Exploration and breakthrough of the process of improving the precision of stud/standoff manufacturing

At present, the general level of stud manufacturing accuracy is constantly improving, but there are still some problems. In terms of materials, the raw material quality of some studs is uneven, and the stability of its physical properties and chemical composition is insufficient, which affects the processing accuracy of studs. For example, the hardness of some materials is not uniform, resulting in deformation and dimensional deviation during processing.

In terms of technology, the traditional manufacturing process has certain limitations in precision control. For example, the cutting parameters in the machining process are not accurate enough, and the unreasonable combination of cutting speed, feed speed and cutting depth is easy to produce uneven surface roughness and dimensional errors.

In terms of equipment, the processing equipment used by some manufacturing enterprises is aging, and the accuracy is difficult to guarantee. Moreover, the maintenance and maintenance work of the equipment is not in place, which further aggravates the problem of reduced accuracy. For example, the guide wear of the machine tool, the spindle runout and other problems will affect the manufacturing accuracy of the stud.

The lack of precision has many effects. First, during the assembly process, the stud may not fit closely with other components, resulting in loose connections and affecting the stability and safety of the entire structure. Second, for some high-precision application scenarios, such as aerospace and automotive manufacturing, insufficient precision studs may reduce product performance and reliability. In addition, the accuracy problem will increase the scrap rate, increase production costs, and reduce the market competitiveness of enterprises.

(1) advanced material selection and treatment

Choosing the right stud material for high precision manufacturing is crucial. For example, the selection of high-quality alloy steel, which has good strength, toughness and wear resistance, can effectively ensure the accuracy of the stud. For stainless steel studs, materials with a high chromium content and uniform composition should be selected to improve corrosion resistance and dimensional stability.

In terms of material pretreatment, pre-annealing treatment can eliminate the stress inside the material and improve its processability, thereby reducing deformation in subsequent processing. In addition, the oxidation layer and impurities on the surface of the material are removed by pickling, which can improve the surface quality and ensure the machining accuracy.

(2) Optimized processing technology

The optimization strategy of turning process includes reasonable selection of geometric parameters and cutting parameters of cutting tools. The use of sharp tools and appropriate cutting speed, feed rate, can effectively reduce the surface roughness, improve the cylindricity and straightness of the stud.

In the grinding process, the use of high-precision grinding machine and fine-grained grinding wheel, combined with the appropriate grinding depth and feed speed, can obtain higher surface accuracy and dimensional accuracy.

The milling process needs to pay attention to the planning of the tool path, the use of spiral or circular cutting tool to reduce the trace of the cutter and improve the shape accuracy of the stud.

(3) Precision heat treatment technology

The temperature control in the heat treatment process is accurate to ±5℃, which is the key to ensure the accuracy of the stud. High temperature may lead to coarse grain size and affect strength and dimensional stability. If the temperature is too low, the expected performance improvement can not be achieved.

The mastery of time is also important, too long holding time may lead to excessive phase change, shorten the service life of the stud; Too short can not fully improve the material properties. For example, for medium carbon steel studs, the quenching temperature is usually controlled at about 850 ° C, heat preservation for 30 minutes, followed by rapid cooling, and then tempering treatment, tempering temperature of about 550 ° C, heat preservation for 1 hour, which can effectively improve the accuracy and comprehensive performance.

(1) Automobile manufacturing

In the automotive industry, the connection studs between the engine block and the cylinder head require high precision. In the past, due to the lack of manufacturing accuracy, these studs were easy to loosen under high temperature and high pressure working environments, resulting in a loose seal and affecting engine performance. Through the use of advanced material selection and treatment technology, such as the selection of high-strength alloy steel, and fine annealing and pickling pretreatment, the internal stress and surface impurities of the material are effectively eliminated. In the machining process, the optimization of turning, grinding and milling processes, combined with precision heat treatment technology, greatly improves the dimensional accuracy and surface quality of the stud. Finally, in practical applications, the reliability and stability of the engine are significantly improved, the maintenance cost is reduced, and the service life of the engine is extended.

(2) Aerospace field

In aerospace equipment, the connecting studs of aircraft wing structure need to withstand huge loads and complex mechanical environment. In order to ensure flight safety, the accuracy of the studs is almost strict. By introducing the latest precision enhancement process, titanium alloy materials with excellent properties are first selected and subjected to rigorous pretreatment. In the processing process, the use of high-precision CNC machine tools and advanced tools, combined with carefully planned cutting paths and grinding parameters. At the same time, in the heat treatment process, high-precision temperature control equipment and strict time management are used. These measures make the accuracy of the stud reach a very high level, can maintain stable performance under extreme conditions, and provide a strong guarantee for the safe flight of the aircraft. For example, the wing connection studs of a certain type of aircraft have successfully passed a series of rigorous fatigue tests and reliability verification after undergoing a precision enhancement process, significantly improving the overall performance and safety of the aircraft.

(1) The introduction of intelligent manufacturing

With the rapid development of science and technology, intelligent manufacturing plays an increasingly important role in the improvement of stud manufacturing accuracy. Through the introduction of intelligent sensors and monitoring systems, various data in the manufacturing process can be collected in real time, such as temperature, pressure, cutting force, etc. These data can be fed back to the control system in time to achieve accurate monitoring of the manufacturing process.

Using artificial intelligence and machine learning algorithms, the collected data is analyzed and predicted. For example, possible accuracy deviations can be predicted in advance, and processing parameters such as cutting speed, feed rate, etc. can be automatically adjusted to ensure that the manufacturing accuracy of the stud is always maintained at a high level.

In addition, intelligent manufacturing also enables the self-diagnosis and maintenance of equipment. When there is a potential failure of the equipment, the system can send an alarm in time and provide corresponding maintenance suggestions to avoid the loss of accuracy caused by equipment failure.

(2) Future research direction

In the future, new material science research results are expected to be applied to stud manufacturing. For example, the emergence of nanomaterials and high-performance composites may bring new breakthroughs in the strength, wear resistance and accuracy of studs.

In terms of manufacturing processes, the continuous development of additive manufacturing technologies (such as 3D printing) may be able to provide new ideas and methods for stud manufacturing. By precisely controlling the layer-by-layer stacking of materials, it is possible to achieve high-precision manufacturing of complex shaped studs.

At the same time, interdisciplinary research will become a trend. Combining knowledge from the fields of physics, chemistry and biology, more advanced surface treatment technologies and coating materials have been developed to further improve the corrosion resistance and dimensional stability of the studs.

In addition, the concept of green manufacturing will also be more widely used in stud manufacturing. Research and development of low-energy, low-pollution manufacturing processes to achieve sustainable development goals.

The process of increasing the accuracy of stud manufacturing is of Paramount importance. It is not only related to the quality and performance of products, but also affects the development and competitiveness of related industries.

In terms of results, through a series of measures such as advanced material selection and treatment, optimized processing technology, precision heat treatment technology and the introduction of intelligent manufacturing, the manufacturing accuracy of the stud has been significantly improved. This allows the stud to play a better role in various application fields, reducing failures and safety hazards, reducing production costs, and improving production efficiency.

We are full of expectations for the future. With the continuous progress and innovation of technology, I believe that the process of improving the accuracy of stud manufacturing will continue to improve and develop. New materials, more advanced manufacturing techniques and intelligent production methods will bring more possibilities to stud manufacturing. We look forward to the future of stud manufacturing can be more accurate, efficient, environmentally friendly, to provide more high-quality products for various industries, to promote the development and progress of the entire manufacturing industry.Get a quote