The automotive industry relies heavily on CNC machining for prototyping and mass manufacturing of OEM and generic parts. It’s useful in the prototyping phase, allowing manufacturers to identify design flaws and make changes.
CNC machining allows for one-off runs in prototyping, or it’s suitable for scaling into large production volumes. CNC operations like milling, turning, and drilling are compatible with several materials, including metals, composites, and plastics.
Some examples of automotive parts produced with CNC methods include gearbox and drivetrain components and cylinder heads.
What are the Advantages of Using CNC Machining for Car Parts?
Implementing CNC processes into automotive part manufacturing offers OEMs and off-brand manufacturers several benefits.
Automated Processes
Automation allows manufacturers to speed up production while maintaining accuracy and precision and reducing costs. CNC machines are capable of running 24 hours a day without any human interaction by operators.
After setting up the machine, the algorithms take charge, running through the production process without any need for operator oversight. CNC machines are capable of cutting intricate designs, allowing OEMs to focus on innovation rather than the limitations in the production process.
CNC automation allows for scaled production. As a result, OEMs have the benefit of getting new models to market faster, increasing their ability to compete in the market.
Precision & Accuracy
Auto parts have tight tolerances. For instance, the piston rings in the cylinder block have a tolerance of approximately 4 μm. It’s incredibly challenging, if not impossible, to produce these spares by hand. CNC machining offers OEMs the advantage of selecting tolerances down to 0.0025mm.
The result is a high level of precision and accuracy where needed in the manufacturing process. CNC machines, especially 4-axis and 5-axis models, are capable of cutting intricate designs not available with other production methods, making them ideal for auto part manufacturing.
Fast Production Speeds
Since CNC machines rely on algorithms and CAD to control the movement of the cutting heads, there’s no need to change the workpiece during operation. A single setup is all that’s required, with automation taking control out of the operator’s hands when they launch to process.
The result is a fast production time, even when manufacturing complex designs. Operators are not required to manage the process, leaving it to run 24/7 if needed. Therefore, there is no downtime due to operator fatigue and fast-tracking production cycles.
Repeatable, Reliable Production
After setting up the CNC machine, it runs through its program, controlled by the parameters of the CAD design. As a result, every part produced is identical, giving OEMs a high degree of repeatability and reliability in production.
Custom cnc wheel
CNC Machining Production Applications in the Automotive Industry
OEMs use CNC machining in the construction of several automotive components. Let’s look at some of the most common industry applications of this technology.
Interior Paneling
OEMs use CNC machines to cut dashboards from wood or plastics. It’s capable of cutting the dials and fan ports. The drilling and milling CNC processes are ideal for this task.
Starter Motor
The starter features a complex design with several moving parts. CNC machines allow for accurate production of starter components, adhering to tight tolerances.
The Cylinder Head
Most cylinder heads feature construction with aluminum. The cylinder head and engine block require machining to very tight tolerances to ensure optimal engine efficiency and extended service life.
Gearbox Components
A vehicle’s gearbox comprises gears and shafts designed to operate at high speeds. Therefore, its essential all gearbox components are accurately machined to provide smooth operation. OