Product Description
CNC fine machining products, such as clutch release bearing sleeves, are components fabricated through Computer Numerical Control (CNC) machining processes with high precision.
1. Function of Clutch Release Bearing Sleeves
- In a vehicle's clutch system, the clutch release bearing sleeve plays a crucial role. When the driver depresses the clutch pedal, the release bearing (which is often mounted on the sleeve) is pushed towards the pressure plate. The sleeve allows the release bearing to move smoothly along the input shaft of the transmission. This movement disengages the clutch by separating the pressure plate from the clutch disc, enabling gear changes in a manual transmission vehicle.
- For example, in a standard car with a manual transmission, every time the driver shifts gears, the clutch release bearing sleeve facilitates the proper operation of the release bearing, ensuring a seamless transition between gears.
2. CNC Fine Machining for Clutch Release Bearing Sleeves
- Precision: CNC machining uses computer - controlled tools to remove material from a workpiece with extreme accuracy. For clutch release bearing sleeves, tight tolerances are essential. The inner diameter of the sleeve that interfaces with the input shaft of the transmission and the outer diameter where the release bearing is mounted need to be machined to within very small tolerances, often in the range of ±0.01 - ±0.05 mm. This precision ensures a proper fit, minimizing wobbling or excessive play, which could lead to premature wear of the bearing and clutch components.
- Complex Geometries: Clutch release bearing sleeves may have complex shapes. They might have flanges, grooves, or specific profiles that are designed to optimize their function. CNC machines can precisely machine these complex geometries. For instance, grooves can be machined to allow for proper lubrication distribution, and flanges can be accurately formed to provide a secure mounting point for the release bearing.
- Material Selection and Machining: These sleeves are typically made from materials such as steel alloys. CNC machining can effectively work with these materials, removing material layer by layer to create the desired shape. The machining process can also enhance the surface finish of the sleeve. A smooth surface finish reduces friction between the sleeve and the moving parts, improving the overall efficiency of the clutch system.
In summary, CNC fine - machined clutch release bearing sleeves are high - precision components that are integral to the proper functioning of a vehicle's clutch system. Their precise manufacturing through CNC processes ensures reliable and efficient operation of the clutch mechanism.
|
Category
|
Specifics
|
Details
|
|
Raw Materials
|
Type
|
Alloy steel (e.g., 4140 steel for its good combination of strength and machinability)
|
|
|
Grade
|
ASTM A29/A29M grade for specified mechanical properties
|
|
|
Supplier
|
Reputable steel mills with a track record of quality supply
|
|
|
Quantity per Finished Product
|
Calculated based on the volume of the sleeve, considering machining allowances. For example, if the finished sleeve has a volume of \(V_f\) and machining removal is \(V_r\), the required raw material volume \(V = V_f+V_r\). This is then converted to weight using the density of the steel alloy.
|
|
|
Chemical Composition
|
For 4140 steel: carbon (0.38 - 0.43%), manganese (0.75 - 1.00%), phosphorus (max 0.035%), sulfur (max 0.040%), silicon (0.15 - 0.35%), chromium (0.80 - 1.10%), molybdenum (0.15 - 0.25%)
|
|
Finished Products
|
Dimensions
|
Inner diameter: Must match the input shaft of the transmission precisely, with a tolerance of ±0.01 - ±0.03 mm. Outer diameter: Matches the inner diameter of the release bearing, with a similar tight tolerance. Length: Depends on the clutch system design, with a tolerance of ±0.1 - ±0.2 mm.
|
|
|
Weight
|
Precise weight determined by the dimensions and material density. For example, a typical sleeve made of 4140 steel with specific dimensions might weigh around \(x\) grams.
|
|
|
Surface Finish
|
Ra value (average roughness) typically in the range of 0.8 - 1.6 µm for the inner and outer diameters to reduce friction. For other surfaces, it may be in the range of 1.6 - 3.2 µm.
|
|
|
Quality Standards
|
Conform to automotive industry standards such as ISO/TS 16949 for quality management systems. Must pass dimensional inspection, surface finish inspection, and material property testing.
|
|
Workcraft
|
Manufacturing Process
|
CNC turning for the cylindrical surfaces, followed by CNC milling for features like grooves and flanges. Drilling operations may also be involved for mounting holes.
