Why are machined parts widely used
Information summary：Machine processed components (parts made through machining processes such as turning, milling, grinding, boring, etc.) are widely used because they can meet the rigid requirements of modern industry for "accuracy, consistency, and material adaptability". At the same time, with the development of technology, their cost controllability and production efficiency continue to improve, further promoting
Machine processed components (parts made through machining processes such as turning, milling, grinding, boring, etc.) are widely used because they can meet the rigid requirements of modern industry for "accuracy, consistency, and material adaptability". At the same time, with the development of technology, their cost controllability and production efficiency continue to improve, further promoting popularization. Specific analysis can be conducted from the following dimensions:
1、 Reliability of accuracy and quality
The core advantage of machining is the ability to achieve high dimensional accuracy and positional tolerance control, which is difficult to replace by other machining methods such as casting, forging, 3D printing, etc
Dimensional accuracy: Through precision machine tools such as CNC lathes and machining centers, the dimensional tolerance of machined components can be controlled at the ± 0.001mm level (such as the inner ring aperture of precision bearings), ensuring the fitting accuracy between components (such as the clearance fit between shafts and holes, interference fit), and avoiding assembly jamming, leakage, or functional failure caused by dimensional errors.
Surface quality: Grinding, polishing and other processes can reduce the surface roughness of components to Ra0.02 μ m (such as the surface of hydraulic valve cores), reduce friction loss (extend service life), and improve sealing performance (prevent fluid leakage), which is crucial for components operating at high speeds (such as engine crankshafts) or in high-pressure environments (such as hydraulic systems).
Performance stability: Mechanical processing achieves molding by removing materials, which does not affect performance due to defects such as porosity and shrinkage like casting, nor does it generate thermal stress and deformation like welding. Therefore, the mechanical properties (strength, hardness) of the components are more uniform and stable.
2、 Strong material adaptability, covering the needs of the entire industry
Machining is almost applicable to all metal materials (steel, aluminum, copper, titanium alloys, etc.) and some non-metallic materials (engineering plastics, ceramics, composite materials), which can meet the differentiated needs of different industries for material properties:
Metal materials: From ordinary carbon steel (such as machine tool beds) to high-strength alloys (such as titanium alloy parts for aerospace), from easy to cut copper (such as motor commutators) to high hardness tool steel (such as mold cutting edges), machining can be achieved by selecting suitable tools and parameters, especially suitable for processing high hardness and high toughness materials (which are difficult to form by casting or stamping).
Non metallic materials, such as wear-resistant gaskets and insulation brackets made of engineering plastics (nylon, polytetrafluoroethylene), can ensure dimensional accuracy through milling and turning processing; Brittle materials such as ceramics (alumina, silicon nitride) can be precision ground to produce high-precision bearings or cutting tools, meeting the requirements of high temperature and high corrosion environments.
3、 High production flexibility, adaptable to multiple scene requirements
Machining can meet both small batch customization and large-scale production, adapting to the entire process from single piece trial production to industrial production:
Small batch and customization: For personalized needs (such as special equipment shaped parts) or parts in the trial production stage, machining can quickly adjust the process through programming (such as changing the program on a CNC milling machine to process different shapes), without the need to invest in expensive molds (such as stamping molds, casting molds), greatly reducing the cost and cycle of small batch production.
Large scale mass production: Through automated production lines (such as CNC lathe assembly lines, robot loading and unloading systems), machining can achieve efficient mass production of standardized components (such as automotive bolts, motor shafts). Combined with fixtures (such as specialized chucks, positioning fixtures), batch product consistency (tolerance fluctuation ≤ 0.01mm) can be guaranteed, meeting the large-scale assembly needs of industries such as automotive and electronics.
4、 Adapt to complex structures and support equipment development
The core components of modern industrial products, such as aircraft engines and precision instruments, often have complex geometric shapes (curved surfaces, irregular holes) and multidimensional precision requirements (such as perpendicularity and coaxiality). Machining is the core means to achieve these structures:
Complex surface machining: Through a five axis linkage machining center, twisted surfaces of aircraft engine blades and streamlined channels of turbine impellers can be machined with an accuracy of up to 0.005mm, ensuring good fluid dynamics performance;
Deep hole and precision hole system: such as the intersecting oil holes of hydraulic valve blocks (with a diameter of 2-10mm and a depth to diameter ratio greater than 10), the straightness and surface smoothness of the holes can be ensured through deep hole drilling and honing processes, avoiding pressure loss caused by rough oil holes in the hydraulic system;
Micro structure processing: In microelectronic devices such as semiconductor wafer cutting devices, precision components at the millimeter or even micrometer level (such as positioning pins and micro gears) can be achieved through precision grinding and electrical discharge machining, meeting the development trend of "miniaturization and high precision".
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