What are the advantages of machining components
Information summary：The advantages of machined parts mainly lie in precision, performance, customization, production efficiency, and overall cost, which can meet the needs of different industries for high-precision and high reliability components. The following is a specific analysis of advantages:
1、 High precision and high consistency
1. High dimensional accuracy
Through CNC machine tools such as CNC lathe
The advantages of machined parts mainly lie in precision, performance, customization, production efficiency, and overall cost, which can meet the needs of different industries for high-precision and high reliability components. The following is a specific analysis of advantages:
1、 High precision and high consistency
1. High dimensional accuracy
Through CNC machine tools such as CNC lathes, milling machines, and grinders, the accuracy can reach ± 0.001mm level (such as aerospace parts), far exceeding manual machining or ordinary machine tools, ensuring tight fit between components (such as interference fit between bearing holes and shafts).
Case: The machining accuracy of the cylinder bore of the automobile engine cylinder body needs to be controlled within ± 0.005mm to ensure the sealing performance of the piston movement.
2. Strict form and position tolerances
It can control the flatness, perpendicularity, coaxiality and other positional tolerances (such as ≤ 0.01mm) to ensure the assembly accuracy of complex structures. For example, the coaxiality error of the gearbox gear shaft should be less than 0.003mm to avoid vibration and noise during transmission.
3.Strong batch consistency
Batch production under program control, with highly uniform dimensions and surface quality of components, reducing debugging time during assembly (such as CNC milling of mobile phone casings, thousands of pieces with identical dimensions).
2、 Advantages of complex structure and surface quality
1. Can process complex geometric shapes
By using multi axis linkage machine tools (such as 5-axis machining centers), shapes that are difficult to achieve with traditional processes such as free-form surfaces, inverted structures, and deep cavity narrow gaps can be machined. For example, the twisted surface and internal cooling holes of aircraft engine turbine blades need to be completed through 5-axis milling.
2. Good surface smoothness
Fine grinding, honing and other processes can achieve a surface roughness of Ra ≤ 0.8 μ m (mirror level), reducing friction loss and fluid resistance. For example, after grinding, the smooth surface of the internal flow channel of the hydraulic valve body can reduce oil turbulence and energy loss.
3. Good compatibility of surface treatment
The surface cleanliness after processing is high, which facilitates subsequent electroplating (such as chrome plating, nickel plating), anodizing or coating (such as PVD coating), and improves corrosion resistance and wear resistance. For example, medical device parts are electroplated and passivated after machining to meet the requirements of a sterile environment.
3、 Material adaptability and performance optimization
1. Widely applicable materials
It can process various materials such as metals (such as stainless steel, titanium alloys, aluminum alloys) and non metals (such as engineering plastics, ceramics, composite materials). For example, the drone frame made of carbon fiber composite material needs to achieve a balance between lightweight and high-strength through CNC milling.
2. Keep the material properties intact
Cold processing (such as turning and milling) does not change the metallographic structure of the material, while hot processing (such as grinding that requires temperature control) can avoid softening caused by overheating. For example, high-speed steel cutting tools maintain blade hardness (HRC62-65) and wear resistance after precision grinding.
3. Structural strength and reliability
The processing process can eliminate internal stress in materials (such as through aging treatment), or improve the rigidity of components by processing ribs, reinforcing ribs, and other structures. For example, after milling and forming the rib plate structure of the machine tool bed, vibration deformation can be reduced and machining stability can be improved.
4、 Production efficiency and cost advantages
1. High efficiency of automated production
Numerical control machine tools can process continuously for 24 hours, coupled with automatic tool changing and automatic loading and unloading systems (such as robots), reducing the production cycle of single pieces by more than 50% compared to traditional processes. For example, CNC machining of automotive gearbox housings takes only a few hours from blank to finished product.
2. High material utilization rate
By adopting low cutting/no cutting processes (such as gear hobbing), the material utilization rate can reach over 90% (traditional casting cutting is only 60% -70%), reducing raw material costs. For example, aviation aluminum alloy structural components are processed directly from the entire blank through five axis milling, reducing forging waste.
3. Controllable comprehensive cost
Although the equipment investment is relatively high, the unit cost significantly decreases during mass production (such as CNC batch processing of mobile phone frames), and reduces manual debugging and scrap rates, resulting in significant long-term benefits.
5、 Customization and rapid response capability
1. Flexibly meet personalized needs
No need for mold opening (such as injection molds), the processing path can be quickly adjusted through programming, suitable for small batch customization (such as medical device customized parts, aerospace prototype parts). For example, personalized denture supports can be quickly produced through 3D scanning and CNC milling.
2. Rapid iteration and repair
When there is a change in product design, only the processing program needs to be modified, without the need to re manufacture the mold, shortening the research and development cycle (such as rapid prototyping of new product prototypes). For damaged components, they can be directly processed and repaired through reverse engineering surveying to reduce downtime losses.
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