Machining Equipment:
1.Lathe:
Lathes are primarily used for machining shafts, disks, sleeves, and other workpieces with rotating surfaces, widely used in mechanical manufacturing. (Accuracy up to 0.01mm)
2.Milling Machine:
It can machine planes, grooves, various curves, gears, and even complex profiles. (Accuracy up to 0.05mm)
3.Grinding Machine:
Used for grinding the surface of workpieces, mostly with high-speed rotating grinding wheels. Some use oilstones, sand belts, or other abrasives for precision work. (Accuracy up to 0.005mm, 0.002mm for small parts)
4.Fitting:
Includes filing, sawing, marking, drilling, tapping, reaming, scraping, grinding, correcting, bending, and riveting.
5.CNC Lathe:
Primarily for mass-produced, high-precision parts. (Accuracy up to 0.01mm)
6.CNC Milling Machine:
Mainly used for mass-produced, high-precision, complex, and large parts. (Accuracy up to 0.01mm)
7.Wire Cutting:
Uses brass or molybdenum wire for high-precision machining, especially for fine holes and slots. (Precision up to 0.003mm for slow wire, 0.02mm for medium wire)
8.EDM (Electrical Discharge Machining):
Ideal for cutting materials and shapes difficult to machine conventionally, such as grooves, corners, and irregular holes in molds. Produces smooth surfaces without burrs or tool marks. (Accuracy up to 0.005mm)
Process Flow:
The machining process specification is one of the process documents that specifies the process and operation methods of machining parts. It is written in a prescribed format to guide production under specific conditions.
The machining process of a part consists of various operations, each divided into installations, workstations, steps, and tool paths. The number of operations in a process is determined by the complexity of the part, accuracy requirements, and production type.
Process Knowledge:
- 1.Holes with an accuracy of less than 0.05 cannot be milled conventionally and require CNC machining. Through-holes can also be done by wire cutting.
- Precision holes (through-holes) after quenching require wire cutting; blind holes need rough machining before quenching and precision machining after. Non-precision holes can be machined in place before quenching (leaving a quenching allowance of 0.2mm on one side).
- Slots narrower than 2mm require wire cutting; slots with depths of 3-4mm also require wire cutting.
- For quenched parts, a minimum allowance of 0.4mm should be left after rough machining, while for non-quenched parts, the allowance should be 0.2mm.
- Plating thickness is generally 0.005–0.008, and machining should be based on pre-plating dimensions.
Process Time:
Standard time is the time required to complete a process, serving as a productivity indicator. It enables production scheduling, cost accounting, equipment and personnel planning, and production area layout. Therefore, standard time is an integral part of the process specification.
Standard time should be determined based on the production technology conditions of the enterprise, achievable by most workers with effort, with some advanced workers exceeding it. It is periodically revised with the improvement of production technology conditions to maintain an average advanced level.
Standard time is typically determined by a combination of process engineers and workers, based on past experience, relevant technical data, and comparative analysis of similar products or processes. It can also be determined through measurement and analysis of actual operation time.
Process time = (setup time + basic time):
Setup time is the time spent by workers familiarizing themselves with process documents, obtaining raw materials, installing fixtures, adjusting machinery, and dismantling fixtures, etc. Calculation method: Estimation based on experience.
Basic time is the time consumed in metal cutting.
Common Cost Calculation Methods:
Cost of Machined Parts = Material Cost + Machining Fee
Equipment Category Cost = Machined Part Material Cost + Machining Fee + Purchased Item Cost + Assembly and Debugging Fee + Design Fee
Material Cost = Weight (Density * Volume) * Unit Price ($/kg)
Machining Fee = Process Time * Unit Price ($/hour)
Imported Purchased Item Cost = Purchase Price / Exchange Rate
Domestic Purchased Item Cost = Supplier Quote
Design Fee = Work Hours * Unit Price ($/hour)
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