I. Industry Overview and Technical Background
Custom-machined metal parts serve as a fundamental component of modern manufacturing, playing a crucial role in various fields such as aerospace, automotive, medical, and electronics. As the global manufacturing industry transitions from “scale expansion” to “value creation,” the demand for custom-machined metal parts has become increasingly diverse and precise. In 2025, the machining industry is undergoing profound changes, with the waves of digitalization, greenization, and intelligence accelerating the reshaping of the industrial landscape.
Against this backdrop, aluminum alloys and stainless steels, as two of the most commonly used metal materials, have become the preferred choices for custom-machined parts due to their excellent physical properties and machining characteristics. Statistics show that more than 70% of the key components of industrial robots are made of aluminum alloys. In the aerospace field, stainless steels are the ideal choice for critical structural components due to their high strength and corrosion resistance.
This technical article aims to provide purchasing managers with a comprehensive technical guide on custom-machined metal parts, focusing on aluminum alloy and stainless steel materials, as well as core processes such as CNC milling, turning, machining, drilling, and threading. It helps purchasing managers make more informed decisions in supplier selection, cost control, and quality assurance.
1.1 Market Status of Custom-Machined Metal Parts
The market for custom-machined metal parts in 2025 shows several distinct trends:
High Precision: With the increasing demand for precision manufacturing, the requirements for part accuracy are constantly rising, and the market for high-precision machining equipment continues to expand.
Lightweight Design: Especially in the automotive and aerospace fields, lightweight design has become an important trend, promoting the widespread application of lightweight materials such as aluminum alloys.
Environmental Protection and Sustainability: The concept of green manufacturing has taken root in the industry. Environmentally friendly cutting fluids, energy-saving equipment, and material recycling have become the focus of the industry.
Intelligent Upgrades: CNC systems equipped with AI algorithms can achieve adaptive machining and predictive maintenance, improving machining efficiency and quality.
Integration of Additive and Subtractive Manufacturing: The combination of 3D printing technology and traditional machining provides better solutions for complex-structured parts.
1.2 Application Comparison between Aluminum Alloys and Stainless Steels
Aluminum alloys and stainless steels, as the main materials for custom-machined metal parts, each have their own advantages:
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Property
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Aluminum Alloy
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Stainless Steel
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Density
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Approximately 2.7 g/cm³, only one-third of that of stainless steel
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Approximately 7.9 g/cm³
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Strength
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Medium strength, can be enhanced by heat treatment
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High strength, especially for 304 and 316 stainless steels
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Corrosion Resistance
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A dense aluminum oxide film forms on the surface, providing resistance to atmospheric corrosion, but may face challenges in chloride environments
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High chromium content gives it excellent corrosion resistance, especially in the chemical industry or marine environments
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Machinability
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Good cutting performance, high machining efficiency, and low tool wear
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More difficult to machine, prone to work hardening during cutting
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Thermal Conductivity
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Good thermal conductivity, beneficial for heat dissipation
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Poor thermal conductivity
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Cost
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Relatively low raw material cost, but high-precision machining cost is high
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High raw material cost, and the machining cost is even higher
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Application Areas
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Aerospace structural components, automotive parts, electronic product housings, robot parts
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Medical equipment, food processing equipment, marine engineering, chemical equipment, architectural decoration
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II. Material Selection and Design Considerations
In the design process of custom-machined metal parts, material selection and design considerations are key factors determining the part’s performance, cost, and manufacturability. This section will focus on the selection criteria, design principles, and design precautions for different processes of aluminum alloys and stainless steels.
2.1 Aluminum Alloy Material Selection and Characteristics
2.1.1 Common Aluminum Alloy Grades and Their Characteristics
In custom machining, commonly used aluminum alloy grades include:
6061 Aluminum Alloy:
Characteristics: Medium strength, good corrosion resistance, excellent weldability, and machinability
Applications: Structural components, fixtures, workbenches, general mechanical parts
Machining Precautions: Moderate hardness after heat treatment, good cutting performance
7075 Aluminum Alloy:
Characteristics: High strength, close to that of steel, good toughness, and fatigue resistance
Applications: Aerospace structural components, high-strength mechanical parts, sports equipment
Machining Precautions: High hardness, requires the use of carbide tools, and the cutting speed should be appropriately reduced
2024 Aluminum Alloy:
Characteristics: High strength, good fatigue performance, and corrosion resistance
Applications: Aircraft structural components, truck wheels, high-strength bolts
Machining Precautions: Prone to work hardening, attention should be paid to tool wear and cooling
5052 Aluminum Alloy:
Characteristics: Medium strength, excellent corrosion resistance, and weldability
Applications: Pressure vessels, ship structures, chemical equipment
Machining Precautions: Good cutting performance, suitable for machining complex shapes
2.1.2 Design Considerations for Aluminum Alloys
When designing aluminum alloy machined parts, the following factors should be considered:
Balance between Strength and Weight:
Aluminum alloys have a low density, but their strength is sufficient to meet the requirements of most structural applications.
In design, their lightweight advantage should be fully utilized. For example, in robot parts, lightweight design can reduce energy consumption and improve movement accuracy and response speed.
Coefficient of Thermal Expansion:
Aluminum alloys have a relatively large coefficient of thermal expansion. When designing, the impact of temperature changes on part dimensions and fits should be considered.
For parts that need to work in different temperature environments, appropriate thermal expansion gaps should be reserved.
Surface Treatment Requirements:
Although the naturally formed aluminum oxide film on the surface of aluminum alloys provides some protection, additional surface treatment is still required in harsh environments.
Common surface treatment methods include anodizing, electroplating, spraying, etc. When designing, the impact of these treatments on part dimensions and fits should be considered.
Structural Rigidity:
The rigidity of aluminum alloys is lower than that of steel. When designing, attention should be paid to structural rigidity issues.
Structural rigidity can be improved by adding stiffeners, changing the cross-sectional shape, etc.
2.2 Stainless Steel Material Selection and Characteristics
2.2.1 Common Stainless Steel Grades and Their Characteristics
In custom machining, commonly used stainless steel grades include:
304 Stainless Steel:
Characteristics: Versatile, good corrosion resistance and heat resistance, non-magnetic
Applications: Food equipment, medical appliances, architectural decoration, general mechanical parts
Machining Precautions: Prone to work hardening, requires the use of sharp tools and sufficient cooling
316 Stainless Steel:
Characteristics: Excellent corrosion resistance, especially to chloride corrosion, good high-temperature strength
Applications: Marine engineering, medical implants, chemical equipment, food processing equipment
Machining Precautions: More difficult to machine than 304 stainless steel, requires greater cutting force and a lower cutting speed
410 Stainless Steel:
Characteristics: Martensitic stainless steel, high strength, can be strengthened by heat treatment, moderate corrosion resistance
Applications: Cutting tools, bearings, pump shafts, valve components
Machining Precautions: High hardness after heat treatment, should be machined in the annealed state and then heat-treated
201 Stainless Steel:
Characteristics: Low-nickel high-manganese stainless steel, lower cost, certain corrosion resistance
Applications: Decorative materials, kitchen utensils, architectural decoration
Machining Precautions: Significant work hardening tendency, cutting parameters need to be controlled
2.2.2 Design Considerations for Stainless Steels
When designing stainless steel machined parts, the following factors should be considered:
Corrosion Resistance Requirements:
Select the appropriate stainless steel grade according to the usage environment. For example, 316 stainless steel should be preferred in marine environments.
In design, avoid crevices and dead corners to prevent the accumulation of corrosive media.
Work Hardening Characteristics:
Stainless steels are prone to work hardening during cutting, affecting tool life and surface quality.
In design, avoid overly complex shapes and deep cavities to reduce machining difficulty.
Thermal Conductivity and Cutting Heat:
Stainless steels have low thermal conductivity, and the heat generated during cutting is not easy to dissipate.
In design, consider heat dissipation issues. If necessary, add heat dissipation structures or select materials with better heat dissipation performance.
Surface Finish Requirements:
The surface finish of stainless steels has a significant impact on their corrosion resistance.
For applications with high corrosion resistance requirements, design surfaces that are easy to polish and avoid rough surfaces.
2.3 Design for Manufacturing (DFM) Principles
Design for Manufacturing (DFM) is an important design concept aimed at ensuring that designed parts are easy to manufacture while reducing costs and improving quality. The following are DFM principles applicable to custom-machined metal parts:
2.3.1 General Design Principles
Simplify the Design:
Simplify the part structure as much as possible, reducing unnecessary features and complexity.
Adopt standardized geometric shapes and dimensions, such as standard hole diameters, threads, and fillet radii.
Optimize Tolerances:
Use strict tolerances only when necessary to avoid excessive tolerances increasing manufacturing costs.
Understand the impact of different tolerance grades on machining costs and set tolerances reasonably according to functional requirements.
Optimize Material Selection:
Select the material with the lowest cost and best machinability under the premise of meeting usage requirements.
Consider the availability and delivery cycle of materials to avoid using scarce or difficult-to-purchase materials.
Reduce the Number of Setups:
Consider the clamping method of parts on the machine tool during design and try to complete multiple machining steps in one setup.
For symmetrically structured parts, design them as symmetric shapes to facilitate the use of universal fixtures.
Consider the Machining Sequence:
Consider the impact of the machining sequence on part accuracy and deformation during design.
For features with high accuracy requirements, reserve sufficient machining allowances and arrange finish machining in subsequent processes.
2.3.2 Design Considerations for Different Machining Processes
Design Considerations for Turning Parts:
Avoid designing slender parts (length-diameter ratio ≤ 8) to prevent deformation during machining.
Design relief grooves to facilitate tool withdrawal and ensure that adjacent parts fit tightly during assembly.
For blind holes, reserve drill guide holes to simplify subsequent machining.
Design Considerations for Milling Parts:
Avoid deep cavity structures. The milling depth should not exceed 5 times the tool diameter.
Design transition fillets (R ≥ tool radius + 0.2mm) at the roots of internal right angles to avoid tool breakage.
Reduce the machining area to lower machining time and cost.
Design Considerations for Drilling:
Avoid drilling on curved surfaces. The drill bit should be perpendicular to the hole’s cross-section.
