Large Heavy Machinery Parts

In machinery fields, metal parts such as CNC machining parts, sheet metal fabrication, and CNC tube bending parts are important for the machinery body construction, the metal parts are heavy and the quantity is small,

Designing the process and establishing a strong quality control system for heavy CNC machining parts, sheet metal fabrication, and CNC tube bending parts in machinery body construction requires careful planning and precision

1. Process Design for Heavy CNC Machining Parts

A. Material Selection and Preparation

B. Machining Process

Machine Selection

Fixture Design

Toolpath Optimization

Coolant System: Use high-performance coolant systems to maintain temperature control, ensuring dimensional accuracy.

C. Finishing and Post-Machining

Deburring and Surface Treatment

Dimensional Inspection

2. Process Design for Sheet Metal Fabrication

A. Design and Prototyping

B. Cutting and Forming

Laser Cutting: Utilize high-precision laser cutting or plasma cutting machines for intricate designs and tight tolerances.

Bending Process: For forming operations, CNC press brakes should be used for accurate and consistent bends, particularly for heavy sheet metal parts.

Welding and Assembly: If assembly is needed, incorporate precise welding techniques like MIG or TIG welding to ensure strong joints without deforming the parts.

C. Finishing and Assembly

Surface Treatment: Use techniques such as powder coating or galvanization to enhance durability and corrosion resistance.

Assembly: If parts need to be assembled, perform checks for alignment, fastening strength, and functionality.

3. Process Design for CNC Tube Bending Parts

A. Material Selection and Design

B. CNC Bending Process

Tooling Setup: Use the appropriate tooling, including mandrels and wipers, to support the tube and prevent deformations during bending.

Bending Simulation: Use CNC simulation software to verify the bend sequence and check for potential collisions or excessive spring-back.

Bend Angle Verification: Ensure that the CNC machine can achieve accurate bend angles without overworking the material.

C. Post-Bending

Dimensional Checks: Verify angles, radii, and overall tube geometry with specialized measuring tools to ensure adherence to design specifications.

Welding and Joining: Where necessary, ensure that welded joints are inspected for defects like cracks or porosity.

4. Quality Control Process

A. Inspection Protocols

First Article Inspection (FAI): For new parts, conduct a detailed inspection of the first manufactured part to verify all dimensions, tolerances, and finishes.

In-Process Inspection: During manufacturing, regular checks should be performed at critical stages, such as after CNC machining or bending, using tools like CMM machines, calipers, and laser scanners.

Final Inspection: Perform a full inspection of each finished part for dimensional accuracy, surface finish, and compliance with engineering drawings and specifications.

B. Testing Methods

Non-Destructive Testing (NDT): Use methods like ultrasonic testing or magnetic particle testing to check for internal cracks or defects without damaging the part.

Destructive Testing: For critical applications, sample parts may undergo destructive testing to measure material properties like tensile strength and fatigue limits.

C. Tolerances and Standards

Tight Tolerances: For heavy CNC machining, ensure tolerances as tight as +/- 0.005mm, based on customer requirements.

International Standards: Follow ISO 9001 or IATF 16949 standards for automotive components, ensuring consistent quality and traceability.

Effective process design and quality control for heavy CNC machining parts, sheet metal fabrication, and CNC tube bending parts involve a combination of precise machine setup, continuous inspection, and strict adherence to industry standards. By following the outlined steps, you ensure that your manufacturing processes produce high-quality parts consistently, meeting your customers' exact requirements while maintaining cost-effectiveness and efficiency.