Unveiling the Manufacturing Process of Foray Precision Engineering's Bearing Bases: The Technological Secrets Behind Precision Quality

In the realm of mechanical manufacturing, the bearing housing serves as a critical foundational component supporting rotating elements. Its machining quality directly impacts the operational precision and service life of the entire machine equipment. Leveraging unique manufacturing processes and precision machining technology, Foray has developed a highly precise bearing housing product for a specific machine model. This article will delve into the complete manufacturing process of Foray's bearing housing, unveil the technical secrets behind its precision machining, and showcase its progression from rough casting to finished product.

▶Starting Point of the Process: High-quality Rough Casting

▼Conventional Lathe：At the primary machining phase, rough machining of Φ80×200 bar stock - drilling through-holes and turning external step features.

A strategy combining "rough-finish machine separation" and "precision correction and Compensated workpiece repositioning" has been developed to achieve ISO IT7 dimensional accuracy and Ra3.2 surface quality on a conventional lathe. It is imperative to acknowledge the significance of key control points, which encompass clamping, deformation suppression, and tool path optimization. This underscores the considerable process potential inherent in traditional machine tools.

▶Reference Surface Preparation: Establishing the Foundation for Accuracy

▼CNC Lathe：Semi-finish machining, and internal bore roughing to final stock allowance.

This process fully leverages the high-performance capabilities of Hardinge CNC lathes. Through meticulously designed fixturing solutions, tiered precision alignment, optimized roughing strategies, and rigorous operational sequencing, it successfully achieves precision machining of both internal bores and external cylindrical features on complex workpieces. The core innovations lie inaccurate datum establishment and transfer, rational division and efficient transition between roughing operations, and maximal utilization of the machine tool's precision potential, which comprehensively demonstrates Foray's advanced manufacturing technical prowess.

▶Five-axis Simultaneous Machining: Enhancing Quality and Precision

▼Five-axis CNC Machining Center：Consistent internal thread milling process ensures compliance with specifications.

This process establishes a closed-loop technical system comprising precision fixturing correction → five-axis simultaneous machining → in-process quality monitoring, effectively resolving challenges like multi-specification thread consistency and thin-wall deformation control. Compared to conventional 3-axis machining: cycle time reduced by 40%, rejection rate decreased from 5% to 0.3%, thread fit accuracy achieves GB/T 197-2018 6H grade.

▶ Precision Quenching Technology: Simultaneous Improvement in Hardness-toughness Properties

Utilizing vacuum heat treatment equipment with strict control over thermal processing parameters, humidity, and duration to minimize part distortion while achieving specified hardness requirements.

▶Precision Turning & Finish Milling: Micro-scale Alignment Control

▼CNC Lathe: Finish turning, machining internal and external diameters, ensuring step dimensions are within tolerance.

This process description details a method for achieving high-precision machining of both ends of shaft-type components, including internal and external diameters, precise total length control, and accurate step dimensions. It utilizes high-precision CNC lathes and precision fixtures, incorporating strict same-datum clamping, step-by-step precision alignment, meticulous residual stock control, and critically, anti-vibration tooling technology. The process specifically emphasizes solving vibration issues during internal boring operations to ensure a high-quality, scratch-free surface finish.The key process characteristics are concentrated in five core aspects: "Datum Consistency," "Micron-Level Alignment Control," "Rigidity Enhancement," "Precision Residual Stock Management," and "Active Vibration Suppression." This represents a quintessential exemplar of Foray's turning capabilities.

▶Precision Grinding: Phased Process Benchmark Optimization

▼Internal and External Cylindrical Grinder: Establishing reference surface A at the neck section, finishing grinding the outer diameter to mirror-like surface, ensuring cylindricity and positioning reference.

This process, through high-rigidity clamping setups, staged datum optimization, and integrated compound machining, achieves the following on long-shaft components:

Key dimensional accuracy: IT6 grade (holes), IT5 grade (external diameters)

Geometric tolerances:

Cylindricity ≤ 0.005 mm

Coaxiality ≤ 0.01 mm

Surface roughness: Ra ≤ 0.4 μm

This embodies Foray's core philosophy in precision grinding: "Datum First, Balanced Rigidity and Flexibility, Integrated Compound Efficiency."

▶Precision Operation: Ensuring Torque Specifications Are Met

▼Machinist/Technician: Perform deburring, clean threads, and tap out residue from threaded holes.

Use files, oilstones, or dedicated deburring tools to trim burrs and flashes on the edges of bearing seats, hole openings, and other areas. Ensure contact surfaces are flat to prevent scratching mating parts or compromising sealing during assembly. For through-hole threads, employ straight-flute taps to swiftly remove debris. As water stains left in threads can easily cause rust, fitters should combine tap cleaning with compressed air blowing or anhydrous ethanol rinsing. This thoroughly removes moisture and electrolyte residues.

▶Programmable Measurement: Micrometer-Level Precision

▼ZEISS Coordinate Measuring Machines (CMMs): Measure geometric parameters including bore diameter, axis distance, flatness, perpendicularity, cylindricity, as well as the distribution of assembly holes using the measuring system.

Utilizing high-resolution grating scales and precision probes, this measurement system achieves micrometer (μm) level accuracy, meeting the stringent requirements for dimensional tolerances and geometric tolerances (such as flatness, coaxiality, and position tolerance) on bearing bases. The system allows flexible adjustment of probe angles to avoid interference, enabling the measurement of deep holes and obscured features. It ultimately outputs Coordinate Measuring Machine (CMM) inspection reports to ensure product quality control.