The selection of manufacturing processes is the major element in production, directly impacting the production efficiency, cost control and product quality. As manufacturing evolves toward intelligent and precision-oriented approaches, process decisions must comprehensively balance technical feasibility with economic viability.
The core element of manufacturing selection
- Process Suitability
Select manufacturing processes based on part geometry complexity, material properties, and precision requirements. For instance, CNC machining is suitable for high-mix low-volume production, enabling complex surface machining through programming to significantly enhance consistency. Conversely, traditional turning and milling processes retain cost advantages for high-volume, simple parts. When machining shaft-type components, prioritize reference consistency to minimize cumulative errors.
- Economic Trade-offs
Process costs encompass equipment investment, labor hours, and scrap rates. High-speed cutting technology reduces machining time but incurs higher tool wear costs; precision casting minimizes secondary processing yet significantly increases mold expenses. Enterprises must conduct life-cycle cost analysis to select the solution offering the most comprehensive benefits.
- Balancing Quality and Efficiency
Modern manufacturing emphasizes systematic optimization. For instance, composite machining centers are employed for box-type components, completing multiple processes such as drilling and milling in a single setup to eliminate repeated positioning errors. Meanwhile, precision techniques like nanometer-level polishing, though time-consuming, meet the surface quality demands of high-end products.
Typical Process Decision Path
- Raw Material Selection
Determine casting, forging, or powder metallurgy processes based on material properties. Sand casting is prioritized for cast iron components to control costs, while die casting is suitable for aluminum alloy structural parts to enhance strength.
- Process Planning
Follow the principle of “establish reference points first, rough before finish.” For example:
– Shaft components undergo external turning first to create positioning references for subsequent operations, followed by precision grinding of critical dimensions; Deep-hole drilling requires a staged drilling strategy to prevent tool deflection.
- Parameter Optimization
Cutting parameters must align with machine tool performance and tool life. When machining cast iron with high-speed steel tools, balance cutting speed and feed rate to prevent chipping;
carbide tools can withstand higher speeds but require adequate cooling systems.
Frontier Trends and Challenges
Intelligent manufacturing systems are reshaping traditional decision-making models. By simulating machining processes through digital twin technology, they can predict process defects and optimize parameters; however, this also demands multidisciplinary expertise from practitioners. In the future, green manufacturing processes—such as dry cutting—will become a key direction for sustainable development.