|
|
|
Key Steps
|
1. Raw material preparation: Cutting the steel bar to the appropriate length. 2. Rough turning: Removing a significant amount of material to get close to the final shape. 3. Precision turning: Achieving the final dimensions of the inner and outer diameters. 4. Milling operations: Creating grooves, flanges, etc. 5. Drilling and tapping (if applicable) for mounting holes. 6. Finishing operations: Deburring and surface treatment.
|
|
|
Tolerances
|
As mentioned in the finished product dimensions, tight tolerances are maintained throughout the machining process. For example, during turning, the diameter tolerance is held within ±0.01 mm at each machining step.
|
|
|
Quality Control Checks
|
In - process inspection: Regularly check dimensions during machining using precision measuring tools like calipers, micrometers, and coordinate measuring machines (CMMs). Final inspection: After all machining operations, perform a comprehensive inspection of dimensions, surface finish, and material hardness.
|
|
|
Machining Time
|
Depends on the complexity of the sleeve. A simple sleeve may take 30 - 60 minutes to machine, while a more complex one with multiple features could take 2 - 3 hours.
|
Our production
1. Personnel Management
- Training and Skill Development
-
- Ensure that CNC machine operators are well - trained in programming, setup, and operation of the specific CNC machines used in the production of clutch release bearing sleeves. Provide regular training on new machining techniques, software updates, and safety procedures. For example, introduce training on advanced multi - axis machining strategies if the production requires complex geometries.
-
- Cross - train employees to handle different tasks within the production process. This can help in case of absences or when there is a need to re - allocate resources during peak production periods. A machine operator could also be trained to perform basic quality inspection tasks.
-
- Establish clear performance metrics for employees, such as production output per hour, number of defective parts produced, and adherence to safety regulations. Regularly review and provide feedback to employees based on these metrics. Offer incentives for high - performing employees, like bonuses or extra vacation days, to boost motivation.
2. Equipment Management
-
- Develop a comprehensive maintenance schedule for CNC machines. This should include daily checks for basic issues like lubrication levels, tool wear, and machine cleanliness. Periodic maintenance tasks, such as spindle alignment, calibration of measuring systems, and replacement of worn - out parts, should be scheduled based on the machine's usage hours or manufacturer's recommendations. For example, replace the cutting tool holders every 500 - 1000 hours of operation to ensure consistent machining accuracy.
-
- Keep a stock of essential spare parts to minimize machine downtime in case of breakdowns. Analyze historical maintenance data to predict which parts are likely to fail and maintain an appropriate inventory level.
- Equipment Upgrade and Investment
-
- Stay updated with technological advancements in CNC machining. Consider upgrading to machines with higher precision, faster processing speeds, or additional features that can improve the production of clutch release bearing sleeves. For instance, if the current machines have limited multi - axis capabilities, upgrading to a 5 - axis CNC machine can enable more complex machining operations and reduce the number of setups required.
3. Quality Management
-
- Implement in - process inspection procedures at critical stages of the machining process. Use sensors and inspection tools integrated with the CNC machines to monitor dimensions, surface finish, and other quality parameters in real - time. For example, use a touch - probe on the CNC machine to measure the diameter of the clutch release bearing sleeve during the turning process. If the measurement deviates from the set tolerance, the machine can be adjusted immediately.
-
- Train employees to identify early signs of quality issues, such as abnormal tool wear, vibration, or noise during machining. Encourage them to report such issues promptly to prevent the production of defective parts.
-
- Conduct a thorough final inspection of each clutch release bearing sleeve. Use high - precision measuring equipment like coordinate measuring machines (CMMs) to verify all dimensions, surface roughness testers to check the surface finish, and material testing equipment to ensure that the material properties meet the required standards.
-
- Implement a non - conforming product handling process. If a defective sleeve is identified, clearly mark it, quarantine it, and analyze the root cause of the defect. Take corrective actions to prevent similar defects in future production.
4. Production Scheduling and Planning
-
- Analyze historical sales data, market trends, and customer orders to forecast the demand for clutch release bearing sleeves. Use this information to plan production volumes and schedules. For example, if the demand for a particular type of sleeve has been increasing steadily over the past few months, adjust the production plan to increase the output.
