The two-sided undercut balances the material removed on both sides of the corner and removes the least amount of material Two-sided undercut with block This style is my go-to whenever it’s allowed. It takes a little bit more calculation for manual machines, but for CNC it’s extremely straightforward. This is an undercut that balances the removed material on either side of the corner, and the result is an overall stronger corner. Here’s an example: One-sided undercutĪnd here’s an example of what it looks like with a mated part: One-sided undercut with mated block Two-Sided Undercut All you need to do is cut half the diameter of the tool further in one axis. This is the easiest type of undercut for manual machines, since no extra calculations are required. Either you can round the corners on that mating piece to make it fit, or you can make undercuts in those corners. Maybe there’s a mating part that’s square and it needs to fit in that pocket that we were using as an example above. Ok, so let’s say that simply putting a radius on the inside corners won’t work for you. Ok, maybe not centuries, but you get the idea.Ī radius on internal corners is a good thing. This is the way that the aerospace industry has been designing components for centuries. Here’s an example of what this would look like, using the example of a pocket: A 0.250″ radius will allow for a 1/2″ endmill to easily and inexpensively cut this pocket. Typically this isn’t a big deal, so unless there is a very specific reason as to why having a normal radius is impossible, just go this route. Radiused Cornerįor many applications, (approximately 99.735% of the time, actually) you can simply allow for a radius to be in the corner. While these square corners look great on paper (or a computer screen), they’re often simply not a good way to make machined components. Since the tool needs to rotate in order to cut, there is no way for one of these styles of tool to make a sharp inside corner. Let me illustrate: Pocket geometry with square corners – doesn’t really work so well. These dreaded square inside corners are anywhere that a round cutting tool will have a hard time reaching. Tools and Equipment for Sharp Internal Corners.
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