4140 demands a slightly higher material cost than non-alloy, pure carbon steel, as well as a substantially higher machining cost. However, because it’s so strong and durable, it’s considered highly cost-effective.

The risk of leakage would be high if the mating features lay at the extremes of the tolerances. This risk might not be caught during development, but over time, during production, the risk would increase, causing failures in the field. In the worst-case scenario, the company would face a recall with damage to brand reputation.

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Tolerance stack analysis can be illustrated using the example of a series of floorboards with a tolerance of +/- 0.005″ in width. If 200 of these boards are laid side by side, each at the bottom end of the allowable tolerance, they can create a 1″ gap on the floor, which may not be acceptable even though each board in isolation was acceptable.

However, the choice doesn’t just come down to aluminum versus steel. Steel is actually a family of materials, and it’s important to carefully evaluate different steels — and their respective advantages and limitations — during the material selection process. Here are four of the most commonly machined types of steel, and what product teams should know about each one.

Design for Assembly (DFA) is an important process that ensures the efficient assembly of components in a product. Tolerance stack analysis is a crucial step in DFA, which involves analyzing the tolerances of individual parts in an assembly to ensure they fit together correctly.

However, since 1045 is a steel of medium tensile strength and medium hardenability, it is not suitable for applications that require a very high-strength material. For applications that require more strength and wear resistance than mild steels, but less strength than the hardest steels, 1045 may be a good option.

4130 steel offers a modulus of elasticity that is higher than most other steels of similar ultimate strength, which enables it to withstand high stresses. This quality makes 4130 steel especially favorable as a structural steel, used for various construction applications. For all of these reasons, 4130 is frequently used in the creation of manufacturing equipment, rock crushing machinery, and resistance welding products. 4130 steel is well-suited for a variety of heat treatment processes.

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1045 is often selected for its relative strength and impact resistance. 1045 steel measures 54 on the Izod impact test. It’s also highly machinable and can be more easily welded than high carbon or high alloy steels, whether in the cold-drawn or normalized condition.

4140 steel is used across numerous industries because of its high fatigue strength, overall toughness, and resistance to abrasion and impact. The chemical composition of 4140 makes it particularly strong, tough, ductile, and hardenable. In addition, the chromium and molybdenum contribute to corrosion resistance, and the manganese and carbon content further increase hardenability while promoting deoxidization. It’s considered highly versatile and readily machinable, and can be used for many general purpose steel parts.

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4140 steel is much tougher than plain carbon steels, so it requires more force for effective forming. In addition, when machining 4140 steel, annealing is more important than with simple, low-carbon steels. While it is often quench-hardened, 4140 is not easily welded and will require pre- and post-weld thermal treatment to prevent cracking, as well as being mindful of using a compatible filler material.

In sectors that require high-performance, durable parts, such as the automotive, aerospace, and robotics industries, steel and aluminum tend to be the materials of choice for many applications. However, steel and aluminum have very different physical characteristics and price points, so it’s very important to determine which is better-suited for a given part.

1045 steel is more expensive and offers greater strength than 1018 steel, but much of the same weldability and machinability, contributing to its higher cost.

1045 steel is composed of iron, carbon, silicone, manganese, and sulfur or phosphorus. It is a medium carbon steel designed for strength and hardness. Its size accuracy, straightness, and concentricity make it especially well-suited for high-speed applications. It’s frequently used to make bolts, studs, gears, axles, and shafts.

The product: The application consisting of five mating components was designed to collect a physical sample to mix with a wet reagent and a dry reagent in preparation for an optical read. The component required a vapor seal with the mating components.

To mitigate the risk of leakage, our engineers defined the dimensional specifications to specific nominals and tolerances with an eye toward steel-safe changes. This meant that steel would be removed in the mold to achieve the desired dimension.

While 4130 steel is highly heat-treatable, it can be challenging to weld. Its high hardenability makes it challenging to select a compatible filler metal that will have comparable strength. An understanding of the properties of 4130 and any filler metal’s properties is necessary to successfully weld this steel.

Tolerance stack analysis is crucial in reducing costs and avoiding expensive fixes during high-volume production. By ensuring appropriate tolerances are selected, unnecessary corrective actions, expensive molds, and higher piece prices can be avoided. It is essential to note that tight tolerances can slow down projects and increase costs. Therefore, it is essential to have experienced professionals perform tolerance stack analysis to achieve optimal fits while avoiding unnecessary costs.

Tolerance Stack Analysis is a method used in engineering design to evaluate the effects of dimensional variation on the performance of assemblies. It involves identifying the sources of variation in the assembly process and determining the cumulative effect on the final product.

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The primary benefit of 1018 steel is its workability. It’s very easy to form, forge, weld, and hot work, which makes it favorable for parts that require severe bends or other fine features. As such, 1018 steel is often used for applications such as shafts, spindles, pins, or rods. It’s also considered a good choice for carburized parts.

One of those determining factors is typically the manufacturing method, which in these industries is often CNC machining. When machining a metal part, there are several key reasons why steel may be a more appropriate material choice than aluminum. While aluminum is incredibly lightweight, steel is much stronger. What’s more, aluminum tends to be much more expensive.

