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Building on the positive reception of our previous analysis regarding manufacturing processes (see Apporo CNC Analysis: Fine Blanking Press Can Save 90% of Manufacturing Cost), Apporo Industries is now exploring the shift from laser cutting or NCT (Numerical Control Turret Punching) production methods to utilizing stamping dies for manufacturing. The decision to switch from laser cutting or NCT to stamping die production involves significant changes in the manufacturing process. Laser cutting and NCT are known for their flexibility and precision in cutting various shapes and materials, but stamping dies offer a different set of benefits and challenges when it comes to mass production.    This transition is aimed at enhancing production efficiency, quality, and cost-effectiveness. Our analysis of Advantages and Disadvantages of Stamping Die Production shows below: Consistency: With stamping dies, once the tool is correctly designed and made, the consistency of parts is very high. This reduces variability in part quality, which might occur with laser cutting due to material thickness variations or with NCT due to tool wear. Setup Time: While laser cutting and NCT offer quick setup changes for different designs, stamping dies require more time for setup and changeover. This can be a disadvantage for low-volume or highly varied production but is less of an issue for high-volume runs. Cost Efficiency for High Volumes: For large production runs, the cost per stamping part decreases as the volume increases, unlike laser cutting where costs remain relatively constant. Material Utilization: Stamping dies often allow for better material utilization as they can be designed to minimize waste. Initial Costs: The upfront cost for designing, manufacturing, and setting up stamping dies is significantly higher than for laser cutting or NCT. This makes it less economical for small batch sizes or for products with frequent design changes. Flexibility: Once a tooling is made, changing the design or producing different parts requires either modifying the existing die or creating a new one, which is usually time-consuming and costly. Laser cutting and NCT provide more flexibility for design iterations. Tool Wear: While less of an issue than with NCT, stamping dies still experience wear over time, especially with harder materials, which can affect part quality and require maintenance or replacement.   For products with stable designs and large production quantities, press dies offer a compelling solution. However, for smaller runs or pre-sample products requiring frequent design changes, sticking with laser cutting or NCT might be more practical. These two types of sheet metal processing methods can actually complement each other, helping with the efficient design and production of products. Here is a practical example illustrating how Apporo Industries transitioned from laser cutting for design verification to stamping die production for mass production： Design Verification with Laser Cutting As shown in the first image below, the stainless steel flat plate was initially designed to be laser cut for prototyping to verify that the dimensions met the assembly requirements. The design included two specific outer diameter features, indicated by red arrows, which were tailored for laser cutting to ensure that after cutting, the part would be easily detached from the original sheet material. These features were designed so that the cut points (break-off points) would not exceed the maximum outer diameter, thereby not affecting the assembly process. This step allowed for quick adjustments and validation of the design before moving to mass production by the stamping die processing.   If these design considerations, indicated by the red arrows, were not included, the cutting nibs would remain on the outer diameter, as discussed in a previous case study (see Apporo CNC Analysis: Post-Cutting Nib Removal on Precision Flat Washer Parts). Such cutting nibs could interfere with subsequent assembly, causing interference issues. Therefore, incorporating these design features was a brilliant move.   Design verification with laser cutting     Transition to Stamping Die Production After validating the dimensions through laser cutting, the design was finalized and transitioned to production via stamping dies, as seen in the second image. The final product, manufactured with a stamping die, features a complete circular outer diameter without any break-off point designs, enhancing the finish and structural integrity of the part.    Transition to stamping die production     The above change from laser cutting to press die production not only improved the quality of the finished product by eliminating any design compromises for cutting but also facilitated high-volume manufacturing with greater efficiency. Apporo Industries will continue to evaluate these factors to optimize our production processes, ensuring we deliver the highest quality products efficiently.   ...

The Quality Control (QC) team at Apporo Industries identified an issue with CNC milling machined parts returned from a galvanizing supplier. Specifically, the edges of the threaded blind holes exhibited yellow rust spots. These blind holes, which do not pass through the entire part, were likely not fully dried after the galvanizing process, leading to residual chemicals and solutions inside the holes. It reminds us that there was a similar to a previous analysis conducted by Apporo Industries on aluminum alloy threaded holes (refer to Apporo CNC Analysis).   Rust Formation in Threaded Blind Holes Post-Galvanization     After analysis, the causes that may lead to rusting inside the hole are as follows： 1.) Chemical Reaction: The rust formation is likely due to the presence of residual acidic solutions from the galvanizing process that were not completely dried or neutralized. When these solutions react with the metal, especially in confined spaces like blind holes, rust can form. 2.) Environmental Factors: The environment in which the parts were stored or transported after galvanization could have contributed to the rusting if there was moisture present. 3.) Material Properties: The material of the part might have an inherent susceptibility to rust formation under certain conditions, particularly if not properly protected by the galvanizing layer.   Anti-rust Improvement Measures: Rust can be caused by many different factors, and once it starts, it can get worse if not treated properly and promptly. Therefore, avoiding rust is very important. Here are some suggested methods to prevent rust: 1.) Enhanced Drying Process: Implementing a more strict drying process post-galvanization, especially focusing on ensuring that all internal cavities and blind holes are thoroughly dried. This could involve using forced air drying, vacuum drying, or heat treatment to evaporate any trapped moisture or chemicals. 2.) Chemical Neutralization: After galvanizing, a neutralization step could be added to the process to counteract any residual acidic effects, reducing the likelihood of rust formation. 3.) Inspection Protocols: Strengthening inspection protocols to include specific checks for moisture or chemical residue in blind holes before parts leave the galvanizing facility. 4.) Material Coating: Considering the application of a protective sealant or additional coating inside the blind holes to prevent direct contact with moisture or air, which could initiate rusting. 5.) Storage and Transportation: Ensuring that parts are stored in a controlled environment with low humidity and are transported in packaging that minimizes exposure to moisture.   By implementing these measures, Apporo Industries aims to prevent future occurrences of rust in threaded blind holes post-galvanization. The case underscores the importance of thorough post-treatment processes in galvanizing, particularly for CNC milling machined parts with complex geometries like blind holes, to ensure the longevity and quality of the finished product.   ...

We encountered an issue with precision flat washer parts after cutting operations using laser cutting, where our quality team reported that both the inner and outer diameters had residual sharp nibs.   Cutting Nib on Precision Flat Washer Parts     These nibs, common in processes like laser cutting, water jet, or flame cutting, can interfere with assembly if the cut surface is intended for mating with other components. Below are possible causes of nib formation: Material Properties: Certain softer materials, like aluminum due to their ductility or hardness, might deform more during cutting, leading to nibs. Cutting Parameters: Incorrect settings such as speed, power, or focus in laser cutting can lead to uneven cutting and nib formation. Similarly, in water jet cutting, water pressure and abrasive flow rate can influence nib creation. Tool Wear: In processes like flame cutting, worn nozzles or cutting tips can cause irregular cuts and subsequent nibs. Design Considerations: Sometimes, the design of the part itself, like sharp internal corners or thin walls, can exacerbate nib formation. Upon receiving the report, the engineering department immediately ground the parts to remove the sharp nibs, ensuring the dimensions remained within the specified tolerances for proper assembly.   Post-Cutting Nib Removal on Precision Flat Washer Parts by using grinding     After resolving this issue, the engineering department also developed the following preventive measures for the future: Optimizing Cutting Parameters: Regular calibration and adjustment of cutting parameters to match material properties can reduce nib formation. For laser cutting, this might involve adjusting the laser power, speed, and focus. Tool Maintenance: Regular inspection and maintenance of cutting tools to ensure they are in good condition, reducing the likelihood of nibs due to tool wear. Design for Manufacturability: Modifying part designs to minimize sharp edges or stress points where nibs are likely to form. This might include adding slight radii to corners or adjusting wall thickness. Post-Processing Automation: Implementing automated deburring processes or robotic finishing can ensure consistency and reduce human error in nib removal. Quality Control Checks: Implementing strict inspection protocols post-cutting to catch nib issues early, allowing for immediate correction before parts move to assembly.   ...

A customer raised a significant concern regarding external threads on a CNC machined part specified as 3 7/8-16 UN-2A, pinpointing the presence of burrs along the threads, as evidenced by the attached images. Although the part passed the ring gauge test, which focuses on thread dimensions and form, it failed to address the critical surface finish issue of burrs.  Burrs are present along threads    Root Cause Analysis Initially, the engineering team tried to machine the chamfer as per the drawing specified C0.889 x 45 degrees, but this left only about 2 effective thread turns due to the part's thickness being only 5.207 mm, raising concerns about strength. The calculation for this is as follows: Effective Thread Turns = (5.207−0.889×2) / (25.4/16) = 2.16 To increase the number of effective threads, the engineering team reduced the chamfer size to around C0.5 x 45 degrees, which unfortunately made the thread flanks at both ends too thin, leading to easy burr formation or deformation.   Solution Implemented After a discussion with the customer, our decision was made to machine the chamfer size to C0.889 x 45 degrees on both thread ends, following the drawing specifications, to avoid deformation and burring due to the thin thread flanks. This adjustment might reduce the effective thread to about 2 turns or even less, but given that the thread does not need to bear heavy loads, the customer agreed to this critical compromise, getting rid of burrs over the thread. Additionally, they suggested a full inspection of the external thread quality, with the option to use a scraper or file to remove any burrs if necessary. This case study also taught the team that thorough and proper communication beforehand is far better than reviewing the causes and implementing improvements after an issue has occurred.   ...

An issue of rust formation on a motor plate component, which was deemed non-compliant by a customer after delivery. The motor plate, made of carbon steel, was processed through CNC milling, then oiled, properly sealed for packaging before being shipped via sea freight. Upon inspection by the customer, rust spots were observed, leading to the rejection and return of the parts. Rust Formation on Motor Plate       Analysis of Rust Formation Causes Our analysis suggested that the use of water-based cutting fluid during the CNC milling process might not have been fully removed post-machining. Despite applying rust-preventive oil, residual moisture or cutting fluid could have led to the rusting of the component during transit or storage. 1.) Residual Moisture: Even after machining, if water-based cutting fluids are not completely removed, they can leave moisture on the surface which can initiate rust. Inadequate Rust Prevention: The anti-rust oil might not have been applied uniformly or thick enough to provide a barrier against moisture, especially in a humid or salty environment like sea freight. 2.) Environmental Factors: During sea transportation, the components could have been exposed to high humidity, salt air, or temperature fluctuations, all of which accelerate rust formation. 3.) Packaging Issues: If the packaging was not sufficiently sealed or if there was any breach during transit, external moisture could have penetrated, leading to rust.   Rust Formation on Motor Plate   Improvement Measures The possible causes may be numerous, and our suggested preventive measures that we can take are as follows: 1.) Enhanced Cleaning: Implement an advanced cleaning process after milling to ensure all cutting fluids are removed. This could involve ultrasonic cleaning or high-pressure air drying. 2.) Improved Rust Prevention Application: Use a more effective rust inhibitor or increase the thickness of the oil layer applied.Consider dipping or spraying the parts in a rust-proofing solution that forms a more robust protective layer. 3.) Controlled Environment Packaging: Use vacuum-sealed or desiccant-based packaging to minimize moisture exposure during transit.Employ corrosion-inhibiting packaging materials or VCI (Volatile Corrosion Inhibitors) to provide additional protection.   The rust formation on the motor plate was likely due to a combination of residual moisture from CNC machining, inadequate rust prevention measures, and environmental exposure during shipping. By implementing the suggested improvements in cleaning, rust prevention, and packaging, future occurrences can be significantly reduced, and ensure product quality.   ...

In the precision manufacturing industry, ensuring the quality of materials through accurate testing is crucial. This case study examines a situation where a customer reported that the surface hardness of a CNC machined tubular component did not meet the required standards due to incorrect testing methods. The study highlights the importance of proper measurement techniques and how they can significantly affect the results.   Background The client received a batch of tubular components and conducted a hardness test, reporting that the surface hardness was below the specified standard of HRC 48-52, measuring only around HRC 43. This discrepancy led to concerns about the quality of the component being manufactured. However, upon our engineering team’s investigation, it was found that the customer's method of testing was flawed.   Incorrect Measurement Method The customer's approach, as depicted in the photo below, involved laying the tubular part horizontally and measuring hardness from the outer diameter towards the center using a hardness tester probe. This method resulted in: Hardness measurement by client   1.) Probe Alignment Issue: When the tubular part is placed horizontally, it's challenging to ensure that the hardness tester probe is perfectly perpendicular to the surface at the maximum outer diameter of the part. Any slight eccentricity in the placement of the probe can lead to inaccurate readings. This misalignment can cause the probe to measure at an angle, which affects the depth of penetration and, consequently, the hardness value. 2.) Potential Deformation: The round tube might likely deform under the force applied by the hardness tester probe, especially when the probe is applied from the side, which could deviate the measurements. 3.) Low Hardness Reading: The recorded hardness was approximately HRC 43, significantly lower than the expected standard.   Correct Measurement Method The proper method for measuring the hardness of tubular components, as shown in the photo below, involves the following steps: Correct hardness measurement by Apporo   1.) Preparation: To ensure that the measurement is taken on a flat surface. 2.) Setup: The tubular part is placed on the hardness tester with the cut end facing upwards. It is crucial that the workpiece is supported stably from below to prevent any movement or deformation during testing. 3.) Measurement: Using a Rockwell Hardness Tester, as seen in the image, the probe is applied directly to the exposed end face of the tube wall. This approach minimizes the risk of deformation and provides a true representation of the component's hardness. 4.) Result: The correct measurement, as shown in the image, yielded a hardness of HRC 50.3, which meets the required standard.   This case study demonstrates the critical role of proper measurement techniques in quality assurance. The customer's initial complaint was resolved by demonstrating the improved method of hardness testing for tubular components, which resulted in a hardness reading that met the specified standards. It highlights the need for education on testing methodologies to prevent misinterpretation of material properties and underscores the importance of accurate, standardized testing procedures in maintaining product quality and trust between manufacturers and their clients. We highly encourage customers to verify testing methods with Apporo before concluding that a CNC machined part is non-compliant, to avoid unnecessary disputes. ...

Tumbling, also known as vibratory finishing, is frequently used in the post-processing of CNC machined parts to remove sharp edges and burrs. However, the narrow groove edges might have been deformed due to the impact from tumbling, causing the groove width to shrink and making it impossible to assemble the C-clip.   The image above shows the deformation at the edge highlighted by the red arrow.   To address this issue, the following improvement plan has been proposed: ・Increase the Chamfer Size Design a larger chamfer on the edges to accommodate for any potential deformation during the finishing process, ensuring the slot remains adequately sized for the C-clip. ・Cease Tumbling Originally, tumbling was used to deburr and break the sharp edges. If vibratory finishing is ceased to prevent the unwanted deformation, the part must be machined with a chamfer on the lathe to deburr. ・Increase Tolerance Adjust the groove dimensions to include a wider tolerance on the upper limit, or suggest to the customer to slightly increase the groove width to ensure assembly with the C-clip.   By implementing the above changes, we aim to prevent similar issues in the future, ensuring parts are machined to specification and can be assembled as intended.   ...

