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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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Thickened Box Board for Securely Transporting Valuable Cargo

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Customizable and Adaptable Business Solution

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Conclusion

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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.

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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.

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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.

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JINPENG: Affordable E Tricycle Options

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Conclusion

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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.

Low-volume or small-batch CNC machining involves manufacturing products or parts in small quantities, usually between 10-1000 pieces. It is one mechanism that helps manufacturers cut down on production costs. Asides from reducing cost, producing on a small scale also makes it easy to change designs without incurring a loss.

In this article, we’d examine low-volume CNC machining in detail, its benefits, and ways to maximize budget when designing for low-volume CNC machining. Keep reading as we provide you with this great information.

Low Volume CNC Machining Explained

Low-volume CNC machining combines the benefits of computer numerical control with CNC principles to produce a small number of pieces. Not all businesses need huge batches of products; some need small batches.

Additionally, Low-volume machined products are cost-effective without requiring costly tooling. It’s perfect for advancing an idea from the conceptual stage through prototyping and then serving as a transitional stage to full-scale production.

Advantages of Using Low-Volume CNC

Businesses leverage low-volume CNC for many beneficial reasons, ranging from low cost to capital protection. Let’s discuss the advantages of low-volume CNC in more detail.

1. Improves Manufacturing Flexibility

Low-volume CNC machining allows for greater design flexibility compared to injection molding or die casting. It becomes easier to identify manufacturing mistakes and make necessary adjustments at a minimal cost. Having manufactured low-volume products, companies or businesses that employ low-volume CNC can take customer feedback and improve their products for optimal client satisfaction.

2. Reduces Time To Market

Technology, trends, and consumer preferences change daily, leading to stiff competition among businesses in the same industry. Using low-volume production is one way to ensure that high-quality products and parts reach the market in the shortest time possible.

3. Improves Business Cash Flow

It also increases cash flow between customers and businesses since low-volume CNC machining reduces time to market. It also increases the business turnover rate, as products arrive on the market in short and drive sales, so businesses generate their revenue and profit quickly.

4. Serves as a Link in the Production Chain

Low-volume CNC machining production is a link or bridge between prototyping and full-scale production of goods. Prototyping involves producing custom goods, and full-scale production happens when there is high demand.

5. High Quality Parts

Low-volume CNC produces high-quality parts with tight tolerances and excellent surface finishes. This is because CNC machines are highly precise and can produce parts to exact specifications.

Ways to Maximize Budget When Designing Low-Volume CNC Parts

Here are some design tips to help you minimize the budget and time spent on low-volume CNC machined parts.

1. Use Simple and Standard Designs

When designing low-volume CNC machined parts, endeavor to keep them simple and uniform. However, manufacturing complex designs often requires a more expensive CNC system, manual repositioning, and rotation. Hence, it could be advantageous to divide a complicated piece into smaller parts for assembly later.

Here are things you want to consider:

1.1 Go with Standard Threads

Just like standard drill sizes, using standard threads can save you time and money when machining for low-volume production. This entails leveraging an existing thread class rather than constructing a unique thread during low-volume CNC machining.

1.2 Avoid Tight Tolerances

Tolerances, especially tight ones, can increase setup time. Aside from set-up time, they also increase inspection and low-volume CNC machining time and the need for specialized production techniques or secondary operations. Because of this, it is best to ensure tolerances are only as tight as necessary to meet the design’s structural and functional requirements.

1.3 Use Standard Sizes When Designing Holes

The metal chip evacuation operation becomes more difficult and expensive as the hole gets deeper, so try to keep the hole depth five to six times the drill diameter. Moreover, be careful to design your holes using common drill sizes. Otherwise, you would need to buy a unique tool, which might increase prices and manufacturing time.

2. Choose the Correct Material For Low-Volume Parts Production

Project costs might skyrocket with the wrong materials, making material selection crucial in both long and short production runs. Also, machinability is a factor to consider, as even when different materials are, there is a good possibility that one will cost more than the other.

In other words, when you choose a CNC machine shop, pick a less expensive and/or more common substance if you don’t need the qualities of costly and unique material.

3. Take into Consideration the Finishing and Text to Use

It is best to avoid elaborate finishing and text when designing low-volume CNC machining parts. While the machined text has a nice visual and can be operationally beneficial, the technique increases the time and cost of low-volume production for each character due to the technique required to track each character.

If your low-volume machined parts need a logo or some lettering consider using a surface finishing technique, as it helps save money and time. For instance, adding text to your product is quicker with direct engraving by using laser marking, painting, or silk screening.

4. DFM (Design for Manufacturing)

Designing for manufacture entails creating pieces that are simple to machine. Furthermore, it’s crucial to consider the machining equipment’s capabilities when planning for low-volume machining. Also, create parts that can be produced with the tools at hand. In other words, if you have a 3-axis CNC machine, do not manufacture products using only 5-axis CNC machining.

5. Reduce Waste

Waste reduction is crucial for cutting down CNC machining costs and environmental reasons. It’s crucial to consider material usage and create pieces that produce the least waste while designing for machining or low-volume injection molding. To reduce material waste, this can be done by requesting the use of recycled materials.