-
- Collaborate with the sales and marketing teams to stay informed about new product launches, customer requirements, and any potential changes in demand.
-
- Create a detailed production schedule that takes into account the machining time for each sleeve, machine availability, and personnel shifts. Optimize the schedule to minimize idle time of machines and ensure a smooth flow of production. For example, group similar jobs together to reduce the time spent on machine setups.
-
- Have a contingency plan in case of unexpected events, such as machine breakdowns, material shortages, or changes in customer orders. Be prepared to adjust the production schedule accordingly to meet the delivery deadlines.
Our quality control
1. Material Inspection
-
- Visual Inspection: When the steel raw material is received, visually inspect the surface for any signs of defects such as cracks, scratches, or rust. For clutch release bearing sleeves, a clean, smooth surface on the raw material is essential as surface imperfections can lead to issues during machining and in the final product's performance.
-
- Documentation Verification: Ensure that the material comes with proper certificates of analysis (COA). The COA should detail the chemical composition of the steel, which for a typical alloy used in clutch release bearing sleeves, like 4140 steel, should have specific ranges of elements such as carbon (0.38 - 0.43%), manganese (0.75 - 1.00%), etc. Any deviation from the specified composition can affect the mechanical properties of the finished sleeve.
-
- Hardness Testing: Use a hardness tester, such as a Rockwell or Brinell hardness tester, to measure the hardness of the steel. The hardness value should be within the acceptable range for the chosen steel grade. Incorrect hardness can lead to difficulties during machining, such as excessive tool wear or improper shaping of the sleeve.
- In - Process Material Monitoring
-
- Chip Analysis: During CNC machining, regularly analyze the chips produced. The shape, color, and size of the chips can provide valuable information about the machining process and the material behavior. For example, if the chips are unusually long and stringy, it may indicate that the cutting speed is too low or the material has an abnormal microstructure. In the case of steel, proper chip formation is crucial as it affects the surface finish and dimensional accuracy of the clutch release bearing sleeve.
2. Machining Process Inspection
- Pre - Machining Setup Inspection
-
- Tooling Inspection: Thoroughly inspect all cutting tools, including drills, end - mills, and turning tools, before starting the machining process. Check for any signs of wear, such as chipped edges or excessive dullness. The right tool geometry and sharpness are essential for achieving accurate dimensions and a good surface finish on the clutch release bearing sleeves. For example, a worn - out turning tool can cause the outer diameter of the sleeve to be out of tolerance.
-
- Machine Calibration and Setup: Verify that the CNC machine is properly calibrated. Check the accuracy of the axes movement, spindle speed, and feed rates. Incorrect calibration can lead to significant dimensional errors in the final product. Additionally, ensure that the workpiece is correctly mounted and aligned in the machine. A misaligned workpiece can result in uneven machining and a defective clutch release bearing sleeve.
- In - Process Dimensional Inspection
-
- On - Machine Probing: Utilize on - machine probing systems, such as touch - probes, to measure the dimensions of the clutch release bearing sleeve during machining. These probes can be programmed to take measurements at specific intervals or after certain machining operations. For example, after rough turning the outer diameter of the sleeve, the touch - probe can measure the diameter and compare it with the target value. If the deviation is within the allowable tolerance, the machining can continue; otherwise, adjustments can be made to the cutting parameters.
-
- Real - Time Monitoring of Machining Parameters: Use sensors integrated with the CNC machine to monitor machining parameters such as cutting force, torque, and vibration. Abnormal values of these parameters can indicate problems such as tool breakage, incorrect cutting speed, or material defects. For instance, a sudden increase in cutting force may be a sign of a tool - workpiece interference or a hard inclusion in the steel material, which can affect the quality of the clutch release bearing sleeve.
3. Final Product Inspection
-
- Coordinate Measuring Machines (CMMs): After the machining process is complete, use CMMs to measure all critical dimensions of the clutch release bearing sleeve. These include the inner diameter, outer diameter, length, and any other features such as grooves or flanges. CMMs can provide highly accurate measurements with tolerances in the range of ±0.001 mm. Compare the measured dimensions with the design specifications, and if any dimension is out of tolerance, the sleeve is considered non - conforming.
