Process And Structure Analysis Of Parts, Preparation Of Processing Procedures, And A Comprehensive Introduction To The Entire Processing Process

Process and structure analysis of parts, preparation of processing procedures, and a comprehensive introduction to the entire processing process

Just understanding mechanical drawings is a basic skill, but the key to determining whether a part can be processed and the cost lies in the depth of your analysis of the part process and part structure. Many people rush to the machine tool after getting the drawings. As a result, either the tool cannot be inserted, or it is deformed and scrapped after processing. This is a typical situation where process analysis is not done properly.

Three elements of part structure analysis

After getting a part drawing, the first thing to do is not to check the dimensional tolerance, but to examine its overall shape. Structural analysis mainly focuses on how to ensure quality in three aspects of non-standard parts processing , namely shape characteristics, size and material properties. For example, there is a slender shaft whose length is measured to be more than 20 times greater than the diameter. In this case, the problem of tool deflection and vibration during processing must be considered.

Tool selection and cutting parameters will be directly affected by material properties. The cutting performance of No. 45 steel and 304 stainless steel is very different. Stainless steel has problems such as sticking to the knife and extremely serious hardening. If it is not identified early in the structural analysis stage, it will be too late to make adjustments during processing. When we processed a batch of medical device parts in 2025, it was precisely because we identified the processing characteristics of 316L material early that we avoided batch scrapping.

Process review needs to be intervened in advance

When drawing, many designers only consider the function, but do not consider the difficulty of processing. It is like setting a right angle at the bottom of a deep hole, making it impossible for the tool to clear the root, or designing an undercut groove that is too small on the inner wall, making it impossible for standard tools to enter. If these problems are discovered during the process analysis stage, they can be fed back to the design for modification.

During the part structure analysis stage, excellent craftsmen will give optimization suggestions. For example, a right angle is replaced by an R angle so that the tool can achieve a natural transition; or an overly deep hole is processed in sections and a process hole is added in the middle. Such changes will not affect the use of parts. The process and structural analysis of the parts, the preparation of processing process procedures, and a comprehensive introduction to the entire processing process can significantly reduce the difficulty and cost of processing.

The core logic of process route design

The design of the process route is not simply a simple arrangement of the processes, but requires a comprehensive and comprehensive consideration of benchmark selection, rough and fine separation, and heat treatment arrangements. The datum first is a principle that must be followed. First, the positioning datum surface must be processed, and then other parts can be processed with the help of this datum. Roughing and finishing must be separated, and sufficient time must be reserved to allow stress to be relieved.

For example, if there is a box-like part, the bottom surface as a reference is processed first, and then the top surface and sides are processed. After rough machining, aging treatment is required to eliminate internal stress, and then it is taken to the machine tool for finishing. In 2024, we produced an object such as a hydraulic valve block. Because rough machining and finishing machining were carried out continuously, deformation occurred half a month after the finishing machining was completed, and oil leakage occurred on the sealing surface.

Practical points for determining process parameters

Process parameters include cutting speed, feed rate, and cutting depth . How to ensure quality when processing non-standard parts ? These are not randomly extracted from manuals. The overall judgment must be based on machine tool power, tool performance, workpiece material and clamping method. For thin-walled parts with poor rigidity, the cutting depth should be small, the rotation speed should be high, and the feed should be fast to prevent deformation caused by excessive cutting force.

The choice of cutting tools is also very critical. Coated carbide cutting tools should be used for processing steel . How to ensure quality when processing non-standard parts ? Diamond cutting tools are required for processing aluminum alloys. Ceramic cutting tools can be used when processing high-temperature alloys. If the wrong cutting tool is selected, either the efficiency will be low or the surface quality will be poor. We have actually measured that the processing time of the same part can be reduced by 30% when the correct cutting tool is selected.

Specifications for preparation of process documents

The legal document that guides production operations is the process specification. This document must be clear and unambiguous. It covers the process number and process name, as well as the specific content of the process, plus the relevant model of the equipment, including the specific and clear specifications and dimensions corresponding to the tool, including the specific parameters of related cutting. Settings cover the specific requirements of the inspection process, including the quota of working hours required to complete the process; each item must be written in extremely specific terms, and there must be no vague descriptions. For example, "acute corners should be chamfered into blunt" is not as accurate as "carrying out C0.5 chamfering operation."

The inspection requirements need to clarify the measurement method, whether it is pass-and-stop gauge inspection or three-dimensional measurement, the measurement tools must be clear, and the judgment standards must be clear. What are the CPK value requirements for critical dimensions and what is the sampling inspection ratio? Write these clearly so that the quality inspection personnel will know how to implement them, thereby avoiding nonsense.

Quantitative indicators for process evaluation

The quality of a process solution needs to consider three indicators, namely processing difficulty, accuracy stability and processing efficiency. Among them, the processing difficulty can be quantified by the number of clampings and the number of special tools; the accuracy and stability are judged by the scrap rate and size distribution; the processing efficiency is measured by the single piece working hours and machine tool utilization.

Process evaluation does not end when the accounts are settled, but requires continuous improvement. Last year, it took 2 hours to process the same part. This year, with the help of optimized cutting parameters and tool paths, the processing time was reduced to 1.5 hours. This is process progress. We will review the process data every month to find points that can be optimized.

When you usually conduct process analysis, is the structural analysis or the parameter determination the most troublesome? You are welcome to leave words in the comment area for communication. If you find the article useful, don’t forget to like and share it so that more peers can see it.