Case Study: Achieving Precision and Cost-Efficiency in a Complex Rotor Project

At ZC Precision, we recently completed a challenging project that highlighted our expertise in precision machining and surface treatment. The project involved manufacturing a rotor with specific requirements that demanded a combination of high technical capability and attention to detail.

Project Overview:

Part Name: Rotor

Material: 4140 Steel

Dimensions: φ300*650mm LONG

Surface Treatments:

• Hard Chrome Plating: Achieving HRC62 on designated functional areas.
• Oxide Blackening: Applied to non-functional areas.

The Challenge:

This project required different surface treatments on the same part, which is a technically demanding task. The functional area of the rotor required a hard chrome plating to HRC62, while the other surfaces needed oxide blackening. The key challenge was to achieve the circular runout of 0.025mm after hard chrome plating and grinding the surface to meet the required precision.

Additionally, hard chrome plating is expensive, so it was crucial to apply it only where necessary, while using a more cost-effective treatment like oxide blackening for the rest of the rotor.

Our Solution:

The success of this project hinged on our ability to apply these different surface treatments precisely without compromising the integrity of the rotor.

1. Selective Surface Treatment: We meticulously covered the areas that did not require hard chrome plating. This ensured that only the designated functional areas were plated, minimizing unnecessary costs while ensuring optimal performance in the functional zones.
2. Precision Grinding: After the hard chrome plating, we performed precision grinding to achieve the required circular runout of 0.025mm. This step was critical to ensuring that the rotor met the tight tolerances needed for its application.
3. Cost-Effective Approach: By using a combination of hard chrome plating and oxide blackening, we provided our client with a part that met all functional requirements while optimizing costs.

Why Different Surface Treatments?

Hard chrome plating is essential in areas where high wear resistance and durability are required. However, because it is a costly process, applying it only to the necessary functional areas ensures that the product remains both effective and cost-efficient. Oxide blackening, while not as durable as chrome plating, offers sufficient protection for non-functional areas, thereby reducing the overall cost without compromising the part's performance.

Conclusion:

This rotor project exemplifies our ability to handle complex machining tasks that require both precision and cost-consciousness. At ZC Precision, we pride ourselves on delivering high-quality, customized solutions that meet our clients' specific needs. Whether it's achieving multiple surface treatments on a single part or meeting tight tolerances, our team is committed to providing the best possible outcomes for our clients.

If you have a project that requires expert machining and surface treatment, feel free to reach out. We're here to help you achieve the best results, both technically and economically.