Industry(s): Automotive
Application(s): Driveshafts, Gear Systems, Mechanical Assemblies
Processes: Precision CNC Machining, Surface Finishing, Inspection Services
Aerostar Global Manufacturing specializes in precision engineered parts and components for industries like automotive, aerospace, and heavy machinery. The Spider component is a key part in assemblies that require reliable load distribution and rotational stability. This case study covers the Spider’s manufacturing process, material marking, cleaning, and inspection steps, ensuring it meets the strict quality requirements of modern mechanical systems.
Precision CNC Machining
Project Overview
Aerostar was tasked with producing Spider components for a client in the automotive sector, where performance under high-stress conditions is critical. The project demanded rapid delivery while maintaining the component’s durability and precision.
Objectives
- Achieve High Precision: Manufacturing to tight tolerances for accurate load bearing and fitment.
- Durability Under Stress: Ensure the Spider can withstand operational loads and wear.
- Efficient Production: Balance cost efficiency with high quality outputs.
Background
The Spider component is crucial in distributing loads evenly across mechanical systems, enhancing stability and reducing stress on individual parts. Commonly used in automotive driveshafts and gear systems, it plays a vital role in ensuring mechanical assemblies operate smoothly and reliably under varying loads.
Quality, Inspection, and Measurement Steps
- Receiving and Initial Inspections: Upon receiving the raw material, an inspection is conducted to verify the material specifications. Key properties like hardness and chemical composition are checked to ensure they meet the requirements.
- Material Marking: Each Spider is marked with a 2D data matrix for traceability. The matrix includes information such as part number, serial number, and production date, ensuring complete tracking through the production lifecycle.
- Cleaning: Before marking, a laser cleaning process is applied to ensure that the surface is free from contaminants, allowing for accurate marking and reducing corrosion risk.
- Dimensional Inspection: The Spider undergoes multiple dimensional checks using CMM tools to ensure that all critical dimensions align with the design specifications.
- Statistical Process Control (SPC) Data Analysis: SPC is reviewed and calculated to control the quality of the product and processes. Monitoring the statistical data helps quantify the defect rate percentage within the manufacturing process to generate continuous improvement efforts.
- Non-Destructive Testing: Ultrasonic and radiographic tests are used to check for any hidden flaws within the material, ensuring structural integrity without damaging the part.
- Final Surface Finish and Coating: All finished surfaces are inspected for smoothness, and protective coatings are applied to protect against wear and corrosion, extending the component’s operational life.
- Technical Cleanliness: The Spider is inspected for cleanliness based on GEN003 Level 2 standards, ensuring that wetted surfaces meet required cleanliness levels. This requirement safeguards against all foreign debris from contaminating and causing premature failure in the transmission system.
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
- Design and Simulation: The Spider is designed using CAD tools, with simulations performed to optimize its performance under load.
- Forging and Heat Treatment: The Spider is forged and undergoes normalizing as per ET-TF-01 specifications to improve its grain structure and durability. The heat treatment follows to achieve a surface hardness of 58-62 HRC, with an effective case depth of 0.8-1.1 mm.
- CNC Machining: The part is machined to precision specifications, ensuring that each component matches the design tolerances.
- Surface Treatment: Protective coatings are applied to resist wear and corrosion, improving the Spider’s longevity in high-stress environments.
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
In addition to the Spider, Aerostar Global Manufacturing produces a wide range of critical components:
- Engine Mounts: Designed to absorb and reduce vibrations in engine assemblies.
- Transmission Components: Key parts that ensure smooth power transfer in automotive and industrial transmissions.
- Couplings: Essential for connecting rotating shafts, ensuring smooth torque transmission.
- Suspension Components: Critical to vehicle stability and performance, enhancing handling and comfort.
- Pump Housings: Provide structure and protection for fluid handling systems.
Conclusion
Aerostar Global Manufacturing’s expertise in precision manufacturing, coupled with rigorous inspection and cleaning procedures, ensures that their Spider component meets the most demanding industry standards. From receiving raw materials to final inspections, each step of the process is designed to deliver reliable, high-performance components that enhance the efficiency and safety of mechanical systems.
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