The hole diameter should be greater than 3mm to prevent the drill bit from breaking.
Avoid designing overly deep holes (length-diameter ratio ≤ 3) or use stepped hole designs.
Design Considerations for Thread Machining:
Give priority to using standard threads to avoid special threads increasing tool costs.
For blind hole threads, leave sufficient space for tool withdrawal.
Avoid machining threads on inclined surfaces to ensure that the thread axis is perpendicular to the machining surface.
2.3.3 Design Optimization Based on Material Characteristics
Design Optimization for Aluminum Alloy Parts:
Utilize the good plasticity of aluminum alloys to design complex but not overly thin structures.
Consider the thermal expansion characteristics of aluminum alloys and reserve appropriate thermal expansion gaps.
For parts that need anodizing, design shapes that are easy for electrical contact.
Design Optimization for Stainless Steel Parts:
Consider the work hardening characteristics of stainless steels and avoid overly sharp internal corners and deep cavities.
Design sufficient support structures to prevent deformation during machining.
For stainless steel parts that need welding, design structures that are easy to weld.
III. Detailed Explanation of the Manufacturing Process
The manufacturing process of custom-machined metal parts usually includes main links such as design, programming, material preparation, machining, surface treatment, and quality inspection. This section will detail the manufacturing process of custom-machined parts based on aluminum alloys and stainless steels, as well as key processes such as CNC milling, turning, drilling, and threading.
3.1 Overview of the Manufacturing Process
The typical manufacturing process of custom-machined metal parts is as follows:
Design and Programming:
Design parts according to requirements and generate CAD models.
Use CAM software to convert CAD models into G-code programs recognizable by machine tools.
Verify and optimize the program to ensure reasonable machining paths and parameters.
Material Preparation:
Select appropriate aluminum alloy or stainless steel materials according to design requirements.
Check the specifications, dimensions, and quality certification documents of the materials.
Perform necessary pre-treatments, such as annealing or surface cleaning.
Machining Preparation:
Select suitable machining equipment and tools.
Prepare fixtures and workpieces to ensure accurate positioning and firm clamping of parts during machining.
Set machining parameters, such as cutting speed, feed rate, and cutting depth.
Machining Process:
Usually includes roughing, semi-finishing, and finishing stages.
Roughing removes most of the allowance, leaving 0.5 – 1mm of machining allowance.
Semi-finishing further approaches the final size, leaving 0.1 – 0.3mm of finishing allowance.
Finishing achieves the final size and surface quality requirements.
Surface Treatment:
Select appropriate surface treatment methods according to the part’s usage environment and requirements.
Common treatment methods for aluminum alloys: anodizing, chemical oxidation, electroplating, spraying, etc.
Common treatment methods for stainless steels: passivation, electropolishing, spraying, PVD coating, etc.
Quality Inspection:
Use measuring tools and inspection equipment to check part dimensions, shape, and position accuracy.
Conduct surface quality inspection and functional testing.
Record inspection results and issue quality certification documents.
3.2 Detailed Explanation of the CNC Milling Process
CNC milling is one of the most commonly used machining methods for custom-machined metal parts, suitable for machining various complex-shaped planes, surfaces, grooves, and cavities.
3.2.1 Milling Process Principles and Equipment
CNC milling is a machining method that uses a rotating multi-edge tool to cut the desired shape on the workpiece. The basic principle of milling is the combined motion of tool rotation (main motion) and the movement of the workpiece or tool (feed motion), thereby removing excess material from the workpiece.
Commonly used CNC milling machines include:
Vertical Machining Centers: The most commonly used milling equipment, suitable for machining the planes, grooves, holes, and other features of small and medium-sized parts.
Horizontal Machining Centers: Suitable for machining large parts or complex parts that require multi-sided machining.
Gantry Machining Centers: Suitable for machining large and heavy parts, with high rigidity and stability.
3.2.2 Milling Tools and Selection
The selection of milling tools directly affects machining efficiency, surface quality, and tool life. The following are common types of milling tools and their applications:
Face Milling Cutters:
Characteristics: Cutting edges are distributed at the end and on the periphery of the tool, enabling side milling and face milling.
Applications: Plane milling, cavity machining, contour machining.
Materials: High-speed steel, carbide, coated tools.
End Milling Cutters:
Characteristics: Cutting edges are only distributed on the periphery of the tool, mainly used for side milling.
Applications: Groove machining, contour machining, surface machining.
Note: Cannot be used for axial feed drilling.
Ball – Nose Milling Cutters:
Characteristics: The end of the tool is spherical, suitable for machining surfaces and fillets.
Applications: Mold machining, surface shaping, complex contour machining.
Note: The cutting efficiency is lower than that of flat-bottomed milling cutters.
T – Slot Milling Cutters:
Characteristics: Special-shaped tools used for machining T – slots.
Applications: T – slots on workbenches, positioning slots on fixtures, etc.
When selecting tools, the following factors should be considered:
Part material and hardness
Type and size of machining features
Machining accuracy and surface quality requirements
Type and performance of the machine tool
Milling process parameters mainly include cutting speed, feed rate, and cutting depth. These parameters directly affect processing efficiency, surface quality, and tool life.
- Cutting Speed:
- Definition: The linear velocity of a point on the cutting edge of the tool, with the unit of m/min.
- Calculation formula: Cutting speed = π × Tool diameter × Spindle speed ÷ 1000.
- Influencing factors: Material hardness, tool material, tool diameter, cooling conditions, etc.
- Recommended cutting speeds: For aluminum alloy milling, it is 100 – 300 m/min; for stainless – steel milling, it is 50 – 150 m/min.
- Feed Rate:
- Definition: The feed distance of the tool relative to the workpiece per revolution or per tooth.
- It is divided into feed per revolution (mm/r) and feed per tooth (mm/z).
- Influencing factors: Material hardness, number of tool teeth, tool diameter, surface quality requirements, etc.
- Recommended feed per tooth: For aluminum alloy milling, it is 0.1 – 0.3 mm/z; for stainless – steel milling, it is 0.05 – 0.2 mm/z.
- Cutting Depth:
- Definition: The thickness of the material removed by the tool in each cut.
- It is divided into axial cutting depth (ap) and radial cutting depth (ae).
- Influencing factors: Material hardness, tool length, machine power, fixture stiffness, etc.
- Recommended cutting depths: For roughing, it is 1 – 5 mm (for aluminum alloy) and 0.5 – 3 mm (for stainless steel); for finishing, it is 0.1 – 0.5 mm.
To improve milling efficiency and quality, the following strategies can be adopted:
- Layered Milling:
- For the processing of deep cavities or deep grooves, the layered milling strategy should be adopted. Mill a certain depth each time and gradually reach the final depth.
- The milling groove depth should be ≤ 5 times the tool diameter (e.g., for a φ10 tool, the maximum groove depth is 50mm). If it is too deep, layered processing or customized extended tools are required.
- Contour Milling:
- It is suitable for the processing of curved surfaces and inclined surfaces. The tool cuts layer by layer along the contour lines.
- It can maintain a constant cutting load and improve processing efficiency and surface quality.
- Trochoidal Milling:
- It is suitable for the processing of deep cavities and narrow grooves. The tool moves along a trochoidal path to avoid full – edge cutting.
- It can reduce cutting force and tool wear and improve processing safety.
- Interpolation Milling:
- It is a new high – efficiency processing method that can machine symmetric part areas on a milling machine without a rotary axis.
- It reduces the number of clamping times and improves processing efficiency.
CNC turning is mainly used to process rotary parts, such as shafts, discs, and sleeves. It can process features such as outer circles, inner holes, end faces, threads, conical surfaces, and formed surfaces.
CNC turning is a processing method that uses the rotation of the workpiece (main motion) and the movement of the tool (feed motion) to remove materials. The basic principle of turning is that the workpiece rotates, and the tool moves along a direction parallel or perpendicular to the axis of the workpiece, thereby removing the excess material on the workpiece.
Commonly used CNC lathes include:
- Horizontal Lathe: The most commonly used lathe type, suitable for processing small and medium – sized rotary parts.
- Vertical Lathe: Suitable for processing large – sized disc – shaped parts, with high rigidity and stability.
- CNC Turning Center: A composite processing equipment integrating milling and drilling functions, capable of completing multiple processes in one clamping.
The selection of turning tools directly affects processing efficiency, surface quality, and tool life. The following are common types of turning tools and their applications:
- External Turning Tool:
- Characteristics: Used to process external cylindrical surfaces and external conical surfaces.
- It is divided into various types such as 90 – degree offset tools, 45 – degree elbow tools, and cutoff tools.
- Materials: High – speed steel, carbide, ceramics, etc.
- Internal Bore Turning Tool:
- Characteristics: Used to process internal holes and internal conical surfaces.
- It is divided into through – hole turning tools and blind – hole turning tools.
- Note: The diameter of the tool shank should be as large as possible to improve rigidity.
- Thread Turning Tool:
- Characteristics: Used to process various threads.
- The tip angle should be consistent with the thread profile angle, such as 60 degrees (metric thread) or 55 degrees (inch – based thread).
- Note: The installation height of the thread turning tool must be accurate; otherwise, it will affect the thread profile accuracy.
- Cutoff Tool:
- Characteristics: Used to cut the workpiece from the bar stock or cut grooves on the workpiece.
- The width of the insert is usually 2 – 5 mm, selected according to the workpiece diameter.
- Note: When cutting off, the feed rate should be reduced to prevent the insert from breaking.
When selecting tools, the following factors should be considered:
- The material and hardness of the part.
- The type and size of the processing feature.
- Processing accuracy and surface quality requirements.
- The type and performance of the machine tool.
Turning process parameters mainly include cutting speed, feed rate, and cutting depth. These parameters directly affect processing efficiency, surface quality, and tool life.
- Cutting Speed:
- Definition: The linear velocity of the surface of the workpiece to be processed, with the unit of m/min.
- Calculation formula: Cutting speed = π × Workpiece diameter × Spindle speed ÷ 1000.
- Influencing factors: Material hardness, tool material, workpiece diameter, cooling conditions, etc.
