| Name | Detail |
|---|---|
| Product | Aluminum CNC Machined Parts |
| Material | 6061 Aluminum |
| Order Quatity | 50 pcs |
| Tolerance | 0.05mm |
| Technology | CNC Machining |
| Location | US |
| Application | Industry |
RPS customized a complex-structured CNC-machined part—a precision base for supporting and securing internal components of industrial equipment—for an industrial equipment manufacturer. This part features a unique triangular geometry, incorporating multiple holes and threaded holes of varying sizes, as well as internal cavities for weight reduction. Its design requirements are extremely high: it not only demands precise dimensional and positional tolerances but also must ensure sufficient structural strength and lightweight properties.
Leveraging our profound experience in complex geometry machining, we provided the customer with a comprehensive solution ranging from material analysis to multi-axis CNC machining and specialized surface treatment, ensuring the high performance and reliability of the final product.
Manufacturing Challenges & RPS Solutions
- Challenge: The part has a complex structure, featuring a unique triangular geometry, multiple holes and threaded holes of different sizes, and internal cavities for weight reduction. These features pose challenges to machining accuracy and efficiency.
- Solution: We selected 6061 aluminum alloy as the material, which boasts an excellent strength-to-weight ratio and good machinability. We utilized multi-axis CNC machining centers to complete the machining of most features of the part in a single setup. This approach significantly improved machining efficiency and minimized cumulative errors caused by multiple setups. We precisely controlled the tool path to ensure that the positioning accuracy and perpendicularity of all holes met the customer’s required 0.01mm-level tolerance. Particularly for internal threaded holes, we adopted advanced tapping technology to ensure thread integrity and strength.
Shot Peening
- Challenge: The part surface needs to have a uniform, fine matte texture while requiring enhanced surface hardness and fatigue strength.
- Solution: After completing CNC milling, we performed shot peening on the part. This process involves high-speed blasting of tiny media (such as glass beads or metal shot) onto the part surface, creating a layer of uniform micro-depressions. This not only achieves a unique matte effect but, more importantly, introduces compressive stress on the part surface—effectively improving its fatigue resistance and wear resistance.
Natural Color Anodizing
- Challenge: The part needs to have good corrosion resistance and an attractive surface while retaining the original metallic color of the aluminum alloy.
- Solution: Following shot peening, we conducted natural color anodizing (or clear anodizing) on the part. This electrochemical process forms a dense, hard oxide film on the aluminum alloy surface. This film not only significantly enhances the part’s corrosion resistance and wear resistance but also preserves the characteristic silvery-white metallic luster of 6061 aluminum alloy, giving it a more professional and refined appearance.
Outcomes & Value
Through RPS’s precision CNC machining services, we successfully manufactured this high-performance precision base for the customer. With its precise dimensions, lightweight structure, durable surface, and excellent machining quality, the part perfectly met all the customer’s technical requirements in industrial equipment manufacturing and received high praise from the customer.
This project once again demonstrates RPS’s core competitiveness in handling complex geometric structures and high-precision metal CNC machining. We are capable of providing professional manufacturing solutions based on the customer’s unique designs and accurately translating every detail on the drawings into high-quality physical products.
