一, Technical adaptability: How to fix the problems that come up when CNC machining makes a lot of different parts in small batches
1. Quick changeover ability: lower the costs of switching
In traditional mechanical machining, you have to switch products by changing fixtures. In CNC machining, you can switch products with just one click using program control. For example, while making parts for Porsche's historic models, a specialised CNC program can make any one of 52,000 different parts in just a few hours without having to rebuild the production line. This feature means that businesses don't have to pay large fees to change tools for small batch orders. Statistics show that CNC machining can cut the cost of transitioning from one small batch to another by more than 60%.
2. High accuracy and consistency: fulfil rigorous standards
Automotive parts need to be quite precise in terms of size. For example, the sealing surface roughness of brake callipers needs to be kept within Ra0.4 μ m. Using closed-loop control systems and five-axis linkage technologies, CNC machining can control things with micrometer-level accuracy. Rolls Royce uses CNC machined pieces that have to pass a 3-ton pressure test to make unique automobile models. Its accuracy and stability are far better than those of previous methods, which makes it possible to provide technical support for high-end custom production.
3. Composite processing ability: Speed up the production cycle
Modern CNC machine tools can do a lot of different things, like turning, milling, drilling, and boring. They can also do complicated part machining in just one clamping. For instance, machining automotive control arms involves drilling and milling on several surfaces, and traditional methods take several steps to finish. But five-axis CNC machine tools can cut the machining time from 8 hours to 2 hours, cut down on three clamping faults, and greatly improve production efficiency.
4. Smart integration: making production more flexible
CNC machining can develop a flexible manufacturing system (FMS) by working with digital twin technology and the industrial Internet. For instance, a certain company that makes car components has set up an intelligent CNC manufacturing line that sends order data to machine machines in real time. The system automatically plans the best way to process materials and connects with AGV carts to finish distributing them. This cuts the delivery time for orders with many different items by 40% and increases the use of equipment to 85%.
二,An example of how CNC machining is changing the way cars are made in the industry
1. Making lightweight parts for new energy cars
Die cast aluminium alloy is the best material for battery trays and motor housings in new energy cars since it is strong and doesn't rust easily. But treating aluminium alloys can cause distortion and wear on tools, and traditional methods only get a yield rate of less than 70%. Using high-speed cutting CNC technology and a precise coolant injection system, one company has boosted the processing yield of aluminium alloy battery trays to 95% and lowered the time it takes to process a single component from 45 minutes to 18 minutes.
2. Customised car parts for quick response
Car makers need to come up with creative solutions quickly since customers want their cars to look and feel unique. A high-end company has set up a CNC digital processing library and brought in more than 2,000 3D models of decorative parts for the outside of the building. The machine tool can finish the whole process, from making the program to processing the finished product, in two hours after clients make their orders. This model raises the percentage of custom orders from 5% to 30% without raising the cost of inventory.
3. Start making spare parts for after-sales service again in small batches
There is a lot of demand for spare parts for cars that are no longer made, and it costs a lot of money to start making traditional moulds again. One company uses CNC reverse engineering to scan the original parts and make a 3D model. This model directly controls the machine tool that processes the copied parts. For instance, to start making steering knuckles for a classic automobile model again, the price of one piece went down from 50,000 yuan for mould development to 800 yuan, and the time it took to deliver went down from three months to seven days.
