Cost Effective Machined Parts: Wall vs. Floor Radii…
It isn't uncommon for engineers to put a radius both on the floor and wall intersection aswell as the vertical walls (see fig A). With the "apply round" or fillet feature on most 3DCAD systems, the easiest thing to do is to select both that floor intersection and the wallintersections and just apply the same size radius to all those. But in fact, what saves you afew seconds work to have just one feature, can cause enormous headaches for themachine shop and cost you a lot of money in the long run.
Fig. A: Equal floor and wall radii lead to a condition like the one in figure B.
It isn't obvious what it takes to machine the area in the corner. It is much morecomplicated if the floor radius is smaller than the wall radius. Because of the equal walland floor radii, two tools must be used to clean up this area completely. The wall needs to be cut with a ball end mill (an end mill with a full radius on the tip). The floor of the partneeds to be cut with a flat end mill, but this will leave a triangular shaped section in thecorner that neither tool can reach. (see fig B).
Fig. B: The material in blue cannot be easily removed.