Get it right
off the machine.
Less labor.
Designing to minimize post-processing reduces total cost. As-machined finishes, in-line deburring, smart fixturing eliminate manual labor.
Key principles.
Designed-in
Specify chamfered edges that are easier to deburr in-line. Avoid features that hold burrs.
Match Ra to function
Specifying tighter Ra than function requires drives unnecessary polishing.
Accommodate growth
For coated parts, machine to accommodate coating growth so no re-machining.
Chamfer or radius
Specify chamfer or radius rather than "deburr". Clearer intent, often cheaper.
As-machined OK
Where appearance unimportant, as-machined finish saves polishing/blast.
Avoid post-mach
Use standard drill or reamer sizes — avoid post-machining adjustment.
FAQ
What is "as-machined" finish?
Ra 1.6-3.2 µm typical milling. Lines visible from cutting tool. Acceptable for many functional surfaces.
When does post-process pay?
For cosmetic parts, customer-facing surfaces. For mating surfaces requiring smooth Ra. Cost-justified per function.
Standard deburring included?
Yes — light edge break, manual deburring of obvious sharp edges. Standard at no extra cost.
Heat-treat distortion?
Hardening causes 0.05-0.2 mm distortion typically. Pre-mach allowance + post-grind for precision.
In-line vs separate operation?
In-line (during machining) cheaper than separate setup. Design for in-line where possible.
Documentation savings?
Fewer process steps = less paperwork. Streamlined documentation for simpler workflow.
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