Choose Wayken for Your Low Volume CNC Machining

Are you looking for a low-volume CNC machining company that will take on your small-batch production projects? Wayken is a reliable and trusted CNC manufacturer for your low-volume production.

With top-notch machining centers and experts, our on-demand manufacturing services include CNC milling, turning, 3d printing, sheet metal fabrication, and injection molding. Contact us today so we bring your low-volume projects to reality.

Conclusion

Low-volume manufacturing is the practice of producing a small quantity of a product or part. Everything above highlights what you need to know about this CNC machining production practice. We also examined the ways to maximize budget when designing for low-volume CNC machining to help you make informed decisions.

FAQs

What are low-volume manufacturing methods?

Before high-scale production or if there is little demand, businesses test their items in the market using a low-volume technique. Examples of low-volume choices are 3D printing, CNC machining, and injection molding. Each low-volume production technique has benefits and drawbacks and works best in certain applications.

Is CNC good for mass production?

Several industries utilize CNC machining because it produces goods with high precision and accuracy, lowering the likelihood of human error. This method is fundamental to the production process in industries where mass output, cost-effectiveness, and accuracy are crucial.

Is additive manufacturing a better alternative to low-volume production?

Generally, additive manufacturing is preferable for projects requiring quick delivery of final parts or prototypes and projects with lax tolerance requirements. Contrarily, CNC machining is better suited for projects that require tight tolerances or a low-volume approach with part counts in the upper double digits or low thousands.

If the thought of dismantling your pool seems like an awful task, relax and review our six-step method for draining and storing your Intex pool for the winter.

1. Check Water Chemistry

Checking the water chemistry before draining a pool is essential to prevent potential environmental harm. The chemical balance of pool water is carefully maintained to ensure the safety of the environment into which the drained water is released. Unchecked, imbalanced water may contain high levels of chlorine, pH, or other chemicals that can be harmful to plants, aquatic life, and soil. By assessing the water chemistry beforehand, pool owners can take corrective measures to neutralize any imbalances and discharge water that is environmentally friendly.

2. Locate the Drain Valve

The drain valve is located on the outside of the pool. Run a garden hose out, with the female end near the drain valve. Connect the other end to a sprinkler, and water your lawn or garden (if pH is good and chlorine low). Remove the cap.

3. Drain the Pool

Connect the female end of a garden hose to the drain connector and you can now drain the pool completely. If draining to an open area, you may want to move the hose during draining to avoid erosion or oversaturation.

On some Intex pools, you may need to screw a hose adapter onto the female garden hose end and then thread the hose adapter into the drain valve. This will prevent the water from coming out immediately when you remove the drain cap.

Because it’s only gravity draining, you can’t drain it too far uphill. It will take a few hours for small Intex pools and more than 12 hours for larger pools. You should begin draining an Intex pool the night before you plan to dry, fold, and store it.

4. Dry the Pool

After complete draining, your pool will need to dry completely before folding. For Frame Set™ pools, this may be easier if the pool is left standing to allow it to air dry. Otherwise, you may find a wet/dry vacuum useful or use some towels to gently wipe your Intex pool dry.

Dry the pool well on the inside and on the outside walls so the vinyl won’t stick together when folded, or grow mildew. As a final step, using Talc or DE powder can help absorb trace moisture. Screw your pool drain cap back onto the drain valve so it won’t get misplaced.

5. Fold Your Intex Pool for Storage

Fold the wall part of the material in on all sides, then with two people, pull one side of the pool over to meet the other side. From here, keep folding in half until you have a long strip, about 3-4 feet wide. Roll or fold this up into a manageable size.

6. Store Your Pool at Room Temperature

If possible, store at room temperature, and keep it away from any nesting mice, birds, or other critters that may chew holes through the vinyl. For winter storage, consider placing a spacious, tidy, and brand-new trash can in the basement or garage.

You’ll also want to drain the pump and filter and store them indoors or out of the elements.

How Do I Drain the Last 100 Gallons From My Intex Pool?

You can use a wet/dry vacuum, or a pail and sponge, but most people move the water to one side and then with two or three sets of hands spill the water over the edge. Before you do this, however, deflate the top ring on Easy Set™ or disassemble the frame pieces for Frame Set™ pools.

The easiest way to move the water is to have two people grab the floor of the pool on one side and “walk the water” to the other side of the pool. Allow the water to spill out slowly. If the pool floor has dirt or debris in it, use a pool brush or a soft push broom to sweep the bottom of any film or remaining dirt before draining.

What if I Can’t Find the Drain Plug?

Sometimes the caps are buried just under the edge of the pool, but if you don’t find it, here are some other ways you can drain the pool.

Gravity Siphon

Push a garden hose or vacuum hose straight into the pool water so that the entire hose fills up with water. After it’s full, secure one end of the hose to the pool edge with tape or string, with 3-5 feet of the hose still sticking down into the pool water, almost touching the bottom.

Cap the other end of the hose with your thumb and quickly pull all of the hose over the wall (except for the 3-5 foot section). Keeping the other end capped with your thumb and low to the ground, pull out the hose to a lower area for draining and release your thumb with the hose on the ground.

As long as the pool end is higher than the discharge end, your siphon should start immediately. This method of siphon draining your pool can also be done with a pool vacuum hose.

Submersible Pump

If you have a small sump pump, or a pool cover pump, these can be used to drain the Intex pool. Connect a garden hose, plug it in, and carefully place the pump in the bottom of the pool, near the edge.

You can rent a small pump at a rental shop, or we have a nice variety of cover pumps.

Skimmer or Return Hoses

You may have already realized that you could remove the hose from the pool filter and drain water right next to the pool. This will work, however, only down to the level of the return.

It’s always best to drain or pump out an Intex pool slowly. With the Easy Set™ pools, you may be tempted to deflate the top ring and just sort of roll the water out. This can be dangerous, not just to nearby plants or mulch beds, but to the pool, which can rip or develop holes during the process.

That’s our super simple six-step system for draining your Intex Frame-Set™ or Easy-Set™ pool. Take the time to do it right and you’ll enjoy many more years of fun with your Intex Pool.

TIP: If you decide to dispose of your Intex pool (after all, they don’t last forever), please try to recycle the vinyl. Most landfills will accept your vinyl pool for recycling.

Enjoy your winter, and we’ll see you next year!

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Spring pool opening goes more smoothly when you have a proper winter pool closing. One of the most important parts is putting your pool cover on — tight! A tightly sealed winter pool cover protects the pool from debris and winter conditions. But you can defeat the purpose if the pool cover comes loose and nothing is done about it for many winter months. Put your cover on correctly to avoid a winter pool cover disaster.

Avoid opening the pool in April or May to a sad surprise or shocking realization that you have a lot of clean-up to do. If the pool cover becomes loose or falls into the pool, put on some warm clothes and get it taken care of now.

Winter Pool Cover Issues

• Strong winds can shred loose above ground pool covers in minutes.
• Leaks in the pool can damage a pool cover, or make it fall in the pool.
• Heavy rain and snow can pull in a solid cover, or rip the seam.
• Heavy snow and ice can rip old safety cover straps.
• Ice sheets on a solid pool cover can be sharp on the edges.
• Large sticks or branches can pierce pool covers.
• Farm animals or wild animals can cause severe damage.

My Cover Fell in the Pool

If your solid cover slipped into the pool, either from a pool leak, or too much water weight on the cover — here’s how to deal.

With several strong hands, grab the edge of the cover and pull it back up over the pool deck. Weigh it down around the edge with water bags. Start pumping water, using submersible pumps, or a cover pump. Use a vacuum hose to siphon additional water from the pool cover.

Break out the skimmer nets. In fact, leaf rakes are the easiest for debris removal. Pull the debris gently towards you to make for better scooping. Place the debris into a container with holes in it to allow the water to drain.

Scoop out as much as possible by using the leaf rake. A pool brush can also be used to gently pull debris to the edge. If the cover is really submerged deeply, a garden hose vacuum like the Leaf Gulper can be a big help.

After you have eliminated all of the accumulated debris and water from the cover, you can tighten up and reset the pool cover as the surface water recedes. Inspect the cover closely for any holes or tears.

Now you can check on the water. Note how much debris went into the pool. You may be lucky and only have smaller debris in the water. If there is more debris, use your leaf rake or leaf gulper to clean it as much as possible. In any case, once the pool cover and debris situations are stabilized, check and balance the water chemistry.

Winter Pool Cover Repairs

If there is a tear or hole in the cover, you can easily repair it using a pool cover winter patch kit. Cover patches allow for quick fixes on any winter pool cover, so you don’t have to buy a new replacement pool cover.

Solid pool covers can be quickly patched with our pool cover patch as they’re self-adhesive and super sticky. Patch both sides of the pool cover for best results.

Small rips or tears of around 6 inches are a prime example of a problem that can be remedied with a pool cover repair patch. The weave of a winter pool cover usually causes pool covers to rip in a straight line, making home repairs simple.

A rip in the cover larger than 12″ may not be possible to repair, but you might make it through the winter before replacing the pool cover.

Pool Cover Problem Prevention

For inground pool covers with water bags, keep your cover tight with a good supply of double water bags. Never use bricks to hold down the pool cover or heavy objects. Periodically check on the water tubes throughout the winter season.

A well-functioning pool cover pump will pump the 1–2 feet of rainwater and snow melt that you will likely receive through winter. For above ground pool covers, use cover clips, wall bags, or a cover seal to keep out high winds. Use a cover pump or siphon method to remove excess water that could weaken the cover seams or rip the cover.

Safety Pool Covers

For safety pool covers, if your pool cover straps aren’t tight enough, water can accumulate on the surface. Tighten straps so the springs are halfway compressed, and the cover deflects only slightly in the center. Keep your water level between 6″–18″ below the safety pool cover.

No matter what pool cover you own – whether it is a mesh cover, solid cover, safety cover or automatic pool cover, take care of winter pool cover maintenance and prevent a mid-winter pool cover disaster.

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