Solving a very bad design

Now that we mentioned a few of the typical problems we may find with parts, we can review an example part to be machined from a squared stock. Let’s suppose that we are CAM operators and that a group of designers give us this part to realize:

Figure 7.21: Example part to machine

This part is most likely an April fool’s joke against us; there are a number of very big mistakes that not even a beginner can be excused for! But let’s imagine this is the real deal and that we have to somehow machine it with our milling machine.

Let’s review the mistakes one by one and try to find possible solutions with the design team.

Undercut face

There is a well-pronounced sloped face that cannot be machined at the moment. As we are about to discover, there are only three options available to us to achieve a similar shape, but all of them require minor changes to the design.

There is no correct one; picking...