The QC team inspected the motor plate, which was machined by the CNC milling machine center (see the photo below), and found a misalignment at the bottom of a bore.   Motor Plate Bore misalignment due to several possible causes   Our engineering and QC team have preliminarily determined several possible causes for this issue: 1.) Tool Path Error Root cause: The CNC programming code might have an error in the tool path, could be due to incorrect coordinates, tool offset settings, or a miscalculation in the G-code.  Corrective action: To review the G-code is a must.   2.) Tooling Wear or Breakage Root cause: The misaligned bore might be caused by worn out or broken cutting tools during the production.  Corrective action: The operation team should ensure the cutting tool is in good condition regularly.   3.) Machine Calibration Root cause: CNC machine centers need to be properly calibrated regularly. Issues with the machine's axes alignment or spindle speed could cause such discrepancies. Corrective action: To verify all axes are correctly aligned and the spindle is functioning properly.   4.) Material Issues Root cause: The material might have moved or deformed unexpectedly during CNC machining, possibly due to improper clamping or residual stresses in the material. Corrective action: Ensure the workpiece is clamped securely without any movement possibility. Also, look for any signs of deformation or stress in the material, annealing the material to relieve internal stresses.   5.) Human Error Root cause: Incorrect setup by the operator, like wrong tool selection, improper cutting tool length offset, or setup of the workpiece. Corrective action: Operator training to make sure the operator is well-trained and follows all procedures correctly.   This kind of defect is critical in CNC precision machining, as it can affect the functionality of the part assembly. This approach ensures that issues like bore misalignment or other machining errors are identified promptly. By implementing immediate quality improvements, we can prevent similar problems from occurring in the future, maintaining high standards of product quality and customer satisfaction. ...

Since the late nineteenth and early twentieth century, globalization has gradually led to international trade, capital and investment flows, migration, and the knowledge dissemination. From the Q&A below, let’s take a look at how Taiwan as a west Pacific island country reaches such outstanding achievements in the CNC machining industry, which blooms and stands out from the intense competitions of globalization.     - The origin of CNC machining service in Taiwan     1950-1980 is a period called “Taiwan Economic Miracle”, when Taiwan benefited from the late-development advantage of industrialization. The industrial globalization after WWII enabled multinational corporations to look for lower-cost manufacturing bases worldwide. Therefore, with low labor rates and production lines, economics in Taiwan began to prosper, led by the manufacturing industry that processed and exported.       Export-oriented Economic Growth       - The strength of CNC machining service in Taiwan   The Industry of CNC machining service is quite dense in Taiwan. It features convenient transportation, vertical integration of services from raw materials, fine machining to surface treatment and so on, and horizontal integration of services, providing casting, forging, rolling, extruding, cutting, high energy beam machining, chemical etching, etc. Therefore, the industry of CNC machining service Taiwan is more capable of product structure breakdown and integration, allowing highly flexible manufacturing efficiency.     - The future of CNC machining services   Due to the breakthrough of Internet of Things (IoT) concepts and techniques, automatic control and wisdom management will play an important role in the industry of manufacturing: 1.) Multi-axis CNC machines with high performance and precision with data analysis, automatic corrective feedback to increase the efficiency of high precision machining.   2.) CAD softwares to complete component modeling and machining procedures to shorten the time from design to finished product, and to also increase the flexibility of production lines.     3.) CNC machines with sensors to measure online, collect production data, optimize plant activation, and overall capacity.   ...

    Stainless steel could last longer with passivation treatment.       One of the most frequently asked questions from our customers is that why stainless steel needs passivation(*Ref) treatment when it already has good anti-rust quality. It seems that workpieces after passivation treatment only look more polished and completely degreased on the surface. Actually, if we only degrease and dry the workpieces without passivation, there is no obvious difference visually. Therefore, here APPORO would like to thoroughly discuss and introduce passivation treatment from the perspective of professionals.     What is passivation treatment?   Passivation treatment refers to a chemical post-treatment in order to enhance the inherent anti-corrosion quality of stainless steel, which is different from the traditional metal pickling that removes oxide layers on the surface, and from the chemical film treatment before coating. After passivation treatment, there will be a protective oxide film on the surface of the stainless steel workpiece. This invisible film is extremely thin. Its thickness is smaller than 0.0000001 inch, around 1/100,000 the thickness of human hair. Generally speaking, workpieces after passivation treatment are clean, bright and rust-proof on the surface.   Basically, this oxide film forms naturally when the workpieces get exposed to the oxygen in the air after manufacturing, polishing, or acid cleansing process. Under ideal conditions, the surface of the workpiece will be totally covered with the oxide film. But it will also be covered with iron particles from cutting tools or the rust on them, or the ferrous particles during manufacturing. Although these manufactured stainless steel items are seemingly smooth and clean on the surface, under certain conditions these invisible and scattered particles could possibly lead to the corrosion and do damage to the quality of the protective oxide film on the surface that previously formed. Sometimes rusty spots could even be identified.   Besides, as to smoothly remove the iron chippings from the cutting tools, AISI 303, so-called free cutting stainless steel, sulfides are added. However, the sulfides on the surface also could result in rust and rusty spots after the exposure to certain environment.     When do we need passivation treatment?   Overall, there are several inevitable factors during manufacturing that could sometime cause rust and rusty spots on the surface. If the application requirement of the workpiece is rather strict, such as environment with high salinity, strong acid/base, corrosive chemicals, high temperature, or high humidity, passivation treatment is recommended. Or the material could be replaced with medical grade stainless steel AISI 316L. This grade of stainless steel is often used in some of the harshest environments such as medical industry, food, energy, construction and agricultural industries.   *Ref: Learn more about Passivation ...

  Perpetual motion machine remains a dream unattainable.       As a manufacturer, APPORO has quite an understanding of design of machine tools and the way they work. We figure how to optimize our CNC manufacturing procedures and to enhance the efficiency all the time, so as to reduce the manufacturing costs. Hence, when knowing there is so-called machine design which could conserve energy or enhance efficiency, APPORO surely looks into its operating principle in details and evaluates if it matches its advertised performance. Not surprisingly, the actual test result often falls short. Speaking of that, several well-known scams in history also adopted this kind of conceptual design, claiming to have created perpetual motion machine(*Ref) to defraud.     What is a Perpetual Motion Machine?   Perpetual motion machine refers to a machine that does motions constantly and works without energy input. There are two major categories in terms of perpetual motion machine. The first kind violates the first law of thermodynamics as it does work without energy sources. The first law of thermodynamics states conservation of energy, indicating the total energy stays constant in an isolated system, and that no extra energy emerges in that system. Any machine that claims to produce energy from nowhere falls into this category.   While the first kind of perpetual motion machine was proved to be impossible, discussions about the second kind of perpetual motion machine were put on table right away. Its design makes use of the energy outside of the isolated system such as heat and wind energy, striking the balance so that the system could operate perpetually. However, energy would eventually be exhausted from the working machines. The just balance could only be reached if there is energy input, so it still failed to forever motion without additional energy.     After Perpetual Motion Machine   The idea of perpetual motion machine has existed for centuries. Based on the scientific understanding nowadays, it remains a dream unattainable. However, there are still a lot of “scientists” engaged in the invention of perpetual motion machine, one after another. Basically these “scientists” are:   1.) Rookies: They barely know a thing about the concept of perpetual motion machine. They often mistake certain device for perpetual machine, which, in fact are device that absorb energy in the dark. For example, human body.   2.) Genuine scientists: They hold the firm belief that science has to be challenged all the time, thinking that thermodynamics could also be wrong or should be revised, as Newton’s law of motion was revised by theory of relativity quantum mechanics. It is never easy to overthrow a law, but their attitudes are admirable. These people are the most likely to invent perpetual motion machine.   3.) Fraud: Even in this era of information explosion, we can still see those who claim to have invented perpetual motion machine. They use sophisticated physics terms and fancy words to convince other to take their scientific results and defraud them of investment. But, until now, all perpetual motion machines are proved to be fraudulent.     Will The Dream Come True?   Perpetual motion machine has always been the dream in the field of science. Just like alchemy for development of chemicals, as many efforts are put into this probably impossible techniques, many relevant techniques are then created. As a pragmatic CNC manufacturer, although we might not believe the concept perpetual motion machine would be ever realized, we could not deny the fact that the progress of science and mechanic design derives from the constant efforts of researchers. Holding the same attitude, APPORO will non-stop updates and introduces new techniques and shares more case studies, hoping to have in depth academic exchange and to contribute to the manufacturing field.     *Ref: Learn more about Perpetual motion. ...