- Recommended cutting speeds: For aluminum alloy turning, it is 150 – 400 m/min; for stainless – steel turning, it is 80 – 200 m/min.
- Feed Rate:
- Definition: The feed distance of the tool relative to the workpiece per revolution, with the unit of mm/r.
- Influencing factors: Material hardness, tool type, surface quality requirements, etc.
- Recommended feed rates: For external turning, it is 0.1 – 0.5 mm/r (roughing) and 0.05 – 0.2 mm/r (finishing); for thread turning, the feed rate is equal to the pitch.
- Cutting Depth:
- Definition: The thickness of the material removed by the tool in each cut, with the unit of mm.
- Influencing factors: Material hardness, tool length, machine power, fixture stiffness, etc.
- Recommended cutting depths: For roughing, it is 1 – 5 mm (for aluminum alloy) and 0.5 – 3 mm (for stainless steel); for finishing, it is 0.1 – 0.5 mm.
To improve turning efficiency and quality, the following strategies can be adopted:
- Step – by – step Turning:
- For shaft – type parts with large diameter changes, the step – by – step turning strategy should be adopted, processing from the large diameter to the small diameter in sequence.
- It can reduce the number of tool changes and idle – travel time and improve processing efficiency.
- Constant Linear Velocity Cutting:
- It is suitable for processing parts with large diameter changes, maintaining a constant cutting speed.
- It can improve the consistency of surface quality and reduce tool wear.
- Turning – Milling Composite Processing:
- It is suitable for the situation where non – rotary features need to be processed on rotary parts, such as planes, grooves, and holes.
- It can complete multiple processes in one clamping, reducing the number of clamping times and errors.
- Interpolation Turning:
- It is a new high – efficiency processing method that can machine eccentric parts and complex shapes on a lathe.
- It reduces the number of clamping times and improves processing efficiency.
Drilling and thread – processing are indispensable processing methods in custom – machined metal parts, used to create various types of holes and thread features.
Drilling is a processing method for creating cylindrical holes in solid materials and is one of the most basic processing techniques in custom machining.
- Drilling Equipment and Tools:
- Common equipment: Drilling machines, machining centers, lathes, etc.
- Common tools: Twist drills, center drills, deep – hole drills, etc.
- Drill bit materials: High – speed steel, carbide, cobalt – containing high – speed steel, etc.
- Drilling Process Parameters:
- Cutting speed: Determined according to material hardness and drill bit diameter.
- Recommended cutting speeds: For aluminum alloy drilling, it is 100 – 250 m/min; for stainless – steel drilling, it is 50 – 150 m/min.
- Feed rate: Determined according to material hardness and drill bit diameter.
- Recommended feed rates: 0.1 – 0.3 mm/r (for small – diameter drill bits) and 0.2 – 0.5 mm/r (for large – diameter drill bits).
- Note: When the drilling depth exceeds 3 times the drill bit diameter, peck drilling should be used, and the drill bit should be withdrawn regularly to remove chips.
- Drilling Design Precautions:
- Avoid drilling on curved surfaces. The drill bit should be perpendicular to the cross – section of the hole.
- Avoid setting inclined holes and drilling along curved surfaces. The axis of the hole should be perpendicular to the end faces of the inlet and outlet.
- The diameter of the hole should be greater than 3mm. If it is too small, the drill bit is likely to break.
- The ratio of hole depth to hole diameter should be ≤ 3:1. If it is too deep, the drill bit is likely to break, and chip removal is also difficult.
- Deep – hole Drilling:
- For holes with a depth exceeding 5 times the diameter, deep – hole drilling technology should be adopted.
- Use special deep – hole drill bits and a high – pressure cooling system to ensure chip removal and drill bit cooling.
- Adopt a staged drilling method. First, drill a pilot hole with a small drill bit, and then ream the hole with a large drill bit.
Threads are commonly used connection and transmission methods in mechanical parts. The main thread – processing methods include tapping, threading, thread milling, and turning threads.
- Tapping Process:
- Definition: A method of processing internal threads in a hole using a tap.
- Scope of application: Internal threads of small and medium diameters (usually ≤ M20).
- Process steps: First, drill a bottom hole, and then tap with a tap.
- Precautions: The diameter of the bottom hole should be appropriate. If it is too large, the thread strength will be insufficient; if it is too small, the tap will break.
- Recommended bottom – hole diameters: For aluminum alloy tapping, it is the nominal diameter – pitch; for stainless – steel tapping, it is the nominal diameter – 1.05×pitch.
- Thread Milling:
- Definition: A method of milling internal threads in a hole or external threads on a cylindrical surface using a thread milling cutter.
- Scope of application: Threads of various diameters and types, especially large – diameter threads and difficult – to – machine materials.
- Process characteristics: High processing efficiency, good thread quality, and long tool life.
- Precautions: Special thread milling cutters and programming techniques are required.
- Turning Threads:
- Definition: A method of processing external or internal threads on a lathe using a thread turning tool.
- Scope of application: External threads of various diameters and large – diameter internal threads.
- Process characteristics: High processing accuracy, strong adaptability, but relatively low efficiency.
- Precautions: The installation height of the thread turning tool must be accurate; otherwise, it will affect the thread profile accuracy.
- Thread – processing Design Precautions:
- Give priority to using standard threads to avoid special threads that increase tool costs.
- For blind – hole threads, sufficient retraction space should be reserved.
- Avoid processing threads on inclined surfaces to ensure that the axis of the thread is perpendicular to the processing surface.
- To facilitate tool retraction during processing and ensure tight contact with adjacent parts during assembly, a relief groove should be processed at the shoulder.
For custom – machined metal parts with high – precision requirements, precision machining and special processes may be required to meet the design requirements.
Precision machining refers to a processing method with a processing accuracy reaching the micron level (μm), suitable for parts with extremely high requirements for dimensional accuracy, shape accuracy, and surface quality.
- Precision Turning:
- Use high – precision lathes and precision tools, and the processing accuracy can reach ±0.001mm.
- Suitable for processing precision shaft – type, disc – type parts, and optical elements, etc.
- Key factors: Machine tool accuracy, tool quality, environmental control, and process parameter optimization.
- Precision Milling:
- Use high – precision machining centers and precision milling cutters, and the processing accuracy can reach ±0.005mm.
- Suitable for processing precision molds, aerospace parts, and medical devices, etc.
- Key factors: Machine tool rigidity, tool – path optimization, cooling system, and environmental control.
- Precision Grinding:
- Use grinders and grinding wheels to precisely process the part surface, and the processing accuracy can reach ±0.0005mm.
- Suitable for processing high – precision shaft – type parts, gauges, molds, and optical parts, etc.
- Key factors: Grinding wheel selection, grinding parameter optimization, cooling system, and workpiece clamping.
Special processing refers to a processing method that uses non – mechanical energy such as electrical energy, thermal energy, light energy, and chemical energy for processing, suitable for processing materials and shapes that are difficult to handle by traditional machining.
- Electrical Discharge Machining (EDM):
- Utilize the high temperature generated by electrical discharge to melt and vaporize metal materials.
- Suitable for processing high – hardness materials, complex shapes, and deep – cavity narrow slots.
- Characteristics: There is no mechanical cutting force during processing, and electrode wear is the main problem.
- Laser Processing:
- Utilize a high – energy – density laser beam to melt and vaporize metal materials.
- Suitable for processing various metal and non – metal materials, especially high – hardness and high – melting – point materials.
- Characteristics: High processing accuracy, small heat – affected zone, and capable of realizing micro – processing.
- Water Jet Machining:
- Utilize a high – pressure and high – speed water jet or abrasive water jet to cut materials.
- Suitable for processing various metal and non – metal materials, especially thin – type materials.
- Characteristics: No heat – affected zone, good cut quality, but high equipment cost.
Quality control is a key link in the manufacturing process of custom – machined metal parts, directly affecting the performance, reliability, and service life of the parts. This section will introduce quality control methods applicable to aluminum alloy and stainless – steel machined parts, including dimensional accuracy control, surface quality control, material property testing, and non – destructive testing.
Dimensional accuracy is the primary indicator of quality control for custom – machined metal parts, directly affecting the assembly and function of the parts.
4.1.1 Measuring Tools and Equipment
Conventional Measuring Tools:
Calipers: Used to measure dimensions such as length, inner diameter, and outer diameter, with an accuracy of up to 0.02 mm.
Micrometers: Used to measure dimensions such as thickness and depth, with an accuracy of up to 0.01 mm.
Dial Indicators: Used to measure shape and position errors, with an accuracy of up to 0.001 mm.
Precision Measuring Equipment:
Coordinate Measuring Machine (CMM): Used to measure the three – dimensional dimensions and geometric tolerances of complex – shaped parts, with an accuracy of up to ±0.001mm.
Optical Measuring Instruments: Such as projectors and tool microscopes, used to measure the contours and angles of precision parts.
Laser Interferometer: Used for high – precision straightness, flatness, and angle measurements, with an accuracy reaching the nanometer level.
3D Scanning and Detection Systems:
Blue – light Scanner: Adopts blue – light fringe projection technology to quickly obtain the three – dimensional data of the part surface.
Industrial CT: Used for non – destructive testing of the internal structure and defects of parts.
Three – dimensional Optical Measuring System: Features portability, scanning speed, and accuracy advantages, suitable for high – precision measurement of parts of different sizes.
4.1.2 Measuring Methods and Strategies
First – piece Inspection:
Conduct a comprehensive inspection of the first piece before mass production to confirm the correctness of the processing technology and procedures.
The inspection content includes dimensional accuracy, shape accuracy, position accuracy, and surface quality, etc.
In – process Inspection:
Regularly sample and inspect during the production process to monitor the stability of the processing process.
Focus on key dimensions and variable parameters, and promptly detect and correct processing deviations.
Final Inspection:
Conduct a comprehensive inspection of the completed parts to ensure that all dimensions and technical requirements are met.
The inspection results should be recorded and archived as the basis for quality traceability.
Statistical Process Control (SPC):
Use statistical methods to monitor the processing process, identify, and control process variations.
Analyze the process stability through tools such as control charts to prevent the occurrence of quality problems.