1045 steel can be flame- or induction-hardened in both the rolled and normalized conditions. However, it does not respond favorably to nitriding, as it lacks the requisite alloying elements.

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4130 steel is a relatively low-cost steel, both in terms of raw material cost and cutting cost. It is, in many ways, comparable to aircraft-grade stainless steel in its physical properties, but comes at a much lower price tag, making it a desirable option for many product teams.

By analyzing the combined effect of multiple component tolerances on the final assembly, we can identify potential issues before they occur and make necessary adjustments to ensure a successful production run.

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1018 steel’s machinability, strength, and precision come with a high price tag. It’s more expensive than some comparable steels, but is much better-suited for CNC machining than these similar steels.

However, four of the five component designs had already been defined in relative isolation, with standard tolerances defined as the part requirements. The molds were being built, and the true dimensions were still unknown.

That’s where a seasoned manufacturing partner like SyBridge can help. Our team of designers, engineers, and project managers has years of experience helping customers streamline and optimize the entire manufacturing process — from design, prototyping, and material selection to production and fulfillment. We’re well-equipped to help product teams of all shapes and sizes select the CNC machining material that’s right for their unique requirements and price point. Contact us today to get started.

For each critical fit dimension, they listed the nominal dimension, upper and lower tolerance, and minimum and maximum allowable values. For each mating dimension group, they calculated the amount of interference or clearance for the nominal dimensions, the maximum material condition, and the minimum material condition.

Tolerance stack analysis is particularly important when there are separate teams responsible for designing and manufacturing a product. The analysis involves reviewing the tolerances of each individual part and considering how they will fit together in the final assembly. If the tolerances of the individual parts are not considered together, they may not fit together correctly, resulting in an assembly that doesn’t work.

The bottom line is that tolerance stack analysis is a crucial step in the manufacturing process that should never be skipped. If skipped, the issue may not be caught until high-volume assembly, leading to an expensive fix. It is important to ensure that the tolerances selected are appropriate for the application.

CNC machining is a highly versatile manufacturing process that allows for the speedy creation of strong and functional parts made out of countless materials, including steels. However, determining the best steel — or other metal or plastic — for a given project can be challenging and time-consuming, particularly when faced with so many options.

Customers often approach us with designs that they believe are production-ready, only to find out that critical steps were overlooked, resulting in unforeseen issues during production. In many cases, customers only test a small quantity of parts that appear to be within tolerances, giving them a false sense of confidence. This is where tolerance stack analysis becomes crucial.

In summary, tolerance stack analysis is a critical step in the manufacturing process that should never be skipped. It is a specific skill requiring experience that can result in fewer changes after first samples. Skipping this process can lead to expensive fixes during high-volume assembly, which is slower and riskier than performing the analysis in advance. Therefore, it is important to ensure that the tolerances selected are appropriate for the application.

Considered a low carbon steel, 4130 steel is composed of iron, carbon, chromium, manganese, molybdenum, phosphorus, silicon, and sulphur. 4130 is an exceptionally tough steel that’s relatively easy to heat-treat and highly workable.

The engineers identified all mating components and the critical fits, labeling each critical fit A, B, C, etc. They identified the mating components and the positions they assume when interacting, which are called fitment positions. Within each fitment position, they identified all mating dimensions and assigned each mating dimension fit type as either clearance or interference.

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While you may not need to fully understand the underlying factors, it’s important to know when and why each step needs to be done. It’s essential to analyze and review the tolerances at each extreme, not just at individual components, but also in the overall assembly. Based on the results, update the requirements to reflect the allowable tolerances. To illustrate, consider this example.

1018 steel is a general-purpose carbon steel composed of iron, carbon, manganese, phosphorus, and sulfur. 1018 steel has excellent weldability, but it is not as hard as some other steels.

Once the current state was understood, they modeled adjustments to the nominal dimensions and tolerances to optimize the fits. Each change impacted other fits, so seeing how each change influenced the overall assembly was critical. In this case, they decreased the nominal dimension of one part by 0.002″. The tolerances were also adjusted. Rather than having a nominal directly in the middle of the upper and lower tolerances, the upper tolerance became +0.000″ and the lower tolerance remained at -0.005″. This specification communicates to anyone looking at the drawing that the dimension is preferably at the top of the specification but absolutely cannot go over. The mold maker knows to start smaller on this feature and increase as needed, which is a steel-safe change. This achieved the needed fit with a nominal clearance of 0.010″.

Though 1018 steel can be welded, welding isn’t recommended when the steel has been carbonitrided and carburized. This is a limitation that manufacturing teams should be aware of when working with 1018 steel. Because of the material’s relatively soft texture, it can also be difficult to finish.

So, instead of asking us to “just make it work,” it’s important to take the time to perform a thorough tolerance stack analysis to ensure a smooth and efficient production process.

The client: A client with a diagnostics application recruited the Natech team to support their transfer from design to manufacture of their program.

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