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1. The Depth of the Milling Area
To reduce tool wear and avoid breakage, the milling depth should remain shallow, maintaining a depth-to-width ratio of no greater than 3:1. Exceeding this ratio increases the stress on the cutter, leading to higher machining costs due to increased risk of tool failure.
2. Optimizing the Milling Cutter’s Life
When a long milling cutter must be used, its design should be optimized to reduce vibration and increase tool life. This can involve altering the geometry to improve rigidity and reduce tool deflection.
3. Corner Radius in Recessed Areas
Avoid sharp inside corners in large pockets. Use a radius that matches the diameter of standard end mills to prevent the need for electrical discharge machining (EDM). Rounded corners are far more compatible with CNC milling tools and allow for smoother toolpaths.
4. Add Boss Structures for Flatness Control
In applications requiring high surface flatness, a raised boss is an effective design feature. By machining only the boss, rather than the entire flat surface, you reduce material removal and improve surface quality while keeping production costs down.
5. Use Beveled Outer Corners Instead of Rounded Edges
Rounded external edges require form-relieved tools and more complex fixturing. Beveled (chamfered) edges simplify the clamping process and reduce overall machining complexity and cost.
