Industry(s): Automotive
Application(s): Engine Components, Crankshaft alignment and connection
Processes: CNC Machining, Heat Treatment, Laser Marking, Coating, Inspection and Testing
Project Overview
Aerostar Global Manufacturing was approached by a client in the automotive industry to manufacture a critical component: the Adapter, Crankshaft. This part is essential for ensuring the precise alignment and connection between the engine crankshaft and other engine components, playing a crucial role in the overall performance and reliability of the engine.
Objectives
The primary objectives of this project were to:
- Deliver the final product within the agreed timeframe while maintaining cost efficiency.
- Manufacture the Adapter, Crankshaft with the highest precision to meet stringent industry standards.
- Ensure the component met the hardness specifications required for high-performance engine applications.
Challenges
One of the main challenges faced during this project was meeting the strict hardness requirements (28-35 HRC) while maintaining dimensional accuracy. Additionally, the machining of the Adapter, Crankshaft required a multi-step process that included CNC turning, milling, and hard turning, which introduced complexities in maintaining the consistency of the final product.
Solution
Aerostar Global Manufacturing utilized its state-of-the-art CNC machining centers and expertise in heat treatment processes to address the challenges. The team developed a detailed process flow that included rough turning, milling, heat treatment, and hard turning, ensuring each step was meticulously monitored for quality.
Quality, Inspection, and Measurement Steps
- Receiving Inspection: Upon receiving the raw material, it was inspected for compliance with the required specifications.
- In-Process Inspections:
o During CNC machining, major characteristics such as diameters and heights were inspected using variable gauges and CMMs (Coordinate Measuring Machines).
o Surface finish and runouts were inspected visually and with attribute gauges. - Heat Treatment Verification: The hardness of the part was verified after the heat treatment process to ensure it met the specified range of 28-35 HRC.
- Final Inspection: Before shipment, the Adapter, Crankshaft underwent a final inspection, including laser marking for traceability and a comprehensive check against all specified dimensions and tolerances.
- SPC (Statistical Process Control) Data Collection: To evaluate, monitor and control the process (Continuous Improvement).
These steps often intertwine with manufacturing steps to ensure a feedback loop exists between the production process and quality controls. Discrepancies detected during quality checks can lead to modifications in the manufacturing steps.
Manufacturing Steps
- Material Procurement: The process began with the procurement of raw steel forgings, which were inspected for quality upon receipt.
- CNC Rough Turning (OP 10-20): The Adapter, Crankshaft was rough turned on a CNC lathe, leaving material for hard turning post-heat treatment.
- CNC Milling (OP 30): The part was then milled to produce the finished mounting hole pattern, ensuring precise alignment.
- Heat Treatment (OP 40): The part underwent heat treatment to achieve the required hardness of 28-35 HRC.
- CNC Hard Turning (OP 50-60): Post-heat treatment, the part was hard turned to achieve the final dimensions, maintaining the necessary hardened material.
- Laser Marking (OP 80): The part was laser etched with 2-D Data Matrix Barcode, Human Readable part number, and country of origin to ensure precise identification and traceability of parts.
- Coating and Storage (OP 100): The Adapter, Crankshaft was coated with rust prevention (RP) material and stored in finished goods storage, ready for shipment.
- Final Inspection and Shipment (OP 200): Before shipment, the part underwent a GP12 process to ensure it adhered to all customer requirements.
The steps in manufacturing are often revisited based on the results of the quality checks. For example, if an intermediate inspection detects an issue, the material may go back to the assembly stage.
Manufactured Components and Parts
- Adapter, Crankshaft: The primary component manufactured for this project, designed to provide a robust connection between the engine crankshaft and other critical engine components.
- Mounting Hole Pattern: Precisely milled to ensure accurate alignment during engine assembly.
