High Performance Aluminum Part
As Dongguan Jili Technology Co., Ltd., in the field of CNC machining, we have always met the diverse needs of customers with excellent craftsmanship and professional services. This high – performance aluminum alloy mechanical part processed for the customer fully demonstrates our profound strength in machining complex parts.
1. Project Background
The customer is an enterprise focusing on high – end machinery manufacturing. In the newly developed new – type mechanical equipment, this aluminum alloy mechanical part plays a key role in structural support and transmission. Since the equipment needs to operate stably under high – strength and high – speed working conditions, there are strict requirements for the strength, precision, and surface quality of the part. After multiple rounds of screening and inspection, the customer entrusted us with the machining task of the part.
2. Machining Difficulties
- Extremely High Precision Requirements: The position tolerance of multiple mounting holes of the part needs to be controlled within ±0.03mm. The flatness requirement of the key mating surface reaches 0.01mm, and the cylindricity error shall not exceed ±0.005mm, so as to ensure accurate assembly and stable operation with other components.
- Complex Structure: There are complex reinforcing rib structures and special – shaped chambers inside the part. The accessibility of the tool is poor during machining, and the thin – walled parts are prone to deformation under the action of cutting force, which affects the dimensional accuracy and surface quality.
- Material Properties: Although the selected high – strength aluminum alloy has the advantages of light weight and high strength, it is prone to tool sticking during cutting, resulting in accelerated tool wear. Moreover, its large coefficient of thermal expansion will have a great impact on the accuracy during the machining process due to thermal deformation.
3. Jili Solutions
(1) Process Planning
- Preliminary Analysis and Programming: After obtaining the customer’s design drawings, our engineer team uses professional CAD/CAM software to perform 3D modeling of the part and conducts in – depth analysis of its structure and machining process. According to the characteristics of the part, a reasonable tool path is planned. At the same time, the cutting parameters are optimized according to the machining requirements of different parts to ensure machining accuracy and efficiency.
- Rough Machining: A large – diameter end mill and appropriate cutting parameters are used to quickly remove most of the allowance and initially form the part contour. During rough machining, we control the impact of cutting force on the part through layered cutting and reasonable cutting direction control, reducing the risk of deformation.
- Semi – finishing: Replace the tool with higher precision to perform semi – finishing on the key parts of the part, further refining the contour and dimensions. For the reinforcing ribs and thin – walled parts, a smaller cutting depth and feed rate are adopted to reduce the deformation caused by cutting force, and a suitable finishing allowance is reserved.
- Finishing: Use a high – precision five – axis linkage machining center to perform the final finishing of the part. By precisely controlling the movement trajectory and cutting parameters of the tool, the position accuracy of the mounting holes, the flatness and cylindricity of the mating surfaces and other key dimensions are ensured to meet the design requirements. At the same time, high – speed milling technology is adopted to improve the surface quality and reduce the surface roughness.
- Surface Treatment: After machining, the part is subjected to fine deburring treatment to ensure that there are no defects on the surface. Then, anodizing treatment is carried out to enhance the wear resistance, corrosion resistance and aesthetics of the part, so that it can better adapt to the working environment of the equipment.
(2) Quality Control
- Monitoring During Machining: During the CNC machining process, an on – line monitoring system is used to monitor the tool wear, cutting force, cutting temperature and other parameters in real – time. Once an abnormality is detected, the cutting parameters are adjusted immediately or the tool is replaced to ensure the stability of the machining quality. At the same time, after each key process is completed, a high – precision measuring instrument is used to detect the dimensions of the part, and machining errors are found and corrected in a timely manner.
- Finished Product Inspection: After the part is machined, a comprehensive quality inspection is carried out. A coordinate measuring machine is used to accurately measure the key dimensions of the part to ensure that all dimensional tolerances meet the design requirements; the surface quality is inspected by an optical microscope to confirm that there are no tool marks, cracks and other defects; the part is subjected to strength and tightness tests to verify its performance under actual working conditions.
4. Project Achievements
Through the careful planning and strict implementation of our team, the machining task of this batch of high – performance aluminum alloy mechanical parts has been successfully completed. The delivered parts have passed the strict inspection of the customer, and all indicators meet or exceed the design requirements. During the subsequent equipment assembly and operation testing, the parts are well – matched with other components, and the equipment operates stably and reliably, which has been highly recognized and praised by the customer. The success of this project not only further consolidates the cooperation relationship between us and the customer, but also demonstrates the excellent technical strength and professional service level of Dongguan Jili Technology Co., Ltd. in the field of CNC machining.
