Cylindrical components come with their own set of unique manufacturing challenges. While an experienced CNC machining company can handle the process, it’s the design that often plays a crucial role in determining the part’s functionality, machining efficiency, and overall cost. As a designer, your input can significantly impact how easily and economically a component can be produced.
In this blog, I’ll take you behind the scenes of how cylindrical parts are made and share my top three design considerations to help you create more efficient and cost-effective components.
**How Are Cylindrical Components Manufactured?**
At Penta, we frequently work on cylindrical parts, and while many people assume they’re all machined on a lathe, the reality is a bit more complex. While turning is the most common method, some features may require milling, especially if they're not accessible from the side of the part. In such cases, a combination of turning and milling might be necessary.
There are also "mill-turn" machines, which combine both functions in one setup. This allows for greater flexibility and can reduce machining time and costs by minimizing the number of setups required.
As a designer, you don’t need to worry about the exact process. Your CNC machining partner should evaluate your design and choose the most efficient and cost-effective method. The goal is always to balance quality, performance, and budget.
**Designing Cylindrical Components**
While the manufacturing process is handled by the CNC machining company, as a designer, you have control over the design itself. Optimizing your design can lead to better performance, faster production, and lower costs.
Here are my top three design considerations when working with cylindrical components:
**1. Wall Thickness**
Thin walls in cylindrical parts can be problematic during machining. The chuck, which holds the workpiece, needs to grip tightly, but if the wall is too thin, it may distort or warp under pressure. This can affect the accuracy of the final product and make it harder to maintain tight tolerances.
Additionally, thin-walled components are more prone to vibration during machining, which can compromise surface finish and dimensional accuracy. While it's still possible to machine thin-walled parts, it often requires more setup time and specialized techniques, which can increase costs.
So ask yourself: Is a very thin wall truly necessary? If not, consider using a thicker wall to save time and money.
**2. Length of the Cylinder**
The length of the component can also affect machining outcomes. The further the feature is from the chuck, the more likely it is to wobble or flex, leading to inaccuracies. This is especially true for long, slender parts.
One solution is to use a center, where a small recess is machined at the end of the part to provide additional support. This helps maintain stability and improves accuracy.
If a center isn't used, alternative methods may be required, which could add to the machining time and cost. Always consider the length of the part and how it will be supported during machining.
**3. Feature Placement on Either End**
Ensuring symmetry or matching features on both ends of a cylindrical component can be challenging. If the application requires perfect alignment, this will increase machining and setup time, which can drive up costs.
However, if the orientation isn't critical, you can specify “orientation not important†on your drawing. This gives the manufacturer more flexibility, allowing them to produce the part in the most efficient way possible.
**Conclusion**
When designing cylindrical components, you don’t need to worry about the manufacturing process—your CNC machining supplier will take care of that. What you can control is the design itself. By focusing on manufacturability, you can improve efficiency, reduce costs, and ensure better results.
Need help optimizing your design? Partnering with a CNC machining company that offers design support can be incredibly valuable. A good supplier will help you balance form, function, efficiency, and cost to achieve the best possible outcome.
**Partner with Penta**
Penta has extensive experience in both turning and milling, and our team provides expert design advice to help you get the most out of your project. We also operate mill-turn machines, which combine the advantages of both processes, making it easier to produce complex cylindrical parts quickly and accurately.
If you'd like to discuss how we can assist with your next project, feel free to contact us at 023 9266 8334 or email sales@pentaprecision.co.uk.
You can also book a Discovery Call with us here.
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