- Surface Finish Inspection
-
- Surface Roughness Testers: Employ surface roughness testers to measure the surface finish of the clutch release bearing sleeve. The surface finish is crucial as it affects the friction and wear characteristics of the sleeve in the clutch system. For clutch release bearing sleeves, a typical surface roughness value (Ra) in the range of 0.8 - 1.6 µm is often required for the inner and outer diameters. The tester measures the average roughness of the surface by moving a stylus over the surface and recording the vertical deviations.
- Functional Testing (Optional but Recommended)
-
- Assembly Testing: If possible, perform assembly testing of the clutch release bearing sleeve with other components of the clutch system. This can help identify any fit - related issues or problems with the sleeve's functionality. For example, check if the sleeve moves smoothly along the input shaft of the transmission and if the release bearing can be properly mounted and operate without any binding or excessive play.
4. Non - Conforming Product Management
- Identification and Quarantine: When a non - conforming clutch release bearing sleeve is identified, clearly mark it with a label indicating the nature of the defect, such as "Out - of - Dimension" or "Surface Defect". Immediately quarantine the non - conforming product in a separate area to prevent it from being accidentally mixed with conforming products.
- Root Cause Analysis: Conduct a detailed root cause analysis to determine why the non - conforming product was produced. This may involve examining the machining process, the quality of the raw material, operator error, or machine malfunction. For example, if a batch of sleeves has inconsistent outer diameters, the analysis may reveal that the cutting tool was not properly set or that there was a problem with the machine's feed rate control.
- Corrective and Preventive Actions: Based on the root cause analysis, implement corrective actions to address the immediate issue and preventive actions to avoid similar problems in the future. Corrective actions may include re - machining the non - conforming sleeves if possible, or scrapping them if they are too far out of tolerance. Preventive actions could involve retraining the operator, adjusting the machining process parameters, or performing additional maintenance on the CNC machine.
Company Profile
Introduction to Services Offered by Zhuji Bosswinn Springs Co., Ltd.
Zhuji Bosswinn Springs Co., Ltd. is a leading manufacturer and supplier specializing in high-quality metal components and precision engineering solutions. With a strong commitment to innovation, precision, and customer satisfaction, the company offers a comprehensive range of services and products tailored to meet the diverse needs of industries worldwide.
Core Services:
-
Metal Springs Manufacturing:
Bosswinn Springs excels in the production of a wide variety of metal springs, including compression springs, tension springs, torsion springs, and more. These springs are engineered to deliver exceptional performance, durability, and reliability for applications across automotive, aerospace, industrial machinery, and consumer electronics.
-
CNC Fine Machining:
Leveraging state-of-the-art CNC machining technology, the company provides precision machining services for complex metal components. With a focus on accuracy and efficiency, Bosswinn Springs ensures that every part meets the highest standards of quality and dimensional precision.
-
Metal Sheet Fabrication:
The company offers expert metal sheet fabrication services, including cutting, bending, welding, and assembly. Whether for prototypes or large-scale production, Bosswinn Springs delivers customized solutions that meet specific design and functional requirements.
-
Punched Parts Production:
Specializing in high-speed punching technology, Bosswinn Springs manufactures precision punched parts with consistent quality and tight tolerances. These components are widely used in electronics, appliances, and automotive industries.
Featured Products:
-
Wave Springs:
Bosswinn Springs is renowned for its high-performance wave springs, which provide superior load-bearing capacity in compact spaces. These springs are ideal for applications requiring reduced axial space and precise force control.
-
Counterbalancing Springs:
Designed to balance and stabilize mechanical systems, counterbalancing springs from Bosswinn Springs ensure smooth operation and enhanced safety in a variety of industrial applications.
-
Clutch Release Bearing Sleeves:
The company produces precision-engineered clutch release bearing sleeves that offer exceptional durability and performance for automotive and machinery applications.
With a dedication to innovation, quality, and customer-centric solutions, Zhuji Bosswinn Springs Co., Ltd. continues to be a trusted partner for businesses seeking reliable metal components and precision engineering services. Whether you need custom springs, machined parts, or fabricated metal products, Bosswinn Springs delivers excellence at every stage of production.
Audited Supplier 
){kind=link}