Sinbo Precision Roller Shaft Machining Case Study: The Perfect Fusion of High Precision and Reliability

Product Description
Sinbo Precision, a professional manufacturer of precision components, demonstrates exceptional technical prowess in the field of roller shaft machining. Roller shafts are core components in industrial drive and conveyor systems, used for supporting, transmitting power, and conveying materials. Utilizing high-quality materials like alloy steel and stainless steel, and advanced processes such as CNC milling, CNC turning, grinding, and EDM (Electrical Discharge Machining)7, combined with a strict quality control system, Sinbo Precision provides roller shaft products characterized by high precision, durability, and reliability. These roller shafts are widely used in high-precision fields like semiconductor equipment, automation systems, and medical devices.

Machining Challenges
In a project for a high-end automated equipment manufacturer, the client required a batch of high-precision roller shafts with the following demands:

• Extremely High Dimensional Accuracy: Diameter tolerance needed to be within ±0.005mm, straightness tolerance ≤0.05mm/m5.
• Excellent Surface Treatment: Surface roughness needed to achieve Ra0.47, with some surfaces requiring hard chrome plating for enhanced wear and corrosion resistance.
• Complex Geometric Features: The roller shafts required machining multiple limit grooves, relief grooves, and waist holes to ensure assembly accuracy3.
• Material Hardness Requirements: Use of hardened materials like GCr15 bearing steel (hardness 62-65 HRC), which are difficult to machine8.

Solution
Leveraging its comprehensive machining capabilities and technical experience, Sinbo Precision developed the following solution:

1. Precision Machining Processes:
• Used CNC turning and milling for initial forming to ensure basic dimensions.
• Employed high-precision grinding machines (accuracy 0.002mm) for finish machining to guarantee dimensional tolerances and surface finish7.
• For hard materials (like hardened steel), introduced advanced processes like cyclone hard milling, enabling efficient, green machining with surface quality comparable to grinding8.
• Utilized EDM (Electrical Discharge Machining) for complex and micro structures7.
2. Heat Treatment and Surface Treatment:
• Applied heat treatment processes like quenching, nitriding based on material and requirements to enhance core mechanical properties.
• Implemented surface treatment technologies such as hard chrome plating, anodizing, hard anodizing to improve wear and corrosion resistance7.
3. Strict Quality Control:
• Utilized inspection equipment including CMM (Coordinate Measuring Machine), toolmaker's microscope, roughness testers (accuracy up to 0.003um) throughout the process7 to inspect dimensions, geometric tolerances, and surface roughness at each key stage.
• Conducted magnetic particle inspection on rollers and other components to ensure absence of crack defects10.
4. Customization Service:
• Flexibly adjusted machining plans according to customer-provided drawings (supporting formats like SolidWorks, Pro/E, AutoCAD, IGES, STEP)7 to meet non-standard requirements.

Implementation Process

1. Material Preparation: Selected high-quality alloy steel, processed through sawing, straightening (runout不大于0.1)3.
2. Rough Machining: Performed initial shaping via CNC turning, leaving appropriate machining allowance.
3. Semi-Finishing and Heat Treatment: Carried out preliminary heat treatment like quenching and tempering, then machined features like keyways and limit grooves3.
4. Finish Machining:
• Used precision grinders for finish grinding of outer circle and end faces, ensuring dimensional accuracy (e.g., diameter tolerance 0.005mm) and geometric tolerances (e.g., concentricity 0.03mm)5.
• Utilized CNC machines to mill waist holes, relief grooves, etc.3.
5. Surface Treatment: Performed hard chrome plating as required7.
6. Final Inspection: Conducted comprehensive final inspection using CMM and other equipment to ensure 100% compliance with drawing requirements7.

Quality Assurance
Sinbo Precision strictly adheres to ISO quality management systems, ensuring each roller shaft undergoes multiple inspection stages:

• In-Process Inspection: Set inspection points at crucial stages like after rough machining and before finish machining1.
• Final Inspection: Reports cover all key dimensions, hardness, surface roughness, and non-destructive testing results (if applicable)710.

Application Results
This batch of high-precision roller shafts was successfully applied in the client's precision automated assembly line, achieving:

• Excellent Operational Performance: The roller shafts transmitted motion smoothly with high precision retention, ensuring efficient and reliable machine operation.
• Long Service Life: Outstanding wear and fatigue resistance significantly extended equipment maintenance intervals.
• High Consistency: Parameters of the batch-produced roller shafts were highly consistent, facilitating client assembly and spare parts management.

Conclusion
Through its exquisite machining technology, comprehensive quality control system, and extensive industry experience, Sinbo Precision successfully delivered high-precision roller shaft products that met stringent requirements, demonstrating its strong capabilities in the field of precision component manufacturing and providing reliable value assurance for its customers.