Photo by Mastars on Unsplash
Adding a processing hole to uniformize the wall thickness, and it can avoid deformation during heat treatment.
In original design, the thin wall thickness is easily deformed by clamping force or cutting force. While in optimal design, the rigidity of part is increased after adding the bosses.
In original design, it's difficult to process an interior annular groove. While in optimal design, it’s easy to manufacture on the outside surface of the part, and does not impact the usage.
The machining area of milling should not be too deep, and the depth-to-width ratio should not exceed 3:1. Otherwise, the milling cutter is easy to break.
If a long milling cutter is unavoidable, the design can be optimized to improve the life of the milling cutter as the following pictures shows.