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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 processing methods based on the inherent characteristics of the product itself. By doing so, you can design suitable tooling, which can significantly enhance efficiency. For instance, take the non-standard parts (produced in small batches) illustrated in Figure 1. At first glance, these parts appear quite simple. The process flow is as follows:
Unloading → Turning the outer diameter to 0.7~0.8mm, turning the inner hole to φ35mm → Turning the eccentric hole (using an eccentric setup for clamping) → Keyway operation (finding the highest point using a dial indicator, as shown in Diagram 2) → Drilling the thread bottom hole and tapping threads → Grinding the outer circle → Packaging.
However, during the process of turning the outer diameter, operators reported that the workpieces were not perfectly round. After analysis, this was primarily due to difficulties in accurately locating the highest point during the keyway operation. If the highest point could be located within ±0.01mm, the left and right deviations would remain within 0.57mm; if located within ±0.02mm, the deviations would increase to around 0.80mm, with a half-angle of approximately 5.7°. Additionally, operator errors made it challenging to maintain precise control over the highest point during keyway operations, leading to products that were prone to becoming out of round. Furthermore, the eccentric grinding tools proved difficult to handle effectively. Ultimately, it was decided to focus on the product itself for a solution. The final decision was to use the top wire hole for positioning. With a designed tooling clearance of 0.13mm, the highest point deviation was virtually eliminated.
The revised process includes: Blanking → Turning the outer diameter to 0.7~0.8mm, turning the inner hole to φ35+0.062+0mm → Positioning the outer hole for finishing → Drilling the bottom hole (a 10mm diameter hole on the outer circle, with a center distance of 19mm for the end hole, i.e., drilling at the top wire hole) → Turning the eccentric hole (using a φ8mm process hole for machining the eccentric sleeve positioning process, as shown in Figure 3) → Keyway operation (positioned by the φ8mm process hole, with the keyway tooling shown in Figure 4) → Drilling the thread bottom hole and tapping threads → Packaging.
The processing results confirmed that the finished products met all drawing requirements, doubled the processing efficiency, and eliminated any defective products. This approach demonstrated the importance of tailoring processes to the specific characteristics of each product, ultimately enhancing both quality and productivity.