Navigating Complexities in Atypical Mechanical Component Development

Friends who work in non-standard mechanical design typically draw every day, and they often encounter various design issues. Today, I want to share some common design problems for your reference, so you can avoid similar issues in your own designs.

 

PART 1 Unreasonable rounded corner design

As shown in Figure 1 (left), the rounded corner design of the part is unreasonable.

It’s common for new engineers to make a particular mistake in their designs. They might create a step transition that features a rounded corner for aesthetic appeal. While this might look nice, it can lead to issues during the milling process, as illustrated in Figure 1 (right). The problem is that if the rounded corner is too pronounced, the cutting edge of the tool may not be sufficient, which can result in tool failure.

To avoid these issues, a more effective design would use a right angle, as shown in Figure 2. This approach eliminates the potential processing complications associated with rounded corners.

 

 

Comments: When evaluating the rationality of a structure, it is essential to consider the convenience and cost of processing. For instance, if using a standard milling machine, right angles are more convenient to work with than curved angles. However, if utilizing fast wire cutting or CNC machining, this distinction is less significant. As processing technology advances, the methods and techniques have changed considerably. Nowadays, laser cutting and fast wire primary processing are commonly used techniques.

 

PART 2 Unreasonable hole design

In Figure 3 below, the punching position is located next to the bending position of the sheet metal. In this scenario, the drilling position is not secure. If a threaded hole is created, the threads may easily become deformed. Therefore, when designing, it is important to ensure that the hole position is situated far away from the bending area.

 

In the example below, the component is a frame constructed from welded square tubes. The drilling position is located near the welding area, where the hardness tends to be higher. This increased hardness can make processing challenging, often resulting in broken drill bits and taps. Therefore, it is advisable to position the drilling area away from the welding zone during the design phase.

 

Comments: After the 3D design of the sheet metal structure is completed, the holes on the bending or welding edges should be adjusted appropriately according to the specific structure.

 

PART 3 The design of shaft parts is unreasonable

As illustrated in Figure 5 below, a simple schematic structure is presented for clarity. In the center of the design is a shaft section that connects two parts. This shaft has a reduced diameter on both ends and a larger diameter in the middle. This design necessitates secondary clamping during the processing of the parts, complicating the manufacturing CNC process and making it challenging to maintain size accuracy. Alternatively, the shaft can be designed to be larger at one end and smaller at the other without compromising functionality. This revised shape simplifies processing.

 

Comment: Not all shafts designed to be small at both ends and large in the middle are unreasonable. In fact, most structures with two bearing positions have this feature.

 

PART 4 ​​Problems with integrated part design

As illustrated in Figure 7, the left side consists of two spliced parts. However, the volume of this spliced structure is relatively small, making it more efficient to manufacture as a single piece. Dividing it into two parts complicates the processing, makes size control difficult, and leads to wasted installation time. In contrast, the right side is made as an integrated piece, which simplifies the CNC manufacturing process. It has fewer holes to process and offers better size consistency.

 

As shown in FIG8 below, the part is relatively large in size. If it is designed as an integrated part, it will lead to problems such as large machining volume, complex machining, and increased costs.

 

When deciding whether to design a part as split or integrated, it is important to consider processing, cost, installation, and debugging comprehensively. Typically, if the dimensions of the structure are smaller than 80 mm x 80 mm x 80 mm, we design it as an integrated part. Conversely, if the dimensions exceed 80 mm x 80 mm x 80 mm, we opt for a split part design.

 

Comment: When deciding whether to design a part as a single integral piece or as a split component, it’s important to consider several factors. These include the size of the part, the simplicity of the manufacturing process, the ease of achieving the required precision, and the overall cost.

 

 

 

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