7 Ways to Keep Part Costs Down from a Design for Manufacturing Perspective

Design for Manufacturing (DFM) is an essential approach to ensure that parts are designed in a way that optimizes production efficiency and minimizes costs. Here are seven strategies to help reduce part costs from a DFM perspective:

1. Optimizing Hole End Angles

When working with lathe components like pistons, valves, or nozzles, ensuring the hole end angles match the tip angles of standard drills can save on production costs. Specifying angles that align with available ready-made drills eliminates the need for custom solutions and additional drilling processes, streamlining production and reducing expenses.

2. Ensuring Adequate Pilot Hole Length for Threading

For parts requiring internal threading, securing a sufficient pilot hole length is crucial. Short pilot holes necessitate special cutting tools to avoid breakage, increasing costs. By ensuring the pilot hole length exceeds the threading length, standard tools can be used, leading to significant cost reductions.

3. Allowing Drill Tip Shapes in Counterbores

Certain lathe products, such as pistons or pins, require flat counterbore end surfaces, which involve extra machining processes. Allowing the drill tip shape to remain at the center of the counterbore end face can eliminate the need for additional machining, thereby reducing production costs.

4. Switching from Radius to Chamfer on Corners

Lathe products often have corners requiring a radius shape, which demands frequent tool maintenance. Changing the corner shape from radius to chamfer allows for the use of standard tools, even when worn, reducing the need for maintenance and lowering management costs.

5. Ensuring Clearance for Threaded Parts

For threaded lathe parts, achieving the effective thread length without a clearance groove can be challenging. Adding a clearance groove allows for the desired thread length and simplifies the threading process. The groove should be at least 150% larger than the thread pitch length to be effective.

6. Enhancing Machinability of Stainless Steel with Copper

Stainless steel grades like SUS303 are commonly used for shafts, but their machinability can be improved by adding copper, transforming it into SUS303Cu. This enhancement improves surface roughness and prevents burr formation, leading to reduced production costs.

7. Optimizing Broaching Dimensions

A major issue in broaching lathe-turned parts is having shallow pilot holes, which cause chip accumulation and obstruct the broaching tool. Increasing the depth of pilot holes prevents chip pooling, ensuring the proper broaching length is achieved without obstructions, thus streamlining the broaching process.






By implementing these design for manufacturing strategies, you can significantly reduce part costs and improve production efficiency.

Beyond the Price Tag: The Value of Quality over Low-Cost Component Manufacturing

In today's fiercely competitive market, businesses are constantly seeking ways to optimize costs and improve profit margins. One common approach is to prioritize low-cost component manufacturing. While cost reduction is undeniably important, focusing solely on the price tag may not always be the best way to move forward. In this blog post, we will delve into the complexities of component manufacturing and explore why a balanced approach that emphasizes quality over low cost can lead to more sustainable and long-term success for businesses.


The Hidden Cost of Low-Quality Components:

Sourcing components at the lowest price may seem strategic, but it often comes with hidden costs. Low-quality components can lead to issues such as increased downtime, frequent breakdowns, and costly repairs or replacements. For Contract Manufacturers, these problems could even cause Production Line Down situations, which are costly affairs manufacturers want to avoid at all costs. These factors can significantly impact overall productivity and customer satisfaction, ultimately outweighing initial cost savings.


The Role of Reliability in Building Trust:

Industries where safety and reliability are paramount, like automotive, aerospace, or medical equipment, cannot overstate the value of quality components. Customers rely on products that perform consistently without fail. Investing in high-quality components builds trust with customers, enhancing a company's reputation, fostering long-lasting relationships, and encouraging repeat business. Recent Product Recalls across various industries could be partially attributed to component-level failures—often linked to extreme cost-cutting in component parts. While these costs might not be apparent during project budgeting, they significantly affect profitability.


Long-Term Cost Savings:

As mentioned earlier, low-cost components might offer immediate financial benefits, but investing in quality components leads to substantial long-term cost savings. Durable and reliable components reduce maintenance expenses, extend product lifespans, and decrease the need for frequent replacements. Enhanced product performance often translates into greater customer satisfaction and higher demand, positively impacting a company's bottom line. The correlation between procuring components of High Quality and Reliability is observable, as they both influence the product owner's reputation.


Innovation and Competitive Advantage:

Innovation drives the manufacturing industry. Investing in quality components empowers manufacturers to unlock new possibilities for product design and functionality. Components with unique features, higher precision, or improved materials can give businesses a competitive edge, setting them apart from competitors focused solely on low-cost options. Collaborating with a Component Manufacturing Partner goes beyond producing parts from drawings.

Finding a partner that considers Design for Manufacturing principles and collaborates with your designers can provide your product with a competitive advantage.


Environmental and Ethical Considerations:

The pursuit of low-cost manufacturing can lead to decisions compromising environmental sustainability and ethical practices. Quality components often prioritize eco-friendly materials and manufacturing processes, aligning with the growing demand for responsible and sustainable products. Amid geopolitical tensions, concerns arise about the origin of certain product materials, prompting the avoidance of conflict areas. Responsible Component Manufacturers provide proper documentation of input material origins, ensuring traceability for all components in the final product.


Conclusion:

While cost reduction is an essential aspect of component manufacturing, focusing solely on low cost can be short-sighted and counterproductive. Quality components play a pivotal role in ensuring the reliability, efficiency, and reputation of a product or business. By investing in superior components, manufacturers can experience long-term cost savings, foster customer trust, drive innovation, and gain a competitive edge in the market.

As the manufacturing landscape evolves, it is crucial for businesses to strike a balance between cost optimization and quality enhancement. By adopting a more holistic approach, manufacturers can position themselves for sustained growth, profitability, and success in an increasingly competitive global marketplace.

Design for Manufacturing: Unveiling the Key to Component Manufacturing Success

In the dynamic world of component manufacturing, success hinges on more than just producing parts that meet specifications. The key to achieving excellence lies in embracing the concept of Design for Manufacturing (DFM). In this blog post, we will explore the significance of DFM for component manufacturers and how it plays a crucial role in ensuring the success of their customers.


Even the smallest parts in a mechanical watch can make or break the whole assembly. Attention to detail is of utmost importance during the design stage.

1. Understanding Design for Manufacturing (DFM):

Design for Manufacturing is an approach that involves considering manufacturability and production processes during the early stages of product design. By proactively addressing potential manufacturing challenges and optimizing designs for efficient production, DFM streamlines the manufacturing process, reduces costs, and enhances overall product quality.


2. The Role of DFM in Component Manufacturing:

a. Enhanced Collaboration:

DFM fosters closer collaboration between component manufacturers and their customers. Engaging in discussions about design intent, material selection, and production feasibility enables a deeper understanding of customer requirements, leading to better outcomes.

By roping in component manufacturers in during the design stage can prevent costly major redesign or design change down the line. These major costs could make or break the launch of your product!

b. Reduced Time-to-Market:

By integrating DFM principles from the outset, component manufacturers can minimize design iterations and identify potential production bottlenecks early on. This accelerated product development process ultimately shortens the time-to-market, giving customers a competitive edge.

c. Cost Optimization:

DFM focuses on optimizing material usage, reducing waste, and improving manufacturing efficiency. By identifying cost-saving opportunities during the design phase, component manufacturers can offer competitive pricing to their customers.


By advising product owners, component manufacturers can advise on quality issues during the mass production of your products. Product owners usually get caught off-guard after pushing their products through the prototyping stage in order to rush their products to market.

3. Benefits for Customers:

a. Higher Quality Products:

Implementing DFM ensures that components are designed with manufacturing limitations in mind, leading to better fit, form, and function. This results in higher quality products that meet or exceed customer expectations.

b. Reduced Manufacturing Costs:

DFM-driven designs simplify production processes, leading to reduced material waste and labor costs. Customers can enjoy cost savings without compromising on product quality.

c. Faster Time-to-Market:

With a streamlined manufacturing process, component manufacturers can produce and deliver parts faster. Customers can introduce their products to the market more swiftly, capitalizing on opportunities and staying ahead of competitors.

d. Greater Innovation Potential:

DFM encourages innovation by allowing component manufacturers to propose design modifications that optimize manufacturability. Customers benefit from the expertise of their manufacturing partners, leading to more innovative and efficient product designs.


Conclusion:

In the ever-evolving landscape of component manufacturing, embracing Design for Manufacturing is not merely a strategy; it is a necessity. By integrating DFM principles into the product development process, component manufacturers can offer their customers a competitive advantage – from shorter time-to-market and cost savings to superior product quality and increased innovation potential.

As a customer-focused component manufacturer, understanding and implementing DFM is at the core of our success. We are committed to collaborating closely with our customers, ensuring that their designs are optimized for seamless production. Together, we navigate the path to success, delivering top-notch components that lead to mutual growth and prosperity in the dynamic world of manufacturing.


Are you in the market for precision turned parts? Do you have intricate drawings and designs that demand the utmost accuracy and attention to detail? We invite you to partner with us as we specialize in delivering top-quality small parts through our subtractive manufacturing processes.
At Turntech Precision, we understand the unique challenges that arise in small parts manufacturing and the importance of precision in every step of the process. Our state-of-the-art CNC machining capabilities ensure that your designs are transformed into reality with the highest level of accuracy and surface finish.
Send us your drawings, specifications, or 3D models, and let our team of experts analyze your requirements. Whether you need prototypes or large production runs, we are committed to delivering exceptional results that meet your expectations and industry standards.
Here's how you can get started:
Email us your design files at geesuan@turntechprecision.com
Our engineering team will thoroughly review your drawings and provide a comprehensive quote tailored to your needs.
We'll work closely with you to ensure that every detail is taken into account, making any necessary adjustments to optimize the manufacturability of your small parts.
Once you approve the quote and design, our experienced machinists will commence production using our advanced subtractive processes to bring your vision to life.
At Turntech Precision, we take pride in our commitment to excellence and customer satisfaction. Whether you're a seasoned professional in the industry or a startup looking to materialize your innovative ideas, we're here to support your small parts manufacturing needs.
Don't miss the opportunity to partner with a dedicated team that values precision and craftsmanship. Reach out to us today, and let's embark on a journey of transforming your designs into high-quality, precision turned parts that exceed your expectations. Your success is our success, and we look forward to collaborating with you on your next project!

Unleashing the Potential of CNC Machining with LFV Feature on Cincom Citizen Machines

In today's fast-paced manufacturing landscape, precision and efficiency are paramount. CNC (Computer Numerical Control) machines have revolutionized the manufacturing industry by enabling automated, high-precision production. Among these cutting-edge machines, Cincom Citizen stands tall as a pioneer in innovation. In this blog post, we will explore one of the game-changing features of Cincom Citizen machines – the Low-Frequency Vibration (LFV) technology – and the incredible benefits it brings to CNC machining.

1. Understanding LFV Technology:

LFV, or Low-Frequency Vibration, is a proprietary technology developed by Citizen Machinery Co., Ltd., for their Cincom series of CNC Swiss-type lathes. The LFV feature allows for real-time control of the cutting tool's vibration frequency during the machining process. Unlike traditional machining, where constant vibrations can cause tool wear and deteriorate surface finishes, LFV technology intelligently manages these vibrations to optimize machining outcomes.

2. Features of LFV on Cincom Citizen Machines:

a. Variable Control of Vibrations: The LFV feature offers dynamic control over the cutting tool's vibrations, adjusting the frequency and amplitude as needed throughout the machining process. This adaptability ensures smoother cutting and significantly reduces chatter, leading to improved surface quality and longer tool life.

b. Built-in Intelligence: Cincom Citizen machines equipped with LFV technology come with intelligent algorithms that analyze cutting conditions in real-time. This data-driven approach enables the machine to make instant adjustments, enhancing the overall stability and reliability of the machining process.

c. Easy Integration: LFV technology seamlessly integrates into the existing machining process without requiring extensive reprogramming or modifications. This user-friendly feature allows both experienced operators and newcomers to take advantage of its benefits with minimal effort.

d. Versatile Applications: The LFV feature is well-suited for a wide range of materials, including difficult-to-machine metals and alloys. From aerospace components to medical devices, Cincom Citizen machines with LFV excel in diverse manufacturing applications.

LFV Explainer from Cincom UK

3. Benefits of LFV Technology:

a. Improved Surface Finish: By effectively reducing chatter and vibration-induced tool marks, LFV technology ensures a superior surface finish for the machined parts. This is especially crucial for components requiring exceptional precision and aesthetics.

b. Extended Tool Life: With reduced tool wear, the LFV feature contributes to longer tool life and less frequent tool replacements. This not only saves costs but also minimizes production downtime, resulting in higher productivity.

c. Enhanced Productivity: The ability to maintain stable machining conditions throughout the process leads to increased productivity. The LFV feature allows for higher cutting speeds and feeds without compromising the quality of the finished product.

d. Consistent Quality: LFV technology's adaptive control ensures consistency in machining outcomes, leading to parts with uniform dimensions and tolerances. This feature is especially valuable for high-volume production runs.

e. Reduced Environmental Impact: By optimizing the machining process, LFV technology helps minimize material waste and energy consumption. Manufacturers can embrace sustainable practices while delivering high-quality products.

Conclusion:

The Low-Frequency Vibration (LFV) feature on Cincom Citizen machines embodies innovation and precision in CNC machining. With its ability to dynamically control vibrations, LFV technology unlocks a host of benefits for manufacturers – from improved surface finish and extended tool life to enhanced productivity and consistent quality. Embracing LFV technology empowers manufacturers to stay competitive in an ever-evolving industry and embrace the future of precision manufacturing.

Unlock the full potential of your CNC machining capabilities with Cincom Citizen's LFV technology and take your manufacturing processes to new heights!


Are you in the market for precision turned parts? Do you have intricate drawings and designs that demand the utmost accuracy and attention to detail? We invite you to partner with us as we specialize in delivering top-quality small parts through our subtractive manufacturing processes.
At Turntech Precision, we understand the unique challenges that arise in small parts manufacturing and the importance of precision in every step of the process. Our state-of-the-art CNC machining capabilities ensure that your designs are transformed into reality with the highest level of accuracy and surface finish.
Send us your drawings, specifications, or 3D models, and let our team of experts analyze your requirements. Whether you need prototypes or large production runs, we are committed to delivering exceptional results that meet your expectations and industry standards.
Here's how you can get started:
  1. Email us your design files at geesuan@turntechprecision.com
  2. Our engineering team will thoroughly review your drawings and provide a comprehensive quote tailored to your needs.
  3. We'll work closely with you to ensure that every detail is taken into account, making any necessary adjustments to optimize the manufacturability of your small parts.
  4. Once you approve the quote and design, our experienced machinists will commence production using our advanced subtractive processes to bring your vision to life.
At Turntech Precision, we take pride in our commitment to excellence and customer satisfaction. Whether you're a seasoned professional in the industry or a startup looking to materialize your innovative ideas, we're here to support your small parts manufacturing needs.
Don't miss the opportunity to partner with a dedicated team that values precision and craftsmanship. Reach out to us today, and let's embark on a journey of transforming your designs into high-quality, precision turned parts that exceed your expectations. Your success is our success, and we look forward to collaborating with you on your next project!

10 Turning Operations You Need To Know

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Lathe machines create sophisticated parts for medical, military, electronics, automotive, and aerospace applications. Read on to find out the top 10 machining operations performed on a lathe. 

A lathe is capable of performing numerous machining operations to deliver parts with the desired features. Turning is a popular name for machining on a lathe. Nevertheless, turning is just one kind of lathe operation.

The variation of tool ends and a kinematic relation between the tool and workpiece results in different operations on a lathe. The most common lathe operations are turning, facing, grooving, parting, threading, drilling, boring, knurling, and tapping.  

1. Turning

Turning is the most common lathe machining operation. During the turning process, a cutting tool removes material from the outer diameter of a rotating workpiece. The main objective of turning is to reduce the workpiece diameter to the desired dimension. There are two types of turning operations, rough and finish. 

Rough turning operation aims to machine a piece to within a predefined thickness, by removing the maximum amount of material in the shortest possible time, disregarding the accuracy and surface finish. Finish turning produces a smooth surface finish and the workpiece with final accurate dimensions.

Different sections of the turned parts may have different outer dimensions. The transition between the surfaces with two different diameters can have several topological features, namely step, taper, chamfer, and contour. To produce these features, multiple passes at a small radial depth of cut may be necessary.

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Step Turning

Step turning creates two surfaces with an abrupt change in diameters between them. The final feature resembles a step.


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Taper Turning

Taper turning produces a ramp transition between the two surfaces with different diameters due to the angled motion between the workpiece and a cutting tool.


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Chamfer Turning

Similar to the step turning, chamfer turning creates angled transition of an otherwise square edge between two surfaces with different turned diameters.


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Contour Turning

In contour turning operation, the cutting tool axially follows the path with a predefined geometry. Multiple passes of a contouring tool are necessary to create desired contours in the workpiece. However, form tools can produce the same contour shape is a single pass.


2. Facing

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During the machining, the length of the workpieces is slightly longer than the final part should be. Facing is an operation of machining the end of a workpiece that is perpendicular to the rotating axis. During the facing, the tool moves along the radius of the workpiece to produce the desired part length and a smooth face surface by removing a thin layer of material.

 

3. Grooving

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Grooving is a turning operation that creates a narrow cut, a "groove" in the workpiece. The size of the cut depends on the width of a cutting tool. Multiple tool passes are necessary to machine wider grooves. There are two types of grooving operations, external and face grooving. In external grooving, a tool moves radially into the side of the workpiece and removes the material along the cutting direction. In face grooving, the tool machines groove in the face of the workpiece. 

4. Parting 

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Parting is a machining operation that results in a part cut-off at the end of the machining cycle. The process uses a tool with a specific shape to enter the workpiece perpendicular to the rotating axis and make a progressive cut while the workpiece rotates. After the edge of the cutting tool reaches the centre of the workpiece, the workpiece drops off. A part catcher is often used to catch the removed part. 

5. Threading

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Threading is a turning operation in which a tool moves along the side of the workpiece, cutting threads in the outer surface. A thread is a uniform helical groove of specified length and pitch. Deeper threads need multiple passes of a tool.

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6. Knurling

Knurling operation produces serrated patterns on the surface of a part. Knurling increases the gripping friction and the visual outlook of the machined part. This machining process utilizes a unique tool that consists of a single or multiple cylindrical wheels (knurls) which can rotate inside the tool holders. The knurls contain teeth that are rolled against the surface of the workpiece to form serrated patterns. The most common knurling pastern is a diamond pattern.

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7. Drilling

Drilling operation removes the material from the inside of a workpiece. The result of drilling is a hole with a diameter equal to the size of the utilized drill bit. Drill bits are usually positioned either on a tailstock or a lathe tool holder.

8. Reaming

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Reaming is a sizing operation that enlarges the hole in the workpiece. In reaming operations, reamer enters the workpiece axially through the end and expands an existing hole to the diameter of the tool. Reaming removes a minimal amount of material and is often performed after drilling to obtain both a more accurate diameter and a smoother internal finish.

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9. Boring

In boring operation, a tool enters the workpiece axially and removes material along the internal surface to either create different shapes or to enlarge an existing hole.

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10. Tapping

Tapping is the process in which a tapping tool enters the workpiece axially and cuts the threads into an existing hole. The hole matches a corresponding bit size that can accommodate the desired tapping tool. Tapping is also the operation used to make a thread on nuts.


Conclusion

Lathes are capable of machining pieces with sophisticated features. The final part features are produced by the utilization of various tools and by changing the kinematical relationship between the cutter and a workpiece. In this article, we explained ten different lathe operations. 

We at Turntech Precision provide the top quality parts machined on the Swiss-type lathes utilizing turning, facing, grooving, threading, knurling, boring, and tapping operations. We work closely with our customers to provide them with the best solution to their engineering problems in a variety of industries. Contact us today with your inquiries.