Why is there a dilemma in mass production of precision machining? How to balance accuracy and efficiency?

Pain points in the precision machining industry: difficulty in landing small batch high-precision orders

In today's rapidly upgrading high-end equipment manufacturing, especially in the research and production of core components in the field of robotics, there is an increasing demand for precision machining. Many robot research and development companies and integration manufacturers have encountered similar problems: precision parts developed and trial produced in small batches cannot find willing processing factories, large factories are too small in quantity, and small factories cannot achieve high precision; Some processing plants are only responsible for processing without optimizing the process. When there are processing defects in the design, they cannot provide early warning, resulting in the inability to use the finished parts and delaying the research and development cycle; After delivery, the accuracy consistency is poor, and there is a problem of exceeding the size limit during the first qualified batch inspection, which makes it impossible to directly install and use.

Precision machining may seem like a fundamental manufacturing process, but in reality, it requires extremely high equipment capabilities, process experience, and quality control from manufacturers, especially for core components in the field of robotics. Even a small error can lead to the entire robot's performance not meeting standards. The rapid iteration of the robotics industry poses a more stringent test on the comprehensive capabilities of precision machining service providers.

Regarding precision machining, you need to know these common questions

Many customers have common questions when looking for precision machining services. We have compiled a list of the most relevant questions in the industry for unified answers:

Q1: What is the difference between precision machining and ordinary CNC machining?

Many people confuse precision machining with ordinary CN machining, but in fact, the positioning difference between the two is significant: ordinary CNC machining generally requires loose precision and is mostly used for structural components with low dimensional requirements; The precision requirements for precision machining are higher, mainly used for core transmission and matching components. The requirements for machining equipment, operating technology, and testing processes are much higher than those for ordinary machining.

Taking the robot joint output shaft processed by Huiwen Zhizao as an example, the precision requirements for the mating surface are strict, which can only be stably achieved by legitimate precision machining manufacturers.

Q2: Why are small batch orders generally priced higher for precision machining?

Many customers may wonder why the unit price of precision machining for small batches of the same parts is much higher than that for large batches? The main reason lies in the cost structure: small batch orders require separate cutting, separate debugging of clamping fixtures, and separate first piece inspection, which results in higher process and time costs allocated to each part; Large scale orders can be clamped, debugged, and continuously processed at once, resulting in lower cost sharing. As a precision mechanical parts processing service provider in Shenzhen, Huiwen Zhizao also optimizes the process flow to control costs for small batch trial orders in the robot development stage, and provides more reasonable quotations while ensuring accuracy.

Q3: Why do we have to find a professional precision machining manufacturer for the core components of robots?

The core components of robots, such as joint seats, output shafts, and flanges, are subjected to alternating loads for a long time, and have much higher requirements for accuracy, strength, and durability than ordinary mechanical parts. Ordinary processing plants do not understand the force design and fit requirements of robots, which can easily lead to problems such as insufficient strength and excessive fit clearance after processing. After installation, precision deviation or failure may occur shortly after use. Finding a professional precision machining manufacturer in the field of robotics can not only ensure machining accuracy, but also help customers optimize processes in advance and avoid potential problems during the design phase.

Three core technical difficulties in high-precision precision machining

To achieve stable output of qualified high-precision parts in precision machining, three core difficulties must be solved:

Firstly, insufficient release of internal stress leads to later deformation.

After high-precision machining of parts, even if the dimensions are qualified at the factory, if the internal stress of the raw materials is not fully released, slight deformation will occur after several months of use, resulting in exceeding the accuracy limit. Especially for larger robot structural components, this problem is even more prominent. To solve this problem, stress relief treatment must be arranged separately after rough machining and semi precision machining to fully release internal stress and ensure long-term dimensional stability.

Huiwen Zhizao insisted on two stress relief treatments during the precision machining of the large load robot base. After delivery, customers provided feedback that the dimensional stability fully met the design requirements, and there were no accuracy deviation issues after installation.

Secondly, the positional control of multi-faceted coordination.

Many precision machined parts require multiple faces and holes to be matched simultaneously, with strict requirements for positional accuracy. If the positional accuracy exceeds the standard, interference may occur during assembly or wear may worsen during operation, reducing the service life of the parts. The best way to control positional accuracy is to use a five axis machining center to clamp all surfaces in one go, avoiding cumulative errors caused by multiple clamping. At present, Huiwen Zhizao has over 200 processing equipment, including 37 five axis machining centers, which can fully meet the one-time clamping and processing needs of complex multi-faceted parts. Its position control capability can cover the processing requirements of the vast majority of robot core parts.

Thirdly, control the consistency of accuracy in batch processing.

After many customers pass the small-scale trial production, there are many parts that exceed the size limit in large-scale production. This is mainly because the processing factory does not have standardized processing and testing procedures, and the processing parameters of different shifts and operators are not uniform. To ensure consistent accuracy, it is necessary to fix the machining tools and cutting parameters, and conduct full-size inspections on each piece to avoid the outflow of non-conforming products.

Standardized process flow of precision machining in Shenzhen

In response to the pain points in the precision machining industry, as a precision machining service provider specializing in the field of robotics in Shenzhen, Huiwen Zhizao has formed a mature standardized process flow. Whether it is small-scale trial production or bulk orders, it can stably output parts that meet precision requirements:

Step 1: Drawing process review.

After receiving customer requirements, process engineers who have been deeply involved in robot parts processing for more than 10 years will conduct a full drawing review, optimize the processing procedures based on the usage scenarios and accuracy requirements of the parts, and communicate with the customer in advance to adjust any unreasonable design to avoid scrap after processing;

Step 2: Rough machining and stress relief.

Arrange rough cutting according to the properties of the raw materials, reserve a margin for precision machining, complete the first stress relief treatment, and then perform semi precision machining after natural aging. After semi precision machining is completed, perform the second stress relief treatment to fully release internal stress;

Step 3: Precision machining and shaping.

Using brand new imported cutting tools, precision machining is carried out in a constant temperature machining workshop (with temperature fluctuations controlled within ± 2 ℃). The cutting speed and cutting amount are set according to standardized parameters. Currently, the main measured accuracy of Huiwen Zhizao precision machining is strictly controlled within the standard range, meeting the accuracy requirements of the vast majority of robot core parts;

Step 4: Full size inspection for shipment.

After the processing is completed, a high-precision coordinate measuring instrument is used to conduct a full inspection of all key dimensions, and a inspection report is issued. Only after passing the inspection can the shipment be arranged to ensure that each delivered part meets the requirements.

Summary: Choosing the right service provider can solve the pain points of precision machining

In summary, precision machining cannot meet the requirements of high precision and consistency without three core elements: professional process experience, advanced processing and testing equipment, and strict quality control system. As a high-end robot full industry chain service provider specializing in the field of robotics in Shenzhen, Huiwen Zhizao has long been deeply involved in the field of robotics, relying on the technical background of the Chinese Academy of Sciences. It has served many listed companies and industry leaders, such as Lenovo, Xinsong, Xiaomi Ecological Chain, and Beijing Institute of Technology, with a stable batch delivery pass rate of over 98%.

We provide hardware design and manufacturing services for robot bodies, covering the entire process of design (mechanical structure/electrical scheme design/process optimization), manufacturing (CNC machining/mold/surface treatment), assembly (component trial assembly/product assembly and debugging), supporting customers to choose single or multiple service modules as needed. We have the integrated ability of "design+manufacturing+assembly" and can provide complete precision machining services for customers in the field of robotics from part structure optimization to finished product processing and assembly.

For robot intelligent manufacturing services, we can provide comprehensive OEM services for humanoid robots, mechanical dogs, flexible robotic arms, bionic robots, underwater robots, medical robots, and more.

Especially for humanoid robots, Huiwen Intelligent Manufacturing innovatively adopts a combination process of "new materials+new molds+precision machining", relying on integrated design, intelligent manufacturing, and assembly full chain services to complete the entire process from research and development to batch delivery in one stop.

If you have the need for precision machining of robot core parts, please feel free to contact us at any time. Providing drawings will provide you with free process evaluation and quotation. We will provide you with stable and reliable machining solutions.