Mechanical Engineer Mock Interview
Master 37 Mechanical Engineer interview questions covering thermodynamics, CAD proficiency, and design problem-solving.
Question 33 of 37
Why are sharp corners on internal geometry very difficult to machine?
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Jason is a freelance mechanical engineer specializing in 3D Printing and CNC Machining.
This is a question that is often asked to gauge whether or not the candidate understands how to design parts for machining operations. Consider a case where you have designed a perfectly rectangular slot inside a block of steel. Because most basic cutting tools are round, it will not be able to leave a corner that is sharper than the radius of the tool itself. Special tools and processes are needed to create sharp corners, and internal features are much simpler to produce if they do not have sharp corners. Another option is an undercut, which extends the cut by one-half of the tool's diameter to create a pocket for a square part to fit in.
Jason is a freelance mechanical engineer specializing in 3D Printing and CNC Machining.
"The reason sharp corners on internal geometry are difficult to machine is that most cutting tools are round, so they remove material with a fillet equal to the tool's radius. You can avoid this by including a radius in the design, or adding an undercut feature for manual or CNC machining. I know that there are ways to machine sharp corners internally, but they are very timeconsuming and expensive, and therefore not necessary for most designs."
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