4.1.3 Tolerance Control and Optimization
Relationship between Tolerance and Cost:
The stricter the tolerance, the higher the processing cost, especially when the tolerance requirements are higher than industry standards.
Choosing a tolerance of 0.001 mm instead of 0.01 mm may lead to a two – to three – fold increase in price.
Tolerance Allocation Principles:
Reasonably allocate tolerances according to functional requirements, give stricter tolerances to key dimensions, and looser tolerances to non – key dimensions.
Adopt a cost – benefit analysis strategy and allocate tolerances to parts that increase the cost the least.
Statistical Tolerance Analysis:
Consider the distribution characteristics of part dimensions in actual production and use statistical methods to calculate reasonable tolerances.
In real – world production, the probability of all parts simultaneously reaching their limit dimensions is extremely low (about 0.00000015%), so a probability – based method can be used to optimize the total tolerance.
4.2 Surface Quality Control
Surface quality directly affects the appearance, wear resistance, corrosion resistance, and fatigue strength of parts, and is an important aspect of quality control for customized machined metal parts.
4.2.1 Surface Quality Indicators
Surface Roughness:
Definition: The microscopic geometric shape error of the part surface, usually represented by Ra (arithmetic mean deviation).
Measurement Methods: Stylus method, optical method, interference method, etc.
Influencing Factors: Processing method, tool quality, process parameters, machine tool accuracy, etc.
Surface Waviness:
Definition: A periodic error between macroscopic shape error and microscopic surface roughness.
Influencing Factors: Machine tool vibration, tool wear, uneven feed rate, etc.
Surface Integrity:
Definition: Includes surface roughness, surface defects, surface modified layer, and surface stress state, etc.
Influencing Factors: Processing method, process parameters, cooling conditions, tool state, etc.
4.2.2 Surface Quality Control Methods
Processing Technology Optimization:
Select appropriate processing methods and process parameters, such as cutting speed, feed rate, and cutting depth.
For aluminum alloys, high – speed cutting can obtain better surface quality.
For stainless steels, control the cutting temperature to avoid excessive heat affecting the surface quality.
Tool Selection and Maintenance:
Select sharp tools and appropriate tool geometric parameters.
Regularly inspect and replace tools to avoid surface quality degradation due to tool wear.
Using coated tools can reduce friction and adhesion and improve surface quality.
Cooling and Lubrication:
Select appropriate cutting fluids and cooling methods to control the cutting temperature.
For aluminum alloys, water – soluble cutting fluids or compressed air cooling can be used.
For stainless steels, extreme – pressure cutting fluids should be used to improve lubrication.
Post – processing Technology:
For parts with high surface quality requirements, post – processing technologies such as polishing, grinding, and sandblasting can be used.
Polishing can achieve a mirror effect and improve corrosion resistance.
Sandblasting can obtain a uniform matte surface and improve appearance consistency.
4.3 Material Performance Testing
Material performance directly affects the service performance and lifespan of parts, so material performance testing is an important part of quality control for customized machined metal parts.
4.3.1 Mechanical Performance Testing
Tensile Test:
Test the strength and plasticity of the material under tensile load to obtain indicators such as tensile strength, yield strength, and elongation.
Testing Equipment: Universal material testing machine.
Sampling Requirements: Samples should be cut from representative parts of the part, and their dimensions and shapes should meet relevant standards.
Hardness Test:
Test the ability of the material to resist local deformation, and commonly used methods include Brinell hardness, Rockwell hardness, and Vickers hardness.
Testing Equipment: Hardness tester.
Precautions: The test area should be flat, and the distance between test points should be appropriate to avoid mutual influence.
Impact Test:
Test the toughness of the material under impact load and evaluate the impact resistance of the material.
Testing Equipment: Impact testing machine.
Precautions: The specimen notch should be accurately processed, and the test temperature should meet the requirements.
4.3.2 Metallographic Analysis
Microstructure Analysis:
Observe the microstructure of the material to evaluate the metallurgical quality and heat treatment effect of the material.
Analysis Content: Grain size, phase composition, inclusions, etc.
Equipment: Optical microscope, electron microscope.
Grain Size Determination:
Evaluate the grain size of the material, which affects the strength, toughness, and processing performance of the material.
Determination Methods: Comparison method, area method, intercept method, etc.
Standard: Evaluate according to relevant national standards or industry standards.
Heat Treatment Quality Evaluation:
Evaluate whether the microstructure and hardness after heat treatment meet the requirements through metallographic analysis.
Check for heat treatment defects such as overheating, burning, and decarburization.
4.4 Non – destructive Testing Technologies
Non – destructive testing (NDT) is a technology for detecting internal defects and quality of parts without damaging them, and is widely used in the quality control of customized machined metal parts.
4.4.1 Common Non – destructive Testing Methods
Ultrasonic Testing (UT):
Principle: Use the propagation characteristics of ultrasonic waves in materials to detect internal defects.
Scope of Application: Detect volume – type defects such as internal cracks, pores, and inclusions.
Characteristics: High detection sensitivity, sensitive to area – type defects, suitable for thick – walled parts.
Radiographic Testing (RT):
Principle: Use X – rays or gamma rays to penetrate materials to detect internal defects.
Scope of Application: Detect volume – type defects such as internal pores, inclusions, and lack of fusion.
Characteristics: The test results are intuitive and can be archived, but not sensitive to area – type defects.
Magnetic Particle Testing (MT):
Principle: Use the leakage magnetic field to adsorb magnetic powder to display surface and near – surface defects.
Scope of Application: Detect surface and near – surface cracks of ferromagnetic materials.
Characteristics: High detection sensitivity, simple operation, but limited to ferromagnetic materials.
Penetrant Testing (PT):
Principle: Use the penetration characteristics of penetrant on the part surface to detect surface – opening defects.
Scope of Application: Detect surface – opening defects such as surface cracks and pores.
Characteristics: Simple operation, applicable to various materials, but can only detect surface – opening defects.
4.4.2 New Non – destructive Testing Technologies
In 2025, non – destructive testing technologies are developing rapidly, and the following are some cutting – edge technologies:
Digital Radiography (DR):
Use digital detectors instead of traditional films to improve detection efficiency and image quality.
Enable real – time detection and image processing, facilitating defect analysis and archiving.
Phased Array Ultrasonic Testing (PAUT):
Use phased – array probes to achieve multi – angle and multi – direction detection, improving detection coverage and defect location accuracy.
Suitable for the detection of parts with complex shapes and structures.
Infrared Thermography:
Use an infrared thermal imager to detect the surface temperature distribution of materials and analyze internal defects.
Suitable for detecting composite materials, honeycomb structures, and thermal barrier coatings.
Electromagnetic Acoustic Testing (EMAT):
Does not require a coupling agent and can be detected in high – temperature, high – speed, and harsh environments.
Suitable for automated detection and on – line monitoring.
4.4.3 Application Cases of Non – destructive Testing
Aerospace Field:
Conduct ultrasonic testing on aircraft structural parts to ensure no internal defects.
Use industrial CT to detect whether the internal cooling channels of engine blades are unobstructed.
Automotive Manufacturing Field:
Conduct X – ray testing on aluminum alloy wheels to detect internal shrinkage cavities and porosity.
Conduct magnetic particle testing on automotive chassis welds to ensure welding quality.
Medical Equipment Field:
Use industrial CT for non – destructive testing of the internal quality of dental implants.
Conduct penetrant testing on surgical instruments to ensure no surface cracks.
V. Cost Analysis and Control Strategies
The cost of customized machined metal parts is affected by various factors, including material selection, design complexity, processing technology, accuracy requirements, and batch size. This section will analyze the cost composition of customized machined metal parts in detail and provide effective cost – control strategies.
5.1 Cost Composition Analysis
The cost of customized machined metal parts mainly consists of the following parts:
5.1.1 Material Cost
Material cost is the most basic cost component of customized machined metal parts, usually accounting for 30% – 60% of the total cost, depending on the material type and part design.
Material Cost Calculation:
Material cost = Material weight × Material unit price
Material Weight Calculation: Calculate according to the dimensions and density of the part blank.
Note: When calculating the material weight, machining allowances and waste losses should be considered.
Factors Affecting Material Cost:
Material Type: The prices of different materials vary greatly. For example, 7075 aluminum alloy is more expensive than 6061 aluminum alloy, and 316 stainless steel is more expensive than 304 stainless steel.
Material Specification: Special – specification materials usually have a higher price.
Material Purchase Quantity: Bulk purchases usually obtain more favorable prices.
Material Cost Control Strategies:
Select materials with lower costs while meeting the usage requirements.
Optimize part design to reduce material consumption.
Consider the recyclability and reusability of materials to reduce the total material cost.
5.1.2 Processing Cost
Processing cost is the main cost component of customized machined metal parts, usually accounting for 30% – 50% of the total cost, depending on the part complexity and processing accuracy requirements.
Processing Cost Calculation:
Processing cost = Processing time × Processing rate
Processing time includes: programming time, clamping time, cutting time, tool – changing time, and inspection time, etc.
The processing rate is determined according to the equipment type and processing technology.
Factors Affecting Processing Cost:
Processing Technology: The costs of different processing technologies vary greatly. For example, five – axis machining is more expensive than three – axis machining, and precision grinding is more expensive than ordinary milling.
Processing Accuracy: The higher the accuracy requirement, the higher the processing cost, especially when the tolerance requirements are higher than industry standards.
Processing Complexity: The more complex the part shape, the more processing steps and the higher the cost.
Processing Cost Control Strategies:
Optimize part design to simplify the processing technology.
Adopt efficient processing strategies, such as machining multiple surfaces in one clamping.
Reasonably allocate tolerances to avoid unnecessary high – precision requirements.
5.1.3 Tool and Fixture Cost
Tool and fixture cost is a non – negligible cost component of customized machined metal parts, usually accounting for 5% – 15% of the total cost.
Tool and Fixture Cost Calculation:
Tool cost = Tool purchase price ÷ Tool life (number of parts processed)
Fixture cost includes: tools, fixtures, measuring tools, and auxiliary tools, etc.
Note: Complex processing may require customized tools, significantly increasing the cost.
