Turning and milling composite aluminum alloy parts precision machining outsourcing orders
Regarding the outsourced processing of aluminum alloy turning and milling composite parts, the prices quoted by the three suppliers actually differed by as much as twice. What everyone is most afraid of is that the accuracy of the product fluctuates and the delivery time is delayed again and again. In the end, the customer's production line can only stop and wait.
Therefore, when choosing an outsourcing factory, you must clearly see what their equipment is like, whether the process specifications are rigorous, and whether the details of the quotation are clear and reasonable.
Why turning-milling composite has become the first choice for aluminum alloy parts
The structure of aluminum alloy parts is relatively complex, and the wall thickness is relatively thin, so it is easy to deform after clamping. In the past, the traditional method was turning first and then milling, which required the machine to be put on twice and repositioned each time, thus accumulating errors again.
The turning and milling composite process is now used. Only this clamping is needed to process the inner hole, outer circle, end face, thread and bevel. The positioning accuracy is stable within the range of 0.01 to 0.03 mm, thus eliminating the need for intermediate turnover links.
When producing parts such as electronic connectors, automobile steering knuckles, and medical equipment drive shafts, one-shot molding is 40 percent more efficient and reduces scrap rates by half. At present, in areas with electronic factories such as Dongguan, Guangdong and Ningbo, Zhejiang, the production schedule is very busy, and these places basically all specify the use of the turning-milling combined processing technology.
The most troublesome pitfalls in outsourcing orders
On the drawing, it realizes threads, irregular-shaped holes, and bevels all in one machining process. This level of flexibility cannot be achieved by ordinary three-axis CNC machine tools, because aluminum alloys will generate a lot of heat when cutting, which will cause the blade to wear very quickly. Every time the tool is replaced, the size will deviate, reaching as much as 0.01 mm. Those parts that require precise turning directly exceed the allowable error range and are scrapped.
In terms of delivery date, the customer needs seven days to deliver the goods, but the reality is that the workshop has been strictly arranged. The size of the aluminum rods entering the factory was quite a bit too large. After an extra cut was made during the rough machining stage, it was found that there was not enough material left for the final finishing, so the entire batch of products had to be reworked.
Besides, the hardness of aluminum alloys still fluctuates between different batches. Once the material is changed to another batch, the size will deviate. When it comes to outsourced processing, you must keep an eye on the condition of the material yourself.
If the equipment is not fully equipped, don’t hard-wire it.
We are in the process of connecting with the outsourced processing business of turning and milling. Linked machining centers with more than four axes, automatic lathes, cylindrical grinders, and wire cutting equipment are all our basic configurations. For aluminum alloy parts, after precision turning, both its outer circle and internal aperture must be ground. This step is a hard requirement.
If you don't have your own grinder, the production process will be directly stuck, and you will be completely unable to continue. The workpiece can only be sent out for external processing, which will increase the overall cost again by one level.
At the inspection end, equipment such as three-dimensional coordinate measuring machines, surface roughness testing instruments, and optical projectors must be fully prepared. If conditions permit, it is best to equip yourself with a hardness tester. When customers come to the site for inspection, they have to check the relevant inspection report documents.
If specific data cannot be provided as a supporting basis, it will be difficult for the goods to pass the relevant review process of the quality assurance department after they are delivered to the destination. This not only means that the previous trip was meaningless, but also leads to the freight being deducted.
Don’t leave out surface treatment in the quote
Pickling process, electroplating process, oxidation process, sand blasting process and spray painting process, each external processing link has processing costs, and it will also generate the cost consumption of medicine. If the thickness of the oxide film on the surface of the aluminum alloy becomes too thick, the color will be uneven, causing the entire batch of products to be judged as scrap, and this situation is not an isolated phenomenon.
In order to avoid the need for rework and blame-shifting in the future, we must clearly stipulate the specific surface treatment process requirements, oxide film thickness standards and color numbers in the outsourcing order at once.
The process of quenching and quenching and tempering is mainly used to treat iron parts, while aluminum alloys are processed by solid solution and aging treatment. When quoting, be sure to list these items in the surface treatment separately, and calculate them separately from the processing fee. In this way, the customer will clearly understand, and no problems will be found during the audit, and you will not suffer.
Standard process for receiving orders with drawings and samples
The customer will send the drawings or samples, and then the craftsman will come up with a plan within two days to determine the processing route, how to clamp and fix it, and which batch of aluminum rod raw materials to use. When quoting, the processing cost, material loss, surface treatment cost, and packaging and transportation costs must be spread out separately to calculate clearly. Then when producing in small batches, try to produce twenty products first.
After the first piece has passed the three-dimensional coordinate inspection and is determined to be qualified, it must be signed and confirmed by both parties before arranging mass production plans.
The delivery date needs to be clearly written into the contract. As for how much money should be deducted each day if delivery is delayed, who will be responsible if the materials do not meet the quality standards, and which party will bear the related costs of packaging and transportation. These relevant terms must be clearly explained to the other party in advance, so that the two parties will not be in conflict with each other in subsequent links.
What is the difference between small batch and large batch
When the processing quantity is less than fifty pieces, this situation is defined as trial production, because the time required to replace the mold, debug the equipment, and perform trial cutting actually accounts for about half of the total production hours, so the final unit price will directly increase by as much as twice.
If the processing quantity can reach more than 500 pieces, then automatic lathes can be used for batch continuous production operations. In this way, the production cost of each product will be greatly reduced, so that customers are willing to sign an annual cooperation agreement to lock in long-term orders.
If you take the aluminum scraps and chips and sell them at a recycling bin, they can be worth about two or three cents per pound. If you save them for a year, you can actually add up to a lot. When you quote the price to the customer, you also include the price of the recyclable materials. This way, the customer seems to think that the price is reasonable and cost-effective, but your profits can also be preserved. This is a win-win situation that has the best of both worlds.
What kind of aluminum alloy turning and milling composite parts do you have now, and have you not found a more reliable outsourcing processing factory? Please report the specific specifications and production quantities in the comment area, so that we can help you connect with matching processing manufacturers.
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