Project:
Since receiving the customer inquiry, we have made a detailed investigation and discussion.
No matter the precision of parts or the tolerance after small die assembly, the tolerance of key dimensions of parts is controlled within ±0.002mm, and the tolerance after assembly is controlled within ±0.005mm.
To achieve the tolerance, it is necessary to make comprehensive consideration in terms of materials, process arrangement, and the use of tools and machine tools.
Processing Highlights:
Challenge 1:
Material Selection:
1. To achieve exquisite appearance and uniform color difference, we make the surface to be anodized. Common 6061 has many impurities, which affect the appearance of anodization and is easy leading to material spots, so national standard materials purchasing is necessary.
2. It is easy to exceed the tolerance due to stress and deformation in 6061-T6 machining. Therefore, purchasing 6061-T651 to ensure that the product is not deformed, to achieve high accuracy in dimension.
Challenge 2:
Tool Selection
1.We choose Sandvik cutting tools to ensure product smoothness and accuracy.
2. It is easy to exceed the tolerance due to stress and deformation in 6061-T6 machining. Therefore, purchasing 6061-T651 to ensure that the product is not deformed, to achieve high accuracy in dimension.
Challenge 3:
4-axis CNC machining: Because it has 6-sided body shape, precision hole angle tolerance of each surface is required to be accurate, and 6-sided structure and angle tolerance are machined by Japanese Sankyo 4-axis turntable.
A: Deep hole processing: the minimum processing radius is R5 and depth 75mm. It requires high rigidity of the tools. We select Sandvik alloy coated milling cutter, matching perfect processing design, to ensure the accuracy and appearance of deep holes.
B: Deburring of cross holes: deburring with customized inner hole reverse chamfering knife.