Factors Affecting Tool and Fixture Cost:
Tool Material: Carbide tools are more expensive than high – speed steel tools but have a longer life.
Tool Type: Tools with special shapes usually have a higher price.
Processing Material: The harder the material, the faster the tool wears and the shorter its life.
Tool and Fixture Cost Control Strategies:
Select cost – effective tools to balance tool price and life.
Optimize processing parameters to extend tool life.
Use standard tools to avoid customized tools.
5.1.4 Quality Control Cost
Quality control cost is a necessary expenditure to ensure the quality of customized machined metal parts, usually accounting for 5% – 10% of the total cost.
Quality Control Cost Calculation:
Quality control cost includes: depreciation of testing equipment, testing consumables, salaries of testing personnel, and maintenance of the quality system, etc.
For parts with high – precision requirements, 100% full inspection may be required, significantly increasing the cost.
Factors Affecting Quality Control Cost:
Accuracy Requirements: The higher the accuracy requirements, the higher the testing cost.
Testing Method: The use cost of high – precision testing equipment such as coordinate measuring machines is relatively high.
Testing Frequency: The higher the sampling inspection ratio, the higher the testing cost.
Quality Control Cost Control Strategies:
Reasonably set quality control requirements to avoid over – inspection.
Adopt Statistical Process Control (SPC) technology to reduce finished – product inspection through process control.
Use automated testing equipment to improve testing efficiency and reduce labor costs.
5.1.5 Management and Indirect Cost
Management and indirect cost is the management and indirect expenses allocated to each part during the operation of the enterprise, usually accounting for 10% – 20% of the total cost.
Management and Indirect Cost Calculation:
Management and indirect cost includes: salaries of management personnel, office expenses, factory rent, equipment depreciation, energy consumption, etc.
Usually calculated as a certain percentage of direct costs, such as 15% – 30%.
Factors Affecting Management and Indirect Cost:
Enterprise Scale: Large – scale enterprises usually have higher management costs.
Production Efficiency: The lower the production efficiency, the higher the indirect cost per unit product.
Production Batch: The unit indirect cost of small – batch production is usually higher than that of large – batch production.
Management and Indirect Cost Control Strategies:
Optimize the enterprise management process to improve management efficiency.
Improve equipment utilization to reduce equipment depreciation and energy consumption per unit product.
For small – batch production, consider using flexible manufacturing systems to improve production efficiency.
5.2 Cost Comparison of Different Processing Technologies
The costs of different processing technologies vary greatly, and understanding these differences helps to make more economical decisions in the design and manufacturing process.
5.2.1 Cost Comparison of Basic Processing Technologies
Cost Comparison between Turning and Milling:
Turning usually has a lower cost than milling, especially for rotational parts.
Milling is suitable for processing complex shapes but has a higher cost.
For parts that require multi – surface processing, a five – axis machining center may be more economical than step – by – step processing on multiple devices.
Cost Comparison between Roughing and Finishing:
Roughing cost is relatively low, mainly focusing on material removal rate.
Finishing cost is higher, focusing on accuracy and surface quality.
Reasonably allocating the roughing and finishing allowances can reduce the total cost.
Cost Comparison between Traditional Processing and Special Processing:
Traditional processing (turning, milling, drilling, etc.) usually has a lower cost and is suitable for most cases.
Special processing (electrical discharge machining, laser, water jet, etc.) has a higher cost and is only used when necessary.
For high – hardness, difficult – to – machine materials or complex shapes, special processing may be more economical.
5.2.2 Cost Comparison of Different Materials
Cost Comparison between Aluminum Alloy and Stainless Steel Processing:
The processing cost of aluminum alloy is usually lower than that of stainless steel, mainly because:
Aluminum alloy has a low density, and parts of the same size are lighter in weight, resulting in lower material costs.
Aluminum alloy has good machinability, longer tool life, and higher processing efficiency.
Aluminum alloy processing consumes less energy and has a lower machine tool load.
Cost Comparison of Different Aluminum Alloy Grades:
Pure aluminum has the lowest processing cost, and heat – treatable aluminum alloys (such as 6061 and 7075) have a higher processing cost.
High – strength aluminum alloys (such as 7075) have a higher processing cost than medium – strength aluminum alloys (such as 6061), mainly because of faster tool wear.
Cost Comparison of Different Stainless Steel Grades:
Austenitic stainless steels (such as 304 and 316) have a higher processing cost than ferritic and martensitic stainless steels.
Molybdenum – containing stainless steels (such as 316) have a higher processing cost than molybdenum – free stainless steels (such as 304), mainly because of higher hardness.
5.2.3 Influence of Batch Size on Cost
Small – batch Production (1 – 100 pieces):
The unit cost is high, mainly because:
The proportion of fixed costs (programming, fixture design and manufacturing, etc.) allocated to each product is high.
The efficiency of automated equipment cannot be fully utilized.
It is suitable to adopt CNC processing and rapid prototyping technology.
Medium – batch Production (100 – 1000 pieces):
The unit cost is moderate. Partial automation and special fixtures can be adopted to improve efficiency.
Modular fixtures and standardized procedures can be considered to reduce costs.
Large – batch Production (more than 1000 pieces):
The unit cost is low, mainly because:
The proportion of fixed costs allocated to each product is low.
Special automated production lines and efficient processing technologies can be adopted.
It is suitable to use special machine tools and automated production lines.
5.3 Cost Optimization Strategies
To reduce the cost of customized machined metal parts, the following strategies can be adopted:
5.3.1 Design Optimization Strategies
Simplify Design:
Simplify the part structure as much as possible, reducing unnecessary features and complexity.
Adopt standardized geometric shapes and dimensions, such as standard hole diameters, threads, and fillet radii.
Avoid features that are difficult to process, such as deep cavities, narrow slots, and complex curved surfaces.
Tolerance Optimization:
Use strict tolerances only when necessary to avoid increasing manufacturing costs due to excessive tolerances.
Understand the impact of different tolerance grades on processing costs and set tolerances reasonably according to functional requirements.
Adopt statistical tolerance analysis methods to optimize the setting of total tolerances.
Material Selection Optimization:
Under the premise of meeting the usage requirements, select materials with the lowest cost and the best processing performance.
Consider the availability and supply cycle of materials, and avoid using scarce or difficult – to – purchase materials.
For appearance parts, consider using low – cost materials combined with high – quality surface treatment.
5.3.2 Manufacturing Process Optimization Strategies
Processing Technology Optimization:
Select the most economical processing technology. For example, turning is suitable for rotational parts, and milling is suitable for complex shapes.
Optimize the processing sequence to reduce the number of clamping times and idle – travel time.
Adopt efficient processing strategies, such as layer – by – layer milling, trochoidal milling, and stepped turning.
Tool Selection Optimization:
Select cost – effective tools to balance the price and lifespan of tools.
Use standard tools as much as possible to avoid customized tools.
For large – batch production, consider using indexable tools to improve efficiency.
Production Batch Optimization:
For small – batch production, consider adopting CNC processing and quick – die – change technology.
For large – batch production, consider using special automated production lines.
Evaluate the cost differences between outsourcing processing and in – house processing to make more economical decisions.
5.3.3 Quality Control Optimization Strategies
Quality Standard Optimization:
Adopt high standards only when necessary to avoid increasing costs due to excessive quality requirements.
Adopt a risk – based quality control strategy, conduct 100% inspection on key characteristics, and sample inspection on secondary characteristics.
Reasonably select inspection methods to avoid over – reliance on high – precision and high – cost testing equipment.
Process Control Optimization:
Strengthen process control to reduce the need for finished – product inspection.
Adopt Statistical Process Control (SPC) technology to prevent the occurrence of quality problems.
Establish a rapid response mechanism for quality problems to reduce the generation of non – conforming products.
Supplier Quality Management Optimization:
Select suppliers with reliable quality and reasonable prices.
Establish long – term cooperative relationships with suppliers to strive for more favorable prices and services.
Conduct quality system audits on key suppliers to ensure the quality of incoming materials.
5.3.4 Life – cycle Cost Analysis
Life – cycle cost analysis takes into account all costs within the entire product life cycle from design to scrapping, not just manufacturing costs.
Balance between Initial Purchase Cost and Long – term Use Cost:
Sometimes a higher initial purchase cost may lead to a significant reduction in long – term use costs.
For example, choosing high – quality materials and processes may increase the initial cost, but it can extend the part lifespan and reduce replacement and maintenance costs.
Design for Maintainability and Repairability:
Consider the maintainability and repairability of parts during the design process to reduce long – term use costs.
For example, adopt modular design to facilitate the replacement and repair of faulty components.
Consideration of Environmental Costs:
Select environmentally friendly materials and processes to reduce the impact on the environment.
Consider the recyclability and reusability of materials to reduce environmental costs.
5.4 Cost Control Strategies for Small – batch and Large – batch Production
Small – batch and large – batch production face different cost challenges and require different cost control strategies.
5.4.1 Cost Control Strategies for Small – batch Production
Adopt Flexible Manufacturing Systems:
Utilize the flexibility of CNC machine tools to adapt to multi – variety and small – batch production.
Adopt quick – die – change technology to reduce equipment adjustment time.
Use group technology to classify and produce similar parts to improve production efficiency.
Optimize Design to Reduce Customization:
Under the premise of meeting functional requirements, use standard parts and common parts as much as possible.
Consider possible future product expansions during the design process, and reserve interfaces and upgrade spaces.
Avoid over – customized designs to reduce the demand for special tooling and tools.
Reasonably Select Processing Technologies:
For small – batch production, CNC processing is usually more economical than special – purpose machine tools.
Adopt additive manufacturing technologies such as 3D printing as a supplement to reduce the costs of molds and tooling.
Consider outsourcing some processing links to avoid investment in special equipment.
5.4.2 Cost Control Strategies for Large – batch Production
Special – purpose Equipment and Automated Production Lines:
For large – batch production, special – purpose equipment and automated production lines are usually more economical.
Adopt an assembly – line production method to improve production efficiency and product consistency.
Utilize industrial robots and automated logistics systems to reduce labor costs.
Standardization and Modular Design:
Adopt standardized parts and processes to improve production efficiency.
Adopt modular design to facilitate the adjustment and expansion of production lines.
