Full Process Analysis of Mechanical Metal Component Processing: Process Chain Design from Blank to Precision Parts

Full Process Analysis of Mechanical Metal Component Processing: Process Chain Design from Blank to Precision Parts

The processing of mechanical metal components is a complex process that transforms metal blanks into precision parts. The design of the process chain is crucial for both production efficiency and product quality. The entire process encompasses core stages such as blank preparation, machining, and surface treatment, with each step requiring precise control.

Blank preparation marks the starting point of processing. Common methods include casting, forging, and welding. Casting is suitable for forming blanks with complex structures, such as automotive engine blocks. Forging, on the other hand, can improve the metal's microstructure and enhance part strength, making it commonly used in aerospace components. Selecting an appropriate blank preparation process can reduce subsequent machining allowances and lower costs.

Machining is a critical step in giving parts their precise dimensions and shapes. Excess material is removed through processes like turning, milling, and grinding. Among them, the application of Computer Numerical Control (CNC) technology has significantly improved machining accuracy and efficiency, especially in the processing of complex curved parts. During machining, tools and cutting parameters must be selected according to the material properties. For example, when machining high-hardness alloy steel, high-performance cemented carbide tools are required, and cutting speed and feed rate need to be optimized.

The surface treatment stage aims to enhance the wear resistance, corrosion resistance, and aesthetics of parts. Processes such as electroplating, anodizing, and spraying can form protective layers on the part surface, while operations like polishing and lapping can improve surface roughness. For instance, electrolytic polishing is often used for metal components in medical devices, which not only improves the surface finish but also facilitates cleaning and disinfection.

Finally, quality inspection runs through the entire processing flow. Coordinate Measuring Machines (CMMs) and non-destructive testing methods are employed to ensure that parts meet design requirements. A reasonable process chain design requires comprehensive consideration of material properties, processing equipment, production cycle, and cost factors, enabling the efficient transformation from blanks to precision parts.