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Finding a processing method from the characteristics of the product can do more with less.
When manufacturing product components, it’s often beneficial to consider the inherent characteristics of the product itself to determine the most efficient processing method. Designing suitable tooling based on these traits can sometimes yield excellent results with minimal effort. Take the non-standard parts (produced in small batches) illustrated in Figure 1, which might seem straightforward at first glance. The process flow is as follows:
Unloading → Turning the outer diameter to 0.7-0.8mm and the inner hole to φ35mm → Turning the eccentric hole (using an eccentrically set tool clamp) → Pulling the key (aligning the highest point of the dial indicator, see rear pull key diagram in Figure 2) → Drilling the thread bottom hole and tapping → Grinding the outer circle → Packaging.
However, during the outer round machining process, operators reported that the workpiece was not perfectly round. After analysis, this issue was primarily due to the difficulty in accurately locating the highest point when pulling the key. If the highest point could be located within 0.01mm, the left and right deviations would be within 0.57mm; if located within 0.02mm, the deviation would increase to around 0.80mm, with a half-angle of approximately 5.7°. This, combined with operational errors, made it challenging to precisely control the key-pulling process, resulting in products that were prone to becoming misshapen during grinding. Additionally, the eccentric grinding tooling proved difficult to operate effectively. Ultimately, it was decided to address the issue by focusing on the product itself. The solution involved using the top wire hole for final positioning, with a tooling clearance designed at 0.13mm, ensuring virtually no deviation in the highest point.
The revised process is as follows: Blanking → Turning the outer diameter to 0.7-0.8mm and the inner hole to φ35+0.062+0mm → Positioning the outer hole to the finished product using the top wire hole → Drilling the bottom hole (creating a φ8+0.10+0mm hole 10mm from the outer circle, with a center-to-center distance of 19mm) → Turning the eccentric hole (positioned using a φ8mm process hole and eccentric sleeve, as shown in Figure 3) → Pulling the key (positioned using the φ8mm process hole, with the pull key tooling shown in Figure 4) → Drilling the thread bottom hole and tapping → Packaging.
The processing outcomes confirmed that the products met the drawing specifications, with significantly improved processing efficiency and no defective items produced. This adjustment not only streamlined the workflow but also enhanced product quality, demonstrating the importance of adapting processes to the specific characteristics of each product.