Establish a product platform to achieve component sharing and bulk purchasing.
Continuous Improvement and Lean Production:
Implement lean production to eliminate waste in the production process.
Establish a continuous improvement mechanism to continuously optimize processes and improve efficiency.
Establish close cooperative relationships with suppliers to achieve collaborative optimization.
VI. Application Cases and Industry Solutions
Customized machined metal parts are widely used in various industries, and different industries have different requirements and concerns for parts. This section will introduce the application cases and solutions of machined aluminum alloy and stainless – steel parts in different industries.
6.1 Applications in the Aerospace Field
The aerospace field has extremely high requirements for customized machined metal parts, which need to meet multiple requirements such as lightweight, high strength, high reliability, and resistance to harsh environments simultaneously.
6.1.1 Main Application Components
Aircraft Structural Components:
Wing Structural Components: High – strength aluminum alloys (such as 7075) and titanium alloys are used, requiring high precision and lightweight.
Fuselage Frame: A mixed structure of aluminum alloy and composite materials is adopted, requiring high precision and good fatigue performance.
Landing Gear Components: High – strength steel and stainless steel are used, requiring extremely high strength and reliability.
Engine Components:
Turbine Blades: High – temperature alloys and titanium alloys are used, requiring high precision and good high – temperature performance.
Combustion Chamber Components: Stainless steel and high – temperature alloys are used, requiring high temperature resistance and corrosion resistance.
Compressor Components: Aluminum alloy and titanium alloy are used, requiring high strength and lightweight.
Interior and Functional Components:
Seat Structural Components: Aluminum alloy and composite materials are used, requiring lightweight and comfort.
Luggage Rack System: Aluminum alloy and stainless steel are used, requiring lightweight and high strength.
Kitchen Equipment: Stainless steel and aluminum alloy are used, requiring corrosion resistance and easy cleaning.
6.1.2 Special Requirements for Aerospace Parts
Material Requirements:
Strict material certification requirements, which must comply with aerospace industry standards.
Special heat treatment and surface treatment requirements, such as anodizing of aluminum alloy and passivation treatment of stainless steel.
Strict material traceability requirements to ensure the traceability of each batch of materials.
Processing Precision Requirements:
Extremely high dimensional accuracy and geometric tolerance requirements, usually within ±0.01mm.
Strict surface quality requirements, including surface roughness and surface integrity.
Precise hole – processing and thread – processing requirements to ensure connection reliability.
Quality Control Requirements:
100% non – destructive testing to ensure no internal defects.
Strict process control and quality records to ensure product traceability.
Comprehensive performance testing to ensure that products meet design requirements.
6.1.3 Solutions and Case Analyses
Processing Solutions for Integral Structural Components:
Adopt large – scale five – axis machining centers to complete multi – surface machining in one clamping.
Use high – speed cutting technology to improve processing efficiency and surface quality.
Case: The integral wing skin of a certain type of aircraft uses 7075 aluminum alloy. Through five – axis linkage processing, the number of parts and assembly work are reduced, and the structural efficiency is improved.
Processing Solutions for Precision Blades:
Adopt precision five – axis machining centers and special blade – processing software.
Use trochoidal milling and contour milling strategies to ensure the profile accuracy of the blades.
Case: The compressor blades of a certain type of aero – engine use titanium alloy materials. Through precision five – axis processing and electrochemical polishing, the profile accuracy and surface quality required by the design are achieved.
Lightweight Structural Design and Processing:
Adopt topological optimization and finite – element analysis to optimize the part structure.
Use hollow structures and rib designs to improve the stiffness – to – weight ratio.
Case: The fuselage frame of a certain type of UAV uses aluminum alloy materials. Through topological optimization and precision processing, the weight is reduced by 30% while ensuring strength.
6.2 Applications in the Automotive and New Energy Vehicle Fields
The automotive and new energy vehicle fields have a huge demand for customized machined metal parts, and the parts are required to have good mechanical properties, reliability, and economy.
6.2.1 Applications in Traditional Automobiles
Engine Components:
Cylinder Blocks and Cylinder Heads: Aluminum alloy casting and machining are used, requiring high precision and good sealing performance.
Crankshafts and Connecting Rods: Alloy steel and ductile iron are used, requiring high strength and wear resistance.
Camshafts and Valves: Alloy steel and stainless steel are used, requiring high strength and wear resistance.
Chassis and Suspension Systems:
Control Arms and Steering Knuckles: Aluminum alloy and high – strength steel are used, requiring high strength and lightweight.
Drive Shafts and Axles: Alloy steel is used, requiring high strength and torsional resistance.
Wheels and Brake Discs: Aluminum alloy and cast iron are used, requiring lightweight and heat – dissipation performance.
Body Structural Components:
Door Frames and Roof Beams: High – strength steel and aluminum alloy are used, requiring high strength and lightweight.
Crash Beams and Bumpers: High – strength steel and aluminum alloy are used, requiring high energy – absorption capacity.
Seat Frames and Slides: High – strength steel and aluminum alloy are used, requiring high strength and comfort.
6.2.2 Applications in New Energy Vehicles
Battery System Components:
Battery Cases and Frames: Aluminum alloy and stainless steel are used, requiring lightweight, high strength, and good electromagnetic shielding performance.
Battery Connectors and Electrodes: Copper alloy and aluminum alloy are used, requiring good electrical conductivity and corrosion resistance.
Battery Cooling System Components: Aluminum alloy and copper alloy are used, requiring good thermal conductivity and corrosion resistance.
Motor and Electronic Control System Components:
Motor Housings and End Caps: Aluminum alloy is used, requiring lightweight and good heat – dissipation performance.
Electronic Control System Enclosures: Aluminum alloy and stainless steel are used, requiring electromagnetic shielding and protection performance.
Sensors and Connectors: Stainless steel and copper alloy are used, requiring high precision and reliability.
Transmission and Suspension Systems:
Drive Shafts and Differential Components: High – strength steel and aluminum alloy are used, requiring high strength and lightweight.
Suspension System Components: Aluminum alloy and high – strength steel are used, requiring high strength and lightweight.
Brake System Components: Cast iron and aluminum alloy are used, requiring high wear resistance and heat – dissipation performance.
6.2.3 Solutions and Case Analyses in the Automotive Industry
Lightweight Solutions:
Replace traditional steel with aluminum alloy to reduce the weight of parts.
Use hollow structures and topological optimization designs to improve the stiffness – to – weight ratio.
Case: The battery tray of a certain type of electric vehicle uses aluminum alloy materials. Through structural optimization and precision processing, the weight is reduced by 40% while ensuring strength.
Solutions for New Energy Vehicle Battery Components:
Use aluminum alloy and composite materials to manufacture battery cases to meet the requirements of lightweight and safety.
Use precision processing technology to manufacture battery connectors to ensure good electrical conductivity and reliability.
Case: The detection of burrs on the pole pieces of a certain type of power battery is achieved through the combination of a large – depth – of – field optical microscope hardware and customized algorithm software, realizing automatic identification and report generation, and the efficiency is increased by 80% compared with manual detection.
Efficient Processing and Mass Production:
Adopt automated production lines and robot technology to improve production efficiency and product consistency.
Use quick – die – change technology to meet the production needs of multi – variety and small – batch.
Case: The production line of a certain automotive engine cylinder block adopts high – speed machining centers and an automated logistics system, achieving a production cycle of one piece per minute.
6.3 Applications in the Medical Equipment Field
The medical equipment field has extremely high requirements for customized machined metal parts, which need to meet special requirements such as high precision, high cleanliness, biocompatibility, and corrosion resistance.
6.3.1 Main Application Components
Surgical Instruments:
Scalpels and Scissors: Stainless steel and titanium alloy are used, requiring high hardness, sharpness, and corrosion resistance.
Orthopedic Implants: Titanium alloy and stainless steel are used, requiring high strength, biocompatibility, and corrosion resistance.
Dental Instruments: Stainless steel and titanium alloy are used, requiring high precision and corrosion resistance.
Medical Equipment Structural Components:
Medical Robot Structural Components: Aluminum alloy and stainless steel are used, requiring high precision and lightweight.
Medical Imaging Equipment Components: Aluminum alloy and stainless steel are used, requiring high precision and non – magnetism.
Medical Bed and Operating Table Components: Stainless steel and aluminum alloy are used, requiring high strength and corrosion resistance.
Implants and Prostheses:
Artificial Joints: Titanium alloy and cobalt – chromium – molybdenum alloy are used, requiring high strength, wear resistance, and biocompatibility.
Dental Implants: Titanium alloy and zirconia are used, requiring high strength and biocompatibility.
Cardiovascular Implants: Stainless steel and titanium alloy are used, requiring high strength and biocompatibility.
6.3.2 Special Requirements in the Medical Field
Material Requirements:
Strict biocompatibility requirements, which must comply with relevant medical standards (such as ISO 10993).
High – purity and non – toxicity requirements to avoid the release of harmful substances.
Special surface treatment requirements, such as passivation, electropolishing, and coating treatment.
Processing Precision Requirements:
Extremely high dimensional accuracy and surface quality requirements, usually within ±0.001mm.
Strict surface roughness requirements, usually requiring mirror polishing.
Precise hole – processing and thread – processing requirements to ensure connection reliability.
Cleanliness and Surface Treatment:
Strict cleaning and disinfection requirements to ensure no residual pollutants.
Special surface treatments, such as passivation and electropolishing, to improve corrosion resistance and biocompatibility.
Design without burrs and sharp edges to avoid tissue damage.
- Adopt high – precision processing equipment and processes to ensure part accuracy and surface quality.
- Use electropolishing and passivation treatments to improve surface finish and corrosion resistance.
Case: A certain artificial joint component uses titanium alloy material. Through five – axis precision processing and electropolishing, it achieves mirror – like surface quality, meeting the biocompatibility requirements.
- Adopt industrial CT and ultrasonic testing technologies to ensure internal quality.
- Use optical microscopes and electron microscopes to evaluate surface quality and microstructure.
Case: A certain dental implant uses industrial CT for non – destructive testing of internal quality, solving the problem of traditional destructive testing.
