Method for mass production of aluminum alloy parts by CNC machining center

In the current development of light industrial products, the selection of structural parts generally includes plastics, stamping sheet metal parts, aluminum alloy die castings, rubber parts, etc., while the use of aluminum alloy full die castings has the following advantages: Mass production, as long as the aluminum alloy die-casting mold is produced and installed on the die-casting machine, it can be produced, and the dimensional stability of the batch parts is better, the machining allowance is relatively small, the material is saved, and the economy is better. In addition, although the mechanical strength of aluminum alloy parts is not as good as that of steel parts, it is much stronger than plastic parts, which can fully meet the requirements of daily industrial products. Moreover, aluminum alloy has relatively low density and is much lighter than steel materials. With good performance, it is increasingly used in industrial products. The gearbox housing of motorcycles is made of aluminum alloy die casting.

Some time ago, the school development department received a batch of production orders for "Gearbox components for enthusiast remote control oil-powered racing cars". The gearbox components consist of an upper cover (blue part) and a lower cover (orange part), as shown in Figure 1. Shown.

The production requirements for this batch of products are as follows: (1) Aluminum alloy materials are used, and the production quantity is not large, each of which is only 1,000 pieces, but there are more than a dozen styles. (2) Customers have relatively high requirements for aluminum alloy parts. First, the dimensional accuracy of the parts is high, and the dimensional tolerances of many key positions are required to be within 0.02 mm; second, as the appearance parts, the surface finish is required to reach the mirror level, and then pass Anodized coloring makes the color brilliant.

Because the batch is too small, if the aluminum alloy die-casting mold is opened in this case, the cost is very high and very unreasonable, and the mold-opening cycle is relatively long; due to the high requirements of the dimensional accuracy and surface finish of the parts, if the aluminum alloy die-casting mold is used In the production of aluminum parts, the surface quality is very rough, and then it is difficult to achieve the smooth and clean requirements of oxidation and coloring through grinding and polishing, and it is time-consuming and labor-intensive.

How to meet customer requirements and provide customers with qualified products under the premise of low parts batch size, many styles, high dimensional accuracy and high surface finish requirements? After production practice, the author uses a CNC machining center, adopts reasonable processing technology and scientific clamping methods to complete the processing of the product. The following takes the lower cover of the gearbox assembly as an example to introduce its processing method and numerical control processing. The upper cover is similar to the lower cover and will not be detailed here.