thickness. The wall thickness of the product depends on the final demand of the product and the external force that the product needs to withstand, whether it is under the pressure of other parts or needs to be used as a supporting part for other parts. The wall thickness is determined based on the initial design of the product to simulate the scenario when it actually works, the weight, properties, electrical properties, stability, dimensional accuracy, and assembly requirements of the final product.

(4) Cost

A thin wall is the most material cost-saving option, but it is also potentially the most costly option because there is a high probability that the item printed to save material cost will fail. Redesigning and printing not only wastes more material but also wastes valuable time. Designing and printing the wall thickness of an item based on its size, capacity, and working environment is undoubtedly the best option if the optimal wall thickness can be determined based on these.

conclusion

After considering all of the above, I believe you have a suitable choice of material and wall thickness. Of course, before your solution is finalized, you can still make inquiries to our engineers and we will recommend you more candidate materials and detailed processing solutions. Get in touch with WayKen and get our advice.

As JINPENG, we take pride in introducing you to our exceptional range of 3 wheel electric trikes. Our commitment to quality and innovation has made us a leader in the industry, and we are excited to showcase our versatile and eco-friendly electric trikes to you.

Know about a 3 Wheel Electric Trike

A 3 wheel electric trike, also known as a tricycle, is a three-wheeled vehicle equipped with a powerful electric motor. It is designed to provide efficient and sustainable transportation solutions for various purposes, including cargo transportation, deliveries, and personal commuting. At JINPENG, we have taken this concept to the next level with our DLS150PRO model.

The Highlights of JINPENG’s 3 Wheel Electric Trike

Our DLS150PRO model is a game-changer in the world of electric trikes. Here’s why you should consider choosing JINPENG:

Unmatched Power and Efficiency: With a 2000W electric motor, our DLS150PRO offers impressive power and acceleration. It’s capable of reaching a maximum speed of 42 km/h, ensuring you get to your destination quickly and efficiently.

Spacious Cargo Area: Whether you need it for business deliveries or personal use, the DLS150PRO comes with a generously sized cargo box, measuring 1500×1100×490 mm. It can carry a substantial load, making it ideal for various transportation needs.

Range and Battery Options: Depending on your requirements, you can choose from battery options ranging from 72V80AH to 100AH. This ensures a range of 80-110 km on a single charge, allowing you to cover significant distances without worrying about recharging frequently.

Built for Tough Terrain: The DLS150PRO is designed to handle challenging terrains with ease. It boasts a minimum ground clearance of 150 mm and can conquer steep slopes with a grade ability of up to 30%.

Quality Assurance at JINPENG

At JINPENG, quality is not just a word; it’s a commitment. We prioritize the following to ensure you get the best 3 wheel electric trike:

Rigorous Testing: Our products undergo extensive testing at our technology research center and testing center in Jiangsu Province, ensuring they meet the highest quality standards.

Innovative Technology: We are proud of our 500 patented technologies, showcasing our dedication to innovation and continuous improvement.

After-Sales Support: Our professional after-sales service team is always ready to assist you, ensuring that any issues are promptly addressed.

In conclusion, if you’re in the market for a 3 wheel electric trike that combines power, efficiency, and reliability, look no further than JINPENG’s DLS150PRO. Experience the future of transportation with our versatile and eco-friendly electric trike, designed to meet your unique needs. Join us on the journey towards sustainable and efficient mobility.

Jiangsu JINPENG Group Co., Ltd, recognized as the world’s premier manufacturer of electric tricycles, stands firmly committed to shaping a sustainable future. Specializing in the development, production, and sales of electric vehicles, we have garnered global trust. In this comprehensive article, we delve deep into the groundbreaking Cargo Tricycle with Cabin, a true game-changer in the realm of efficient, eco-conscious cargo transportation.

Pioneering a New Era in Cargo Transport

Cargo transportation is the backbone of numerous industries, and efficiency is non-negotiable. Enter our Cargo Tricycle with Cabin, a revolutionary solution that redefines the way businesses move their goods. The cabin’s inclusion ensures the safety and security of valuable cargo, making it the go-to choice for diverse applications, from urban logistics to rural deliveries.

Safety and Operator Comfort in the Cargo Tricycle with Cabin

Safety and operator comfort are paramount considerations in the design of the Cargo Tricycle with Cabin. This innovative vehicle prioritizes the well-being of both the cargo and the operator, ensuring a secure and pleasant experience for all. Let’s delve into how the Cargo Tricycle with Cabin excels in these crucial aspects:

1. Enclosed Cabin for Operator Protection:

The enclosed cabin shields the operator from external elements such as rain, snow, and extreme temperatures, ensuring their comfort during deliveries.