- Select appropriate materials and surface treatment processes to improve biocompatibility.
- Adopt special surface treatment technologies, such as hydroxyapatite coating, to improve bone – bonding ability.
Case: A certain orthopedic implant uses titanium alloy material. Through sandblasting and hydroxyapatite coating treatment, it improves the bone – bonding ability and long – term stability.
The electronics and communication field has a wide demand for customized machined metal parts, which are required to have good electrical conductivity, thermal conductivity, shielding performance, and lightweight characteristics.
- Housings and Frames: Aluminum alloy and stainless steel are used, requiring lightweight, good rigidity, and electromagnetic shielding performance.
- Heat Sinks and Fins: Aluminum alloy and copper alloy are used, requiring good thermal conductivity and heat – dissipation performance.
- Support Structures and Connectors: Aluminum alloy and stainless steel are used, requiring high strength and stability.
- Antennas and Waveguides: Aluminum alloy and copper alloy are used, requiring good electrical conductivity and corrosion resistance.
- RF Shields and Filters: Aluminum alloy and copper alloy are used, requiring good electromagnetic shielding performance.
- Base Station Structural Components: Aluminum alloy and stainless steel are used, requiring high strength and weather resistance.
- Wafer Fixtures and Carriers: Aluminum alloy and stainless steel are used, requiring high precision and thermal stability.
- Vacuum Chambers and Valves: Stainless steel and aluminum alloy are used, requiring high – vacuum sealing performance and corrosion resistance.
- Lithography Machine Components: Granite and invar are used, requiring high dimensional stability and low coefficient of expansion.
- Good electromagnetic shielding performance to prevent electromagnetic interference.
- Conductive connection design to ensure shielding effectiveness.
- Special surface treatments, such as conductive coatings and electroless nickel plating, to improve electrical conductivity.
- Good thermal conductivity and heat – dissipation performance to ensure the normal operation of equipment in high – temperature environments.
- Optimized heat – dissipation structure design, such as heat sinks and heat dissipation grooves.
- Select appropriate materials and surface treatments to improve heat – dissipation efficiency.
- High – precision processing requirements to ensure the fitting accuracy and function of parts.
- Miniaturization design to reduce the volume and weight of equipment.
- Precise hole – processing and thread – processing to ensure connection reliability.
- Adopt aluminum alloy and copper alloy materials to improve thermal conductivity.
- Design optimized heat – dissipation structures, such as heat sinks and heat dissipation grooves.
Case: A certain server heat – dissipation module uses aluminum alloy material. Through precision processing and surface blackening treatment, its heat – dissipation efficiency is increased by 30%.
- Adopt highly conductive materials and optimized shielding structures.
- Use conductive sealing materials to ensure shielding continuity.
Case: The shielding housing of a certain communication equipment uses aluminum alloy material. Through precision processing and conductive coating treatment, it achieves a shielding effect of – 80dB.
- Adopt high – precision processing equipment and processes to ensure the accuracy of miniaturized parts.
- Use micro – milling and micro – electrical – discharge machining technologies to achieve micro – structure processing.
Case: The wafer fixture of a certain semiconductor equipment uses aluminum alloy material. Through five – axis precision processing and electrochemical polishing, it achieves a dimensional accuracy of ±0.002mm and mirror – like surface quality.
The general machinery and industrial equipment field has a wide demand for customized machined metal parts, which are required to have good mechanical properties, reliability, and economy.
- Gears and Shaft – type Parts: Alloy steel and stainless steel are used, requiring high strength and wear resistance.
- Bearings and Couplings: Alloy steel and cast iron are used, requiring high strength and reliability.
- Chains and Sprockets: Alloy steel and stainless steel are used, requiring high strength and wear resistance.
- Valve Bodies and Valve Cores: Stainless steel and aluminum alloy are used, requiring high precision and sealing performance.
- Cylinder Bodies and Pistons: Cast iron and aluminum alloy are used, requiring high strength and wear resistance.
- Hydraulic Connectors and Pipe Fittings: Stainless steel and copper alloy are used, requiring high strength and corrosion resistance.
- Joints and Connecting Rods: Aluminum alloy and high – strength steel are used, requiring high strength and lightweight.
- Reducer Components: Alloy steel and stainless steel are used, requiring high precision and wear resistance.
- End Effectors: Aluminum alloy and stainless steel are used, requiring high strength and lightweight.
- Select high – strength materials and appropriate heat – treatment processes to improve the strength and wear – resistance of parts.
- Adopt surface hardening treatments, such as quenching, carburizing, and nitriding, to improve surface hardness and wear – resistance.
Case: A certain industrial gear uses 20CrMnTi steel material. Through carburizing and quenching treatment, its surface hardness reaches HRC58 – 62, improving wear – resistance and fatigue life.
- High – precision processing requirements to ensure the fitting accuracy and motion accuracy of parts.
- Select materials and processes with good stability to reduce part deformation and dimensional changes.
Case: The gear of a certain precision reducer uses 40Cr steel material. Through precision processing and nitriding treatment, it reaches a 6 – level accuracy, ensuring transmission accuracy and stability.
- Select appropriate materials and surface treatments according to the use environment.
- Adopt protective coatings and surface treatments to improve the corrosion – resistance and protection performance of parts.
Case: The pump shaft of a certain chemical equipment uses 316 stainless steel material. Through precision processing and passivation treatment, it improves corrosion – resistance and long – term reliability.
- Adopt high – precision gear – hobbing machines and gear – grinding machines to ensure gear accuracy.
- Use advanced heat – treatment processes and precision processing technologies to improve the strength and accuracy of gears.
Case: The gear of a certain precision reducer uses 20CrMnTi steel material. Through precision processing and carburizing and quenching treatment, it reaches a 5 – level accuracy, meeting the requirements of high – precision transmission.
- Adopt high – precision processing equipment and processes to ensure the fitting accuracy of valve bodies and valve cores.
- Use advanced surface treatment technologies to improve the wear – resistance and corrosion – resistance of parts.
Case: A certain hydraulic valve block uses aluminum alloy material. Through five – axis precision processing and hard anodizing treatment, it improves wear – resistance and corrosion – resistance and reduces the risk of leakage.
- Adopt aluminum alloy and carbon – fiber composite materials to reduce the weight of robots.
- Use topological optimization and finite – element analysis to optimize part structures.
Case: The joint arm of a certain industrial robot uses 7075 aluminum alloy material. Through topological optimization and precision processing, its weight is reduced by 35% while ensuring strength, improving the movement speed and energy efficiency.
The customized machined metal parts industry is undergoing rapid changes. New technologies, materials, and processes are emerging continuously, driving the industry towards higher precision, higher efficiency, and greater intelligence. This section will introduce the future trends and development directions of the customized machined metal parts industry.
The progress of material technology will continue to drive the development of the customized machined metal parts industry. The following are some important development trends:
- New Aluminum Alloys: Such as aluminum – lithium alloys, which have lower density and higher strength, and are expected to be widely used in the aerospace field.
- High – strength Steels: Such as the third – generation automotive steels, which have higher strength and better formability, and are expected to replace some aluminum alloys in the automotive field.
- Titanium Alloys: Such as β – type titanium alloys, which have higher strength and better processing performance, and are expected to expand their applications in the aerospace and medical fields.
- Shape – memory Alloys: Such as nickel – titanium alloys, which have shape – memory effects and super – elasticity, and can be used for medical implants and intelligent structures.
- Vibration – damping Alloys: Such as beryllium bronze and high – damping alloys, which have good vibration – damping performance, and can be used for precision instruments and aerospace structures.
- Superconducting Materials: Such as NbTi and Nb3Sn, which can be used for manufacturing high – magnetic – field equipment and superconducting motors.
- Metal – matrix Composite Materials: Such as aluminum – matrix and titanium – matrix composite materials, which have high strength, high modulus, and low coefficient of expansion.
- Gradient Materials: Such as functionally gradient materials, whose composition and properties change continuously along the thickness direction, and can meet the needs of special environments.
- Nanostructured Materials: Such as nanocrystalline alloys, which have excellent strength, toughness, and wear – resistance.
- Diamond – like Carbon Coating (DLC): It has high hardness, low friction coefficient, and good wear – resistance, and can be used for cutting tools and wear – resistant parts.
- Nanocomposite Coatings: Such as TiAlN – and CrN – based coatings, which have higher hardness and thermal stability, and can be used for high – speed cutting tools.
- Self – lubricating Coatings: Such as MoS2 – and WS2 – based coatings, which have good self – lubricating performance, and can be used in high – temperature and vacuum environments.
- Chromium – free Passivation: It replaces the traditional chromium – containing passivation process to reduce environmental pollution.
- Low – temperature Iron Plating: It replaces the traditional chromium – plating process to reduce energy consumption and environmental pollution.
- Biodegradable Coatings: Coatings that can be degraded in the natural environment, reducing long – term environmental pollution.
- Hydrophobic/Hydrophilic Surfaces: Through surface treatment, super – hydrophobic or super – hydrophilic characteristics are achieved, which are used for antifouling and self – cleaning.
- Antibacterial Surfaces: By loading silver ions or other antibacterial agents, the surface antibacterial function is realized, which is used for medical equipment.
- Photocatalytic Surfaces: Such as TiO2 – based coatings, which have photocatalytic performance and can be used for air purification and self – cleaning.
The innovation of processing technologies will continue to drive the development of the customized machined metal parts industry. The following are some important development trends:
- Ultra – precision Processing: The accuracy reaches the nanometer level, which is used for manufacturing optical components, semiconductor equipment, and precision instruments.
- Atomic – level Processing: Such as focused ion beam processing, which can achieve the manipulation and removal of single atoms.
- Quantum Processing: A new processing technology based on quantum effects, which is expected to achieve precise control at the molecular level.
- High – precision Five – axis Machining Centers: The accuracy and stability are continuously improved, enabling the processing of more complex shapes.
- Five – axis Turning – milling Compound Processing: It integrates turning and milling functions and can complete the processing of complex parts in one clamping.
- Five – axis Additive – subtractive Composite Processing: Combining 3D printing and precision processing to achieve the efficient manufacturing of complex structures.
