Manufacturing Category | Engineering Production Guidelines |
---|
Material Engineering & Certification | Select structural steels (e.g., 42CrMo4, AISI 4140, S355JR) for mechanical integrity under cyclic load. Use certified bar, plate, or forged blanks with traceable EN 10204 3.1 or ASTM A6 documentation. For wear zones, apply tool steel (e.g., D2, H13) with ≥58 HRC or bronze alloys (C93200). |
|
CNC Machining & Accessibility | Ensure 3-axis/5-axis tool path clearance, maintaining tool reach ratio ≤6×D for hole depths and pocket features. Design for efficient fixture clamping and eliminate undercuts unless supported by indexed setups. Target rough-to-finish allowance of 1.5–2.5 mm for forged inputs. |
|
Dimensional Control & Critical Features | Apply ISO 8015-compliant GD&T to control datums, holes, and profiles. Specify flatness ≤0.03 mm, positional tolerance ≤0.02 mm on dowel holes, and perpendicularity ≤0.05 mm on orthogonal faces. Design inspection points for CMM or optical metrology with ≥10 mm probe clearance. |
|
Weldability & Mechanical Assembly | Define weld zones with 30°–45° chamfers, ≥1 mm root gap, and access from ≥2 sides. Verify joint fatigue per ISO 5817 or AWS D1.1. For bolted assemblies, use precision bores with H7/h6 fits and preload torque specifications (ISO 898-2) to control clamping force. |
|
Surface Treatment & Corrosion Protection | Specify functional coatings per ISO 2063 or ASTM B633. For structural carbon steel: zinc plating (≥12 µm), phosphating, or epoxy powder coating (60–90 µm). Apply hard chrome or PVD (CrN/TiAlN) for sliding interfaces. All coating specs should pass ≥240 h salt spray testing (ISO 9227). |
|
Batch Repeatability & Process Stability | Implement CNC tool offset compensation and closed-loop feedback for multi-lot stability. Define process capability with Cp/Cpk ≥1.33 for all CTQs. Validate fixtures with gauge R&R <10% and apply batch control via barcode-linked work orders tied to final inspection records. |
|
Threaded Features & Assembly Interfaces | Design blind holes with ≥2×D thread depth; use thread milling or form tapping to minimize chip entrapment. Verify threads per GO/NO-GO gauges (ASME B1.2 or ISO 1502). For frequently serviced parts, use captive inserts (e.g., Heli-Coil, Keensert) to maintain thread integrity. |
|
Part Identification & Digital Traceability | Mark part numbers and revision codes via laser engraving (depth ≥0.1 mm) or dot peen. Encode serial and lot numbers in ECC200-compliant Data Matrix or QR format. All parts must link to digital inspection records, material certs, and machining logs in ERP or PLM systems. |
|
Assembly Validation & Fit Assurance | Define fits using ISO 286 tolerancing—transition fits (H7/p6) for shafts, clearance fits (H7/g6) for bushings. Conduct dry-run pre-assembly for functional groups and verify mating gaps ≤0.1 mm with feeler gauges. Record all fitting operations in FAI or PPAP Level 3 documentation. |
|
Regulatory Compliance & Export Readiness | Ensure material and coatings meet RoHS/REACH directives. For EU-bound assemblies, include CE mark compliance per Machinery Directive 2006/42/EC. Provide documentation: 2D/3D drawings, EN material certs, ISO 9001 inspection reports, and export packing standards (ISPM-15). |