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This parts is from American company who specialized in metal detector.

From this case, we have the cooperation more that 6years,after this case, we have manufacture many aluminium detector parts that the surface finish is Black Hard Anodized.  

 

Example . Milling head box

 

skills requirement

 

1. The offset of reference B to reference A-D<0.015mm.

2. Castings are not allowed to have casting defects such as blisters and looseness.

3. Aging treatment

4. The remaining cast fillets are R5~R10.

5. Material: QT600-3.

Part drawing analysis

1) The tolerance of the perpendicularity between the inner hole of ϕ270H7 and the C plane is 0.01mm, and the tolerance of the parallelism between the C plane and the A and D axis is 0.01mm.

2) The coaxiality tolerance of the inner hole of ϕ230H7 and ϕ140K6 is ϕ0.01mm.

3) The axis of the ϕ230H7 inner hole and the ϕ140K6 inner hole are perpendicular to the ϕ270H7 inner hole axis, and the intersection error is less than 0.015mm.

4) The part material is QT600-3.

5) Artificial aging treatment.

Process analysis

1) When processing this part, first process the C surface and the ϕ270H7 inner hole, and then use the C surface as the reference to process the ϕ230H7 inner hole and the ϕ140K6 inner hole. Note that when boring ϕ230H7 inner holes and ϕ140K6 inner holes, the machining must be completed in one clamping.

2) In order to ensure that the axis of the ϕ230H7 inner hole, the ϕ140K6 inner hole axis and the ϕ270H7 inner hole axis are perpendicular and intersecting, the C surface and the ϕ270H7 inner hole are processed first, and then the E surface, the ϕ230H7 inner hole, and the ϕ140K6 inner hole. Note  that the C surface must be perpendicular to the E surface.

  1. Machining process

The machining process of the milling head box (unit: mm)

Part NameBlank speciesMaterialProduction type
Milling head boxcastingQT600-3Small batch
ProcessWork stepProcess contentEquipmentTools, measuring tools, auxiliary tools
10Casting
20Aging
30Oil primer
40Scribe: Guarantee the processing of the inner hole of ϕ270H7, ϕ230H7, and ϕ140K6Marking table
The margin should be as even as possible
50Rough millingVertical milling machine
1Aligning according to the line, rough milling C surface, leaving the amount of fine milling 2Disc cutter
2Rough milling 500 size four sides, leaving fine milling amount 2Milling cutter
3Rotate 180° for rough milling of face E, leaving fine milling amount 2Disc cutter
4Rough milling of F surface, leaving fine milling amount 2Disc cutter
60Fine milling, boringVertical plus work center
1Finish milling C surface to the requirement, surface roughness Ra1. 6μmDisc cutter
2Finish milling 500 size four sides, surface roughness Ra3. 2μmRod cutter
3Milling 15× 45°Rod cutter
4Milling 86. 4 × 40. 5 × 65. 5 (4 locations). Groove done.Rod cutter
ProgressWorkStepProcess contentEquipmentTools, measuring tools, auxiliary tools
5Drill 12 × M8 threaded bottom holes to ϕ6.7ϕ6.7 Twist drill
6Tap 12 × M8, 25 deep threaded hole intoM8 thread tap
7Drill 8 × M8 threaded bottom holes to ϕ6.7ϕ6.7 Twist drill
8Tap 8 × M8, 25 deep threaded hole intoM8 thread tap
9Boring ϕ230 inner hole, surface roughness Ra12. 5μmBoring tool
10Rough boring ϕ270H7 inner hole, leaving fine boring amount 2Boring tool
11Fine boring ϕ270H7 inner hole is formed, guarantee 85 ± 0.1, surface roughness Ra1. 6μmFine Boring Tool
12Bored ϕ320 inner hole, guaranteed size 30, surface roughness Ra3. 2μmBoring tool
70Fine milling, boringHorizontal machining center
1Take the C surface as the reference, align it, press the workpiece with a pressing plate, and finish milling the E surface to the required,surface roughness Ra3. 2μmDisc cutter
2Rough boring ϕ230H7 inner hole, leaving fine boring amount 2Boring tool
3Fine boring ϕ230H7 inner hole, guaranteed size 137, surface roughness Ra1. 6μmFine Boring Tool
4Boring ϕ220 inner hole, surface roughness Ra3. 2μmBoring tool
5Boring ϕ130 inner hole, surface roughness Ra6. 3μmBoring tool
6Rough boring ϕ140K6 inner hole, ϕ170 inner hole, ϕ200H9 inner hole to ϕ138Boring tool
7Rotate 180° horizontally, without loosening the pressure plate, finish milling F surface, surface roughness Ra3. 2μmFine Boring Tool
8Fine boring ϕ140K6 inner hole to requirement, surface roughness Ra1. 6μmFine Boring Tool
9Boring ϕ170 inner hole, surface roughness Ra3. 2μmBoring tool
10Boring ϕ200H9 inner hole, surface roughness Ra3. 2μmBoring tool
11Drill 12 × M6 threaded bottom holes to ϕ5ϕ5 twist drill
12Tap 12 × M6, 15 deep threaded holesM6 thread tap
13Drill 4 × M6 threaded bottom holes to ϕ5ϕ5 twist drill
14Tap 4 × M6, 15 deep threaded holesM6 thread tap
15Drill 4 × M10 threaded bottom holes to ϕ8.5ϕ8.5 Twist drill
16Tap 4 × M10, depth 25 (4 places) threaded holesM10 thread tap
80Bench workBench
1Print mark: year, month, sequence number
2Cleaning, deburring, chamfering
90TestInspection station
1Check the size and surface roughness of each part
2Check the perpendicularity and intersection error of the ϕ230H7 inner hole, the ϕ140K6 inner hole axis and the ϕ270H7 inner hole axis
3Check the tolerance of coaxiality between ϕ140K6 inner hole and ϕ270H7 inner hole
4Inspection ϕ270H7 Tolerance of perpendicularity between inner hole axis and C surface
5Fill in the inspection report
100Warehousing
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