- Adaptive Processing: Automatically adjust processing parameters according to the real – time monitored processing state to improve processing efficiency and quality.
- Predictive Maintenance: Predict equipment failures through sensors and big – data analysis to reduce downtime.
- Digital Twin: Establish a virtual processing process model to optimize and verify the processing process.
- Higher spindle speeds and feed rates to increase material removal rates.
- More advanced tool materials and coating technologies to support higher cutting speeds.
- More efficient cooling and lubrication systems to reduce cutting heat and tool wear.
- AI – based Processing Parameter Optimization: Optimize processing parameters through machine – learning algorithms to improve processing efficiency and quality.
- Automated Processing Flow: A fully automated process from CAD model to finished product, reducing human intervention.
- Digital Twin Technology: Optimize the processing process through a virtual model to improve processing efficiency and quality.
- Dry Cutting and Minimum Quantity Lubrication (MQL): Reduce the use of cutting fluids to reduce environmental pollution.
- Energy – saving Machine Tool Design: Adopt high – efficiency motors and intelligent control systems to reduce energy consumption.
- Waste Recycling and Reuse: Improve material utilization and reduce resource waste.
The progress of quality control technologies will improve the quality and reliability of customized machined metal parts. The following are some important development trends:
- Blue – light Scanning and White – light Interference: Achieve high – precision, non – contact three – dimensional measurement, suitable for parts with complex shapes.
- Confocal Microscope: Achieve nanometer – level surface roughness measurement, suitable for high – precision optical components.
- Laser Tracker: Achieve high – precision three – dimensional measurement of large – sized parts, suitable for large – scale machinery and aerospace structures.
- Deep – learning – based Defect Recognition: Through training with a large number of defect samples, automatic defect recognition and classification are realized.
- Quality Prediction and Early Warning: Analyze production data through machine – learning algorithms to predict quality problems and intervene in advance.
- Intelligent Detection System: Combine robots and vision systems to achieve fully automated detection and quality control.
- Real – time Monitoring of the Processing Process: Monitor parameters such as vibration, temperature, and force in the processing process in real – time through sensors.
- In – situ Measurement: Directly measure the dimensions and shapes of parts during the processing process to reduce secondary clamping errors.
- On – line Detection: An automatic detection system integrated into the production line to achieve 100% full inspection.
- Establish a digital model of the product’s entire life cycle to achieve high – level collaboration in design, manufacturing, and inspection.
- Predict product performance and quality through the digital twin model to optimize the design and manufacturing processes.
Case: The blades of a certain aero – engine achieve high – level collaboration in design, manufacturing, and inspection through digital twin technology, improving product quality and reliability.
- Use blockchain technology to record the quality data of the product’s entire life cycle to ensure the non – tampering of data.
- Achieve the whole – process quality traceability from raw materials to finished products, improving product quality and safety.
Case: A certain automobile manufacturer uses blockchain technology to record the quality data of key components, achieving rapid quality traceability and problem – location.
- Collect and analyze a large amount of production data to identify the root causes of quality problems.
- Establish quality prediction models to identify potential quality risks in advance.
Case: A certain electronics manufacturer identifies the key factors affecting product quality by analyzing production data and takes targeted measures to reduce the defect rate by 30%.
Intelligent manufacturing and Industry 4.0 will profoundly change the production methods and business models of the customized machined metal parts industry. The following are some important development trends:
- Equipment Interconnection based on the Internet of Things (IoT): Achieve information sharing and collaborative work among equipment.
- Intelligent Logistics System: Automatically identify, track, and distribute materials to improve production efficiency.
- Digital Thread: A data chain running through the entire product life cycle, enabling high – level collaboration in design, manufacturing, and service.
- Reconfigurable Production Line: Rapidly adjust the layout and functions of the production line according to production requirements.
- Mixed – model Production: Simultaneously produce multiple different products on the same production line to enhance production flexibility.
- Adaptive Manufacturing: Automatically adjust production plans and resource allocation according to real – time demands.
- Collaborative Robots: Collaborate safely with human workers to improve production efficiency and flexibility.
- Augmented Reality (AR) – assisted Assembly: Guide workers to complete complex assembly tasks through AR technology.
- Digital Twin and Remote Operation: Monitor and operate equipment remotely through the digital twin model.
- Modular Design: Decompose products into interchangeable modules to balance mass production and personalized customization.
- Configurator Technology: Enable customers to configure products independently through software tools and generate customized designs.
- Flexible Manufacturing System: Support multi – variety and small – batch production to reduce customization costs.
- Distributed Manufacturing: Allocate manufacturing demands to the most suitable manufacturing resources via the network to optimize global resource allocation.
- 3D Printing and Localized Production: Realize localized on – demand production through 3D printing technology, reducing inventory and logistics costs.
- Predictive Demand Management: Predict market demands through big – data analysis and optimize production plans.
- Shift from Product Sales to Service Provision: Charge according to usage time or output, for example.
- Product – as – a – Service (PaaS) Model: Provide an integrated solution including products, software, and services.
- Performance – based Contract: The supplier is responsible for the operation and maintenance of the equipment to ensure that the agreed – upon performance indicators are met.
Custom – machined metal parts, as a fundamental component of modern manufacturing, play a crucial role in various fields such as aerospace, automotive, medical, and electronics. With the global manufacturing industry evolving towards digitalization, greening, and intelligentization, the custom – machined metal parts industry also faces new opportunities and challenges.
- Material Selection is Key: Aluminum alloy and stainless steel are the most commonly used materials for custom – machined metal parts, each with its own advantages. Aluminum alloy has advantages such as low density, good processing performance, and low cost, making it suitable for applications with high lightweight requirements. Stainless steel has high strength, excellent corrosion resistance, and high – temperature stability, making it suitable for applications with high requirements for corrosion resistance and strength.
- Design Determines Cost and Manufacturability: The Design for Manufacturing (DFM) principle can significantly reduce manufacturing costs and improve quality. Tolerance optimization is the key to cost reduction, and tolerances should be set reasonably according to functional requirements. Simplifying the design, reducing the number of clamping times, and adopting standardized designs can improve processing efficiency and reduce costs.
- Processing Technology Affects Quality and Efficiency: The costs and applicable scopes of different processing technologies vary greatly. Appropriate processing technologies should be selected according to the characteristics of parts. Advanced processing technologies such as five – axis machining and turning – milling compound machining can improve processing efficiency and quality. Reasonably setting processing parameters and using advanced tools can improve processing efficiency and extend tool life.
- Quality Control is the Guarantee of Product Reliability: A complete quality control system is the key to ensuring product quality. Advanced detection technologies such as non – destructive testing and coordinate measuring machines can improve detection accuracy and efficiency. Statistical Process Control (SPC) and continuous improvement mechanisms can prevent the occurrence of quality problems.
- Cost Control Requires a Life – cycle Consideration: The total cost of custom – machined metal parts consists of material costs, processing costs, tool costs, quality control costs, and management costs. The costs of different processing technologies vary significantly, and the most economical processing technology should be selected according to the characteristics of parts. Life – cycle cost analysis takes into account all costs from design to scrapping, helping to make more economical decisions.
Based on the analysis of this article, the following are specific suggestions for purchasing managers:
- Optimize Material Selection: Under the premise of meeting usage requirements, select materials with the lowest cost and the best processing performance. Consider the availability and supply cycle of materials, and avoid using scarce or difficult – to – purchase materials. Establish long – term cooperative relationships with suppliers to strive for more favorable prices and services.
- Emphasize Design Optimization: Involve the manufacturing and quality teams in the design stage and apply the DFM principle to optimize the design. Set tolerance requirements reasonably to avoid increasing costs due to unnecessary high precision. Adopt standardized designs to reduce customization requirements and lower processing costs.
- Select Appropriate Suppliers: Evaluate the technical capabilities, equipment conditions, and quality systems of suppliers. Consider the geographical location of suppliers and logistics costs, and choose the most cost – effective suppliers. Establish strategic cooperative relationships with key suppliers to jointly optimize costs and improve quality.
- Strengthen Process Control: Participate in the monitoring of suppliers’ production processes to ensure product quality. Adopt Statistical Process Control (SPC) technology to prevent the occurrence of quality problems. Establish a rapid response mechanism for quality problems to reduce the generation of non – conforming products.
- Embrace New Technologies and Innovations: Pay attention to the development of new materials, new processes, and new technologies, and evaluate their potential value for products. Consider adopting advanced technologies such as additive manufacturing and five – axis machining to improve product performance and reduce costs. Explore the application of intelligent manufacturing and Industry 4.0 technologies in the supply chain to improve overall efficiency.
The custom – machined metal parts industry will continue to develop in the direction of high precision, high efficiency, greening, and intelligentization. The following are the main future development directions:
- Material Innovation: New alloy materials and composite materials will continue to emerge, providing more choices for custom – machined metal parts. The application of functional materials and intelligent materials will expand the application fields of custom – machined metal parts. Environment – friendly surface treatment technologies will reduce environmental pollution and meet the requirements of sustainable development.
- Processing Technology Innovation: Nanoprocessing, five – axis linkage processing, and intelligent processing technologies will improve processing precision and efficiency. Additive – subtractive composite processing technology will achieve the efficient manufacturing of complex structures. Green manufacturing technologies will reduce energy consumption and environmental pollution, meeting environmental protection requirements.
- Quality Control Innovation: Advanced detection technologies such as three – dimensional optical detection and industrial CT will improve detection precision and efficiency. Digital twin and blockchain technologies will realize the quality traceability of the entire product life cycle. Artificial intelligence and big – data analysis will achieve quality prediction and optimization, preventing the occurrence of quality problems.
- Intelligent Manufacturing and Industry 4.0: Smart factories and flexible manufacturing systems will improve production efficiency and flexibility. Mass customization will balance personalized demands and large – scale production. Product servitization and performance – based contracts will change the traditional business model.
The custom – machined metal parts industry will continue to develop driven by technological innovation and market demand, providing high – quality and high – precision basic components for the global manufacturing industry. Purchasing managers should pay close attention to industry development trends, actively adopt advanced technologies and management methods, optimize supply chain management, improve product quality, and reduce costs to create greater value for enterprises.