It offers protection against dust, debris, and urban pollutants, creating a clean and safe working environment.

The cabin’s robust construction enhances operator safety by providing a secure enclosure in the event of accidents or collisions.

2. Advanced Safety Features:

Anti-lock braking systems (ABS) enhance braking performance, preventing wheel lockup and improving vehicle stability during sudden stops.

Stability control systems assist in maintaining control of the tricycle, especially in challenging road conditions or when carrying heavy cargo loads.

Effective lighting systems, including headlights, taillights, and turn signals, ensure visibility and promote road safety, even in low-light conditions.

3. Ergonomic Operator Workspace:

The cabin is designed with ergonomics in mind, providing a comfortable seating position and easy access to controls, reducing operator fatigue during long shifts.

Ample legroom and adjustable seats contribute to operator comfort, accommodating operators of various heights and body types

Efficiency Meets Sustainability in Harmony

Efficiency and sustainability are intricately woven into the cargo tricycle with cabin’s DNA. Powered by electricity, it offers a clean and cost-effective solution for businesses. The electric motor is engineered for robust torque and acceleration, making it versatile for various terrains and urban environments. Importantly, this tricycle leaves no carbon footprint, championing a greener, healthier planet.

Uncompromising Quality and Reliability

At JINPENG, quality and reliability are etched into our core values. The Cargo Tricycle with Cabin epitomizes our dedication to these principles. Constructed with durable materials and engineered with precision, the cabin is designed to endure the rigors of daily use, ensuring that your cargo arrives safe and sound. Our tricycle is a testament to innovation, with safety features and ergonomic design elements that guarantee a comfortable and secure driving experience.

In conclusion, the Cargo Tricycle with Cabin is a testament to our unwavering commitment to sustainable and efficient transportation solutions. We invite you to partner with JINPENG, where innovation converges with reliability. Our Cargo Tricycle with Cabin is more than just a vehicle; it’s a statement of purpose—a vision for optimizing efficiency while minimizing environmental impact. Together, let’s chart a course towards a world where sustainable transportation solutions drive progress, one cargo at a time.

In today’s rapidly evolving urban landscape, cost-effective transportation solutions are in high demand. As cities become more congested and environmental concerns intensify, the need for affordable and sustainable mobility options has never been greater. JINPENG, a trusted name in the industry, is proud to offer a range of affordable E tricycles that combine high cost performance with reliable urban transportation and cost effective E tricycle price. In this article, we will explore the concept of cost performance, highlight our commitment to providing affordable E tricycles, and discuss the benefits of investing in their cost-effective solutions.

Affordable E Tricycle Price: High Cost Performance

Cost performance refers to the value and benefits derived from a product relative to its price. JINPENG understands the importance of offering high cost performance E tricycles to meet the diverse needs of urban commuters. By optimizing production processes and leveraging economies of scale, JINPENG is able to provide affordable pricing without compromising on quality or performance. With JINPENG E tricycles, customers can enjoy the perfect balance between affordability and functionality.

JINPENG’s commitment to offering high cost performance E tricycles is reflected in their stringent quality control measures and use of durable materials. Each tricycle undergoes rigorous testing to ensure optimal performance, reliability, and longevity. Despite their affordable pricing, JINPENG E tricycles are built to withstand the demands of daily urban commuting, providing customers with a cost-effective solution that doesn’t compromise on quality or durability.

Benefits of Investing in an Affordable E Tricycle from JINPENG

1. Cost Savings: By choosing an affordable E tricycle from JINPENG, customers can significantly reduce their transportation expenses. With rising fuel costs and maintenance expenses associated with traditional vehicles, E tricycles offer a cost-effective alternative. Additionally, the low operating costs of electric vehicles contribute to long-term savings.

2. Environmental Sustainability: JINPENG’s affordable E tricycles are powered by clean and efficient electric motors, resulting in zero emissions. By opting for an electric tricycle, customers contribute to reducing their carbon footprint and improving air quality in their communities. It’s a win-win for both the environment and budget-conscious individuals.

3. Customization Options: JINPENG understands that every customer has unique preferences and requirements. That’s why they offer a range of customization options to suit individual budgets and preferences. Customers can choose from various models, colors, and features, ensuring their E tricycle is tailored to their specific needs.

JINPENG: Affordable E Tricycle Options

JINPENG offers a diverse range of affordable E tricycles to cater to different budgets and preferences. Whether you’re a daily commuter or a business owner in need of reliable transportation, JINPENG has the perfect solution for you. Their range includes compact and maneuverable models designed for urban environments, ensuring easy navigation through crowded streets and tight spaces. Despite their affordable pricing, JINPENG E tricycles boast premium build quality, advanced features, and optimal performance.