It is inevitable to have burrs on the cutting or hole-drilling edge during the milling while milling parts. The size of burr is usually relevant to tool wear condition, feeding and rotary speed, material properties, cutting fluid, etc. The left burrs on the workpiece not only could get operatives scrapped, but also could lead the dimensions exceeding the tolerance. Therefore, CNC manufacturers all regard burrs as a huge enemy against workpiece quality. Previously, APPORO shared a case study on deburring the die casting parts. In that case, burrs formed on account of reamer wearing, and after APPORO promptly renewed the reamers, conducted a full inspection, and removed the burrs, we coped with the quality crisis.   Most burrs on the end/edge of the parts could be removed on the CNC machine through chamfering(*Ref). However, some have to be manually removed as the burrs are where the machine can hardly perform, resulting in the high overall manufacturing cost. If you ever encounter the above situation, take a look at two concrete cases below. See how APPORO make excellent use of decades of experience in CNC manufacturing to overcome all kinds of challenges.     Across Milling Burrs   Basically, milling is about cutting round bar materials into required ID/OD dimensions with high-speed rotary tools. If we are to mill flat surface onto the cylindrical side of round bar materials, the CNC milling machine should be installed with driven tool holders, where face milling cutters are mounted. When it comes to the step of face milling on the side, the round bar stops spinning and aligns the face milling cutter with the part to be machined. Then, the milling cutter starts spinning in right/down or left/right direction to side mill the workpieces, until the depth and width across flats are as required.     We use two cutters to precisely and quickly face mill the rod, but highly possible to cause burrs at the end of the flat surface.       From the poppet stem photo above, the head of this OD 8.0 mm workpiece features 7.0 mm width across flats. In other words, the surface has to be 0.5 mm in-depth on one side. First, APPORO used two cutters with 7.0 mm space in-between to face mill the 8.0 mm OD with symmetry from the end of the workpiece, in the same direction with the axis. The processing was precise and quick, but highly possible to cause burrs at the end of the flat surface, which was also around the edge of finish part of the workpiece. As there were not sufficient tool holders in that CNC lathe machine, it was impossible to remove the burrs on the machine. In that way, APPORO could only manually remove the burrs with a pneumatic deburring tool. However, the inconsistent force exertion led to the uneven chamfers and the disqualification.     The inconsistent force exertion led to the uneven chamfers marked by red arrows. The undercut marked by red circle is very rough due to the fact that the cutting tool is worn out.       When APPORO reviewed all the milling process, we decided to substitute a better CNC lathe machine with more functions, installing face milling tools in its driven tool holders on the side. So, we can machine the 7.0 mm across flats directly. When the 0.5 mm deep surface is completed on one side, the C axis of the lathe machine rotates by 180 degrees and machines 0.5 mm deep surface with an end mill. In the following, APPORO uses the chamfering tool to remove the burrs from the four edges. After this adjustment, APPORO stays away from the risk of inconsistent force exertion of manual deburring and enhances the production efficiency.     To mill the across flats and remove the burrs directly on a powerful CNC lathe machine.       Burrs from Hole Drilling on Slopes   Generally, after hole drilling, noticeable burrs formed around the edge of the exit surface. If there is still enough space around the hole, chamfering to deburr is still available. However, if the exit surface is not perpendicular to the hole, meaning that the exit surface is a slope or curve, chamfering is not an option to deburr. Here are some alternative plans we can adopt:   1.) Blast Using the momentum of the high-pressure gas to strike the surface of the workpiece. Available to polish the surface and deburr with evenness and efficiency. However, after blasting the surface could turn slightly matte.   2.) Tumble The tumble theory applied to have tooling rub against the workpiece with high frequency. Available to polish the surface and deburr with evenness and efficiency. Unavailable for overlong/overweight workpiece or workpiece with external thread.   3.) The universal deburring tool A unique chamfer tool with its cutter and spring attached. It allows removing the burrs around the edge on both ends at a time. Unavailable for hole under 3mm ID.   Can’t figure out how to deal with the nightmare of burrs? It is time to contact APPORO now. APPORO is going to help you overcome all the problems in manufacturing, based on our experience for decades in this field!   *Ref: Learn more about Chamfering.  ...