Classification and Processing Requirements for Automotive Components

Powertrain components
Engine components:

Cylinder block/cylinder head: Materials are predominantly cast iron or aluminium alloy, requiring high dimensional stability and precision of sealing surfaces.

Crankshaft/Camshaft: High fatigue strength materials, requiring strict control of roundness, coaxiality and surface hardness.

Connecting rod: Demands exceptional symmetry, with weight grouping accuracy within ±2 grams.

Transmission components:

Gears: Precision grade ISO 6-8, critical for noise control

Housing: Machining of complex internal cavities, requiring multi-axis coordination

Clutch components: Special treatment of friction surfaces

Chassis and Suspension System
Steering knuckle: Safety component, 100% non-destructive testing

Brake discs: Heat dissipation performance is equally as important as dynamic balance.

Control arm: Welding and machining composite process

Bodywork and interior components
Mould manufacturing: Large mould precision 0.02/1000mm

Decorative elements: Mirror finish and texture consistency

Part Two: Detailed Explanation of Core Processing Technologies and Equipment
1. High-speed machining technology(HSM)
Technical Features:

Spindle speed: 15,000–40,000 RPM

High feed rate (10–50 m/min)

Shallow-cut, high-feed strategy

Applications in automotive manufacturing:

Machining of intake and exhaust ports in aluminium alloy cylinder heads

High-efficiency rough machining of mould cavities

Composite component machining

Typical equipment:

DMU Series Five-Axis Machining Centres

Mazak FF Series High-Speed Machine Tools

Fitted with HSK-A63 or CAPTO toolholders

2. Composite processing technology
Turning and milling combined machining:

A single machine capable of turning, milling, drilling and tapping

Reduce the number of set-ups and improve positioning accuracy

Swiss-type turning and milling centre for precision shaft components

Case Study: Machining of Transmission Output Shaft
Traditional craftsmanship: 6 pieces of equipment, 8 set-ups
Composite machining: one machine, two set-ups
Effect: Machining time reduced by 651 hours, precision improved by 301 hours.

3. Flexible Manufacturing System (FMS)
System Composition:

4–10 machining centres

Automatic Pallet Changer (APC)

Central tool magazine (120–400 tools)

Automated logistics system

Applications in automotive component factories:

Multi-variety, small-to-medium batch production

Engine variant parts co-line production

24-hour unmanned operation

Return on Investment Data:

Initial investment: US$2 million to US$5 million

Staff reduction: 50–70%

Equipment utilisation rate: increased from 45% to 85%

Payback period: 2–3 years

4. Specialised machine tools and production lines
Engine block production line:

Process: Rough machining → Semi-finishing → Finishing → Cleaning → Inspection

Cycle time: 3-5 minutes per item

Annual production capacity: 200,000–300,000 units

Key equipment: Dedicated machine tools + machining centres

Typical configuration:

Rough machining: Three-sided milling specialised machine

Hole machining: Multi-spindle drilling and tapping centre

Finishing: Horizontal machining centre

Online measurement: pneumatic gauge + visual inspection

Part Three: The Transformation in Manufacturing Brought About by New Energy Vehicles
Machining of core components for electric motors
Rotor shaft:

Material: Electrical steel laminations + shaft assembly

Key requirements: Dynamic balance G2.5 grade, journal roundness ≤5μm

Special Process: Finishing of Permanent Magnets After Assembly

Stator housing:

Cooling channel machining: Deep hole drilling + seal testing

Accuracy requirement: Bearing position coaxiality ≤ 0.01 mm

New Material: Machining of Aluminium-Silicon Alloy Die-Castings

Battery system components
Battery tray:

Dimensions: up to 2000 × 1500 mm

Material: Aluminium alloy extruded profiles

Challenge: High flatness (0.2/1000mm), lightweight structure

Solution: Five-axis machining centre + vacuum fixture + deformation compensation algorithm

Module end plate:

Batch size: in the millions

Process: Stamping + Precision Machining Composite

Efficiency requirement: Single-piece processing time ≤ 45 seconds

Part IV: Quality Assurance Systems and Testing Technology
Special Requirements for the Automotive Industry
Process Audit Criteria:

VDA 6.3 (German Association of the Automotive Industry standard)

IATF 16949 Quality Management System

Customer Specific Requirements (CSR)

Full-size inspection:

Frequency: First item + per shift + post-change

Method: Online inspection + offline coordinate measuring machine

Data Management: Real-time SPC Monitoring

Application of Advanced Detection Equipment
Online measurement system:

Machine tool integrated probe: Critical dimension inspection after each operation

Laser Scanning: Rapid Detection of Geometric Tolerances

Visual Inspection System: Automated Surface Defect Detection

Case Study: Crankshaft Production Line Inspection Solution:

Online measurement for machining centres: Real-time compensation for journal diameter

Dedicated measuring machine: All dimensions + roundness + cylindricity

Comprehensive Measuring Instrument: Dynamic Balancing + Deflection

Surface roughness tester: Rz ≤ 2 μm control

Part V: Cost Control and Efficiency Enhancement Strategies
Optimisation of Tool Management
Characteristics of tool consumption in the automotive industry:

Annual tooling costs account for 8-15% of manufacturing costs.

Cemented carbide tools account for over 70% of TP3T applications.

Utilisation rate of coated cutting tools: 90%

Cost-reduction and efficiency-enhancement measures:

Standardisation: Reducing tool variety by 30-50% TP3T

Lifetime Management: From Fixed Lifetimes to Monitoring-Based Replacement

Regrinding Programme: Precision cutting tools can be reground 3-5 times

Supplier Management: VMI (Vendor-Managed Inventory)

Pathways to Enhancing Production Efficiency
OEE (Overall Equipment Effectiveness) Enhancement:

Automotive Industry Benchmark: OEE ≥ 85% TP3T

Key improvements: Reducing changeover time, implementing preventive maintenance

Single-Minute Exchange of Dies (SMED) Application:

External Operations Standardisation: Fixture and Tooling Pre-Adjustment

Internal Operations Simplification: Hydraulic Quick-Change System

Target: Changeover time for large components ≤ 15 minutes

Part Six: In-Depth Analysis of Typical Cases
Case Study 1: Engine Cylinder Head Production Line Upgrade for a German Automotive Brand
Background:

Product: Four-cylinder aluminium alloy cylinder head

Annual production: 400,000 units

Original production line: Commissioned in 2010, with insufficient efficiency.

Upgrade Plan:

Equipment Upgrade: Introduction of 8 dual-spindle machining centres

Automation: Robotic loading/unloading + Automated Guided Vehicle logistics

Intelligent: Tool life monitoring + adaptive machining

Quality Enhancement: Online Measurement of Critical Dimensions for 100%

Investment and Return:

Total investment: €18 million

Production efficiency: increased by 401%

Staff reduction: from 32 to 12 personnel

Quality Enhancement: Scrap rate reduced from 1.21% to 0.31%

ROI: 3.2 years

Case Study Two: Battery Tray Manufacturing for New Energy Vehicle Manufacturers
Challenge:

Large dimensions: 1860 × 1450 mm

High precision: Flatness 0.3mm, hole position ±0.05mm

Large production volume: Initial annual output of 150,000 sets

Lösung:

Process Innovation:

Integrated casting + five-axis precision machining

Vacuum clamping reduces deformation

Laser Marking Traceability System

Production Line Design:

Four parallel production lines

Cycle time: 18 minutes per unit

Automation level: 85%

Quality Control:

Three measurements per item (after rough machining, after finish machining, final)

Leak Test 100%

Three-coordinate spot check 10%

Results:

Yield rate: Stable at 99.21% or above

Cost: 251 TP3T lower than the resistance welding solution

Lightweighting: Weight reduction of 15%

Case Study Three: Mass Production of Transmission Gears
Technical challenges:

Accuracy: ISO Grade 6-7

Noise: ≤68 decibels

Consistency: CPK ≥ 1.67

Advanced Process Combination:

Soft machining: Gear hobbing/Gear broaching

Heat treatment: carburising and quenching

Hard machining:

Worm gear grinding (high efficiency)

Forming grinding wheel gear grinding (high precision)

Hobbing (to improve surface finish)

Innovative Features:

Online measurement closed-loop control

Integrated pre- and post-heat treatment processing

Intelligent Sorting System

Production data:

Single-piece processing time: 3.5 minutes

Daily output: 3,500 units

Tool life: 4,000 pieces per dressing

Quality costs: 1.81% of total costs

Part Seven: Future Trends and Response Strategies
Technological Development Trends
Processing technology:

Ultrasonic vibration-assisted machining: Enhancing machining efficiency for hard and brittle materials

Laser hybrid processing: integrated welding, heat treatment and cleaning

Green Manufacturing: Dry/Minimum Quantity Lubrication Machining

Equipment Development:

More direct-drive electric spindles

Linear motor adoption

Applications of Carbon Fibre Reinforced Structural Components

Business Model Transformation
From manufacturer to solution provider:

Provide a complete solution encompassing parts, assembly and inspection.

Participate in client early design

Shared Quality Data Platform

Digital services:

Remote Operations and Maintenance with Predictive Maintenance

Cloud-based optimisation of machining parameters

Virtual debugging reduces downtime

Key Focus Areas for Talent Development
New competency requirements:

Mechatronics commissioning capability

Data analysis and optimisation capabilities

Automation system integration capability

Mastery of New Materials and New Processes

Training System Recommendations:

Targeted training through university-industry collaboration

Establishment of an online learning platform

Regularisation of overseas technical exchanges

Conclusion: The Path to Survival and Development in Automotive Component Manufacturing
The automotive components manufacturing sector is undergoing a period of unprecedented transformation. Demand for traditional internal combustion engine components is declining, while demand for electrified and intelligent components is surging. Successful enterprises must:

Strike a balance between three elements:

Balancing flexibility and specialisation: meeting diverse product requirements while maintaining cost competitiveness

Balancing Automation and Intelligence: First Achieve Process Automation, Then Advance Decision Intelligence

Balancing Quality and Cost: Controlling Costs While Maintaining the Automotive Industry’s Stringent Quality Standards

Establish four core capabilities:

Rapid response capability: Addressing the challenge of accelerating model iteration

Technology integration capability: Rapidly transforming new technologies into productive capacity

Quality control capability: Establishing a fully traceable quality system throughout the entire process

Cost control capability: Maintaining price competitiveness through lean production and economies of scale

For small and medium-sized component manufacturers, the survival strategy should be to specialise in a niche segment to achieve excellence, establish deep integration with vehicle manufacturers, and moderately expand capability boundaries while maintaining specialisation. For large enterprises, the focus should be on establishing technological platforms to enable parallel development across multiple technical pathways.

Regardless of scale, digital transformation is no longer optional but imperative. From digital blueprints to digital factories, from data collection to data-driven decision-making, this path demands substantial investment yet promises equally substantial returns. Within the automotive sector – a domain characterised by its technological, capital and talent intensity – only those who persistently innovate will secure the future.