Balancing speed and quality—medium-sized complex motor housings achieve stringent tolerance control of 0.02mm, accelerating the development and deployment of innovative products.
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Product
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Motor Housing
|
Industry |
Industrial Equipment Manufacturing |
|---|---|
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Technology |
CNC machining（4-axis machining + turning） |
|
Materials |
Aluminum Alloy 6061 |
|
Post-machining |
As-machining (deburring) |
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Production Demand |
Small-batch production |
|
Why choose us |
Experience in machining electromechanical components |
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Result |
Delivered ahead of schedule, 100% parts compliant. |
The client in this case study is a top-ten global manufacturer of industrial fluid handling equipment, dedicated to delivering leading fluid management products worldwide.
Within the client’s R&D fluid handling equipment, the motor serves as the core power component, playing a pivotal role in ensuring the system’s efficient operation.
Faced with the challenge that standard motors on the market could not meet their innovative design requirements, the client resolved to develop a motor structure meeting higher specifications. This means that the project must rely on experienced manufacturers to ensure the precision and reliability of critical components.
At this critical stage of product development, Xmake distinguished itself among numerous manufacturers through its specialised production expertise and exceptional machining capabilities, successfully joining the project and providing crucial support to realise the client’s vision.
Upon receiving the client’s drawings, our engineers promptly conducted process analysis and formulated machining solutions, ensuring every production parameter was precisely defined.
Bolstered by mutual trust, the client’s engineers swiftly adopted our machining proposal. Following thorough communication and once scheme optimisation, the project rapidly progressed from the design phase into full production.
However, during production, we encountered a series of challenges. The motor components developed by the client were relatively large in size and required extremely tight machining tolerances of 0.02 mm. This made the entire manufacturing process highly challenging:
◆ Large housing dimensions: The 140 × 110 × 106 mm motor housing extended machining time and risked vibration-induced deformation during heavy cutting, increasing demands on fixture design and machining sequence for precision and stability.
◆ Tight hole tolerances: Several critical holes required extremely precise tolerances, where even slight deviations could impact assembly accuracy and motor performance.
◆ Complex part geometry: The housing incorporates heat sinks, internal bores, and mounting slots, significantly complicating toolpath planning.
◆ Tight schedule: Processing large, complex components individually takes a long time, and any rework could cause delays on the client’s production line.
Faced with these challenges, every stage tests the team’s experience and judgement. The Xmake team is undoubtedly capable of tackling these challenges with composure from multiple dimensions:
✓ Stable machining strategy: Designing custom fixtures and support solutions to stabilise large components during machining, minimising housing deformation.
✓ Precision tolerance control:To meet stringent tolerance requirements, we independently invest in specialised high-precision cutting tools, rigorously controlling cutting parameters and tool paths to ensure accuracy without passing on additional costs to the client.
✓ Multi-process coordination: For efficient production of complex structures, we employ 4-axis simultaneous machining. This ensures stable part processing while enabling deep cavities and multi-surface machining to be completed in a single setup.
✓ Multi-stage quality control:Incorporating in-process inspections and final coordinate measuring machine verification; each batch delivery includes a comprehensive inspection report.
Throughout the collaboration, we maintain transparent, real-time communication with client engineers, ensuring full visibility into progress and details at every stage.
Through our exceptional manufacturing expertise and highly efficient production management system, we completed the component fabrication within just two weeks – a full week ahead of the client’s stipulated deadline.
Leveraging our exceptional component machining capabilities, we have successfully delivered parts that meet our client’s requirements, thereby establishing a solid foundation for once-further collaboration. Both parties are currently expanding their technical cooperation into broader areas.
