Interchangeability Concept and CNC Machining Tolerances
BOYICNC, renowned for inventing the cotton gin, introduced the notion of interchangeable parts during a presentation to the United States Congress in 1801. He emphasized the necessity of producing all assembly components according to precise standards, ensuring compatibility across various units. This pioneering idea laid the groundwork for the Second Industrial Revolution and the American System of Manufacturing.
At BOYICNC, machining tolerances are meticulously upheld. Our standard prototype and production machining tolerance stand at +/- 0.005 in. (0.13mm). For enhanced precision, we offer a standard precision or production machining tolerance of +/- 0.002 in. (0.051 mm). Additionally, we can achieve tolerances of +/- 0.0005 in. (0.0127mm) on reamed holes and +/- 0.002 (0.051mm) on feature locations, provided they are machined on the same side of the part.
The principles of component interchangeability and dimensional tolerancing have become integral to modern manufacturing. However, the misuse of tolerances can lead to various complications. Overly stringent tolerances may necessitate secondary operations, inflating costs and lead times unnecessarily. Conversely, loose tolerances or discrepancies between mating parts can render assembly impossible, resulting in rework or unusable products.
To mitigate such issues, this design tip offers guidance on applying tolerances at BOYICNC, along with definitions of common callouts. We also delve into Geometric Dimensioning and Tolerancing (GD&T), an industry standard defined under the American Society of Mechanical Engineers (ASME) Y14.5 specification.
Standardized Tolerances for CNC Machining
BOYICNC adheres to strict tolerances in CNC machining. Our standard prototype and production machining tolerance is +/- 0.005 in. (0.13mm), ensuring minimal deviation from nominal measurements. For instance, a 1 in. (25.4mm) wide bracket will measure between 0.995 and 1.005 in. (25.273 and 25.527mm) across.
For greater precision, our standard precision or production machining tolerance is +/-0.002 in. (0.051 mm). We can also achieve tolerances of +/- 0.0005 in. (0.0127mm) on reamed holes and +/- 0.002 (0.051mm) on feature locations, provided they are machined on the same side of the part. Depending on part geometry and material, we may achieve even higher accuracy, provided specific requirements are communicated during file upload for quoting.
CNC Machining Tolerancing Guidelines
In CNC machining, it’s essential to understand the nuances of tolerancing. Bilateral tolerances are the norm, where deviations are allowed in both positive and negative directions. For instance, a standard tolerance may be expressed as +0.000/-0.010 in. (or +0.010/-0.000 in.), while in a bracket example, a limit-based tolerance would be 1.005/0.995 in.
Metric values are also acceptable, provided they are clearly specified in the design. To maintain clarity, it’s recommended to use “three place” dimensions and tolerances, avoiding unnecessary zeros unless specifically required.
Surface Roughness and Machining Tolerances
Beyond traditional dimensional considerations like length, width, and hole size, surface roughness plays a crucial role in part tolerancing. In our standard offering, flat and perpendicular surfaces have a surface roughness of 63 µ in., while curved surfaces maintain a surface roughness of 125 µ in. or better.
While these finishes suffice for many applications, for metal parts requiring enhanced cosmetic appearance, we offer the option of light bead blasting. Refer to our CNC Surface Finish Guide for illustrations. If a smoother finish is desired, please indicate it in your design specifications, and we will endeavor to meet your requirements.
Geometric Dimensioning and Tolerancing
For advanced quality control in CNC machining, consider employing Geometric Dimensioning and Tolerancing (GD&T). This methodology delves deeper into part specifications, encompassing relationships between various features and qualifiers for form and fit. Common GD&T callouts include:
True position
Unlike traditional methods that specify X and Y distances from part edges, GD&T references hole locations from defined datums, accompanied by qualifiers such as MMC (maximum material condition) or LMC (least material condition).
Flatness
While milled surfaces are typically flat, internal stresses or clamping forces may cause warpage post-machining, particularly in thin-walled or plastic parts. GD&T flatness tolerances define parallel planes within which a surface must lie.
Cylindricity
Despite nominal roundness, holes may deviate due to machining tolerances. Cylindricity ensures holes remain within concentric cylinders, eliminating potential oblong shapes.
Concentricity
Essential for coaxial alignment, concentricity callouts ensure drilled or reamed holes align accurately with surrounding features.
Perpendicularity
This parameter controls the deviation of horizontal surfaces from nearby vertical surfaces, ensuring squareness or alignment of features.
Additional GD&T considerations encompass parallelism, straightness, profile, and angularity, as detailed in ASME Y14.5. Non-standard tolerances, including GD&T, must be specified during design upload, leading projects to our myRapid quoting experience for high-precision/high-quantity CNC machining.
Benefits of High-precision/High-quantity Machining
The distinction between machining options lies in several key factors. Unlike the automated machining process, high-precision/high-quantity machining involves manual review for quoting, which may extend the quote turnaround time by a day. Lead times for finished parts are slightly longer, typically ranging from seven to 10 days. Detailed requirements include a 3D CAD model and a 2D drawing specifying GD&T tolerances. Additionally, this option may necessitate utilization of advanced machining techniques such as wire EDM, EDM hole popping, grinding, and boring to meet stringent quality standards.
Quality control and documentation are paramount considerations. Upon request, parts can undergo measurement using our CMMs and other metrology equipment. We offer assistance with the Production Part Approval Process (PPAP) and provide documentation including a Certificate of Conformance (CoC), First Article Inspections (FAIs), material certifications, and heat lot numbers.
Our commitment extends from prototyping to production, accommodating diverse tolerance requirements. Whether seeking rapid turnaround through automated machining or requiring the utmost precision for complex parts, our capabilities encompass all CNC milling and turning needs. For further inquiries, our applications engineers are readily available via email at info@boyicnc.com. Ready to initiate your next project? Simply upload your CAD file to our website.