Conclusion

JINPENG’s commitment to affordability and high cost performance makes them a leading provider of E tricycles for cost-effective urban mobility. With their range of affordable options, customization capabilities, and dedication to quality, JINPENG offers customers the opportunity to embrace sustainable and budget-friendly transportation solutions. By investing in an affordable E tricycle from JINPENG, individuals can enjoy the benefits of cost savings, environmental sustainability, and personalized mobility options. Experience the convenience and value of JINPENG E tricycles and unlock cost-effective urban mobility today.

As long as screws are still present in machined parts, threads remain an important aspect of metalwork. It facilitates the connection of parts at a low cost, making them ideal for use with fasteners, fittings, and connectors.

Asides from knowing what threads are, it is also important to identify the right type of thread for your project. So, what exactly does the term machining threads mean? what are the types of machining threads? Keep reading as we answer these questions and provide other important information about threading.

Contents
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I
What is Thread Machining in Part Manufacturing?

II
Main Parameters for Thread

III
Types of Machining Threads

IV
How to Cut a Machining Thread?

V
Great Tips for Machining Thread

VI
Common Screw Thread Machining Methods in CNC Process

VII
Get Thread Machining Services at WayKen

VIII
Conclusion

IX
FAQ

What is Thread Machining in Part Manufacturing?

Thread machining is one of the most important applications in a CNC machining center. It is a subtractive method used in making external and internal threads of different sizes. This machining occurs through the circular movement of a rotating tool calibrated with the required thread depth and density.

The primary function of a thread is to act as a coupling agent between two mechanisms. During the coupling process, motion between parts occurs.

A thread has different parts. These include the crest, root, Helix angle, pitch, and flank. Let us examine these parts in detail.

Main Parameters for Thread

Helix Angle: Helix angle in machining is the angle between the thread axis and the helix in a straight thread or the angle made by the conical helical area of a thread for taper threads.

Root: This is the bottom of the threads. It is the adjacent area of the projected cone or cylinder.

Crest: The crest is the top of the threads. It is the farthest area of the projected cone or cylinder. The crest is also the thread surface that joins the flanks.

Flank: This threaded part connects the root to the crest. In theory, the intersection of a flank surface with an axial plane is a parallel line.

Pitch: The diameter of the pitch equals that of the cylinder or cone, in theory. The pitch is the distance measured between areas on adjacent threads. The parallel areas measured must correspond.

Types of Machining Threads

There are many types of threads according to different classification standards. For the Unified thread system, the UNF (fine) thread and UNC (coarse) thread are standard. However, the two major types of threads are internal and external threads.

Internal Threads

An internal thread, also known as a female thread, undergoes machining using a single-lip threading tool. Aside from this single-lip tool, a traditional threading cap could also help cut CNC internal threading. It is important to note that cutting internal threads occur only on concave surfaces.

So, when is an internal thread needed? You would require one if your workpiece needed screw insertions. Machinists use either hand taps or machine taps for cutting internal threads.

External Threads

Also known as a screw thread, this type of thread finds application in screws, bolts, studs, and plug gages. Using a lathe is one of the most effective ways of making external threads.

Another method is to use a round die to cut the external thread by hand. The round die used in this case remains in a fixed die stock. Aside from round dies, there are also hexagonal square dies, ideal for interlocking use.

How to Cut a Machining Thread?

Thread cutting is ideal for making parts with screwed connections. Knowing how to cut threads is beneficial. For instance, with this knowledge, you can manufacture a single-piece screw or nut or repair them if necessary. Also, threading machines may not always be available.

So, here is how to cut threads.

1. How to Cut an Internal Thread

Are you looking to cut an internal thread? First, get the right tools, which include safety goggles, a box column drill (for machine taps), an adjustable tap wrench (for hand taps), an internal tap, a twist drill, and a 90-degree countersink.

After getting the right tools, the next step is determining what diameter of the hole you want to place the thread in. With the diameter determined, knowing the right tap for cutting is the next stage. To determine the core hole diameter, subtract the thread pitch from the Tap diameter.

To start cutting the internal thread, you first center with a punch and then drill a core hole using a twist drill. To make a chamfer into the core hole, use the 90-degree countersink. Cutting the thread involves turning the tap wrench into the core hole with the tap attached.

2. How to Cut an External Thread

Tools you need to cut external threads include file, die stock, flat-tip, round die, rod, vise (for gripping), and cutting spray.

To cut external threads, file the edges of the round rod first and then chamfer it at an angle of 45 degrees. Ensure that when compared to the depth of the thread, the chamfer is bigger.

The next step is clamping or gripping the round die to affix it firmly. This prevents unwanted motion since the rod requires a lot of pressure to cut the external thread optimally. Use cutting sprays to improve the quality of the part’s surface.

Great Tips for Machining Thread

There are several benefits attached to knowing how to machine threads. However, getting great tips for machining might spell the difference between an optimal thread and a suboptimal one. So, here are some tips for machining threads.

• Include a chamfer to external thread end parts;
• Ensure the starting end of a thread has a flat surface. Also, ensure that it is consistent with the central axis of the thread;
• Make internal threads end with a countersink;
• During forming or cutting thread, tubular parts often experience pressure, which is why they should have increased wall thickness;
• While going for unique thread sizes is fine and good, using a standard thread size is more economical;
• Lower-height threads are preferred to higher-height ones if there are no thread specifications.

Common Screw Thread Machining Methods in CNC Process

There are several screw thread machining methods in CNC. These different methods have their features and benefits. Here, we’d discuss the common ones and what makes them stand out.

1. Tapping

Tapping holes are ideal for use in producing internal threads. It is an economical as well as efficient threading method. This CNC method is applicable for use in threaded holes with the low accuracy of position as well as holes with a small diameter.

It as a method of screw thread machining has reduced CNC threading machine downtime. Also, the machining structure here is quite simple compared to other methods. Furthermore, tapping is a high-speed cutting process that greatly improves productivity and machining efficiency.

Cutting tools used in this machining method are cheaper, thereby reducing the cost of manufacturing. It is also a versatile process with a wide range of applications.

2. Thread Milling

This is another method used in making screw threads. This process utilizes a milling cutter as well as a 3-axis machining center. It also adopts a circular interpolation of the three main axes; x, y, and z linear feed. Thread milling is ideal for threading large parts or materials of high value.

Thread milling has a fast processing speed, high precision, and efficiency. The milling tool used often contains hard alloys. Also, milling cutter tools are versatile, reducing the need to acquire different tools for different milling processes. For instance, the same cutter can cut the left and right-hand thread using the same pitch of screws. You can adjust the hole diameters, tolerances, and material cut with minimal difficulty.

Threads made using milling have a superior-quality surface with zero burrs. This method is ideal for making thin-walled parts, machining blind holes, and asymmetric/ non-rotating parts.

3. CNC Threading on Lathes

Thread cutting on a lathe is another common screw threading process with a wide range of adoption. CNC lathes facilitate the production of high-quality screw threads. With this method, machinists can make several tapered threads, lead threads, and thread pitches.

Rigid tapping and single-point threading are two of the most common methods used in CNC lathe threading. Single-point threading uses a tool with an indexable insert with a shape and size that corresponds to that of the finished screw head.

4. Thread Grinding

This is ideal for use in threading hardened workpieces. Two main types of grinding wheels are used for this process; multi-line grinding wheels and single-line grinding wheels. The single-line grinding wheel has a pitch accuracy with grades 5 ~ 6. It also has a surface roughness of R1.25～0.08 μm.

Single-line grinding is ideal for making a precision screw, worm, thread gauge, shovel grinding hob, and small batch threading.

The multi-line grinding is divided into cut-in and longitudinal grinding methods. The major difference between these two methods is the width of the grinding wheel. In the longitudinal method, the width of the grinding wheel is less than the length of the thread being ground. On the other hand, the width of the grinding wheel used in the cut-in method has a greater length than the thread.

Get Thread Machining Services at WayKen

Machining threads is a challenge because of the need for skilled and professional equipment. If you want to make standard threads that stand the test of time, then WayKen is the right company for you.

Who is WayKen? We are a machining company with over 20 years of experience making parts that meet industry standards. With us, your threading project is in good hands as we have one-stop CNC machining services and advanced machines to attend to your order. 

Get A Free Quote Now

Conclusion

To produce high-quality parts, it is important to have an in-depth understanding of the various manufacturing processes involved. Knowledge also enlightens you on how to deal with some machining challenges like chatter in machining.

Machining threads are an important aspect of most products that require coupling or connection. Knowing how they work, their parameters and the different machining processes available would help you make the right machining decisions.

FAQ

Is thread milling faster than tapping?

Tapping is generally quicker than thread milling. However, thread milling machines sometimes feature additional edges to compensate for the reduced speed.

What is the difference between a thread mill and a tap?

The major difference between thread milling and tapping is the smoothness of the cut. Thread milling creates smoother and more even cuts, while cuts made by tapping are rough and jagged.

What is the threading operation in the lathe?

It is a process used to create a helical ridge with a uniform cross-section on the workpiece. It involves using a threading tool bit to make cuts on the workpiece successively. It is important to note that the tool bit used for this operation should be the same shape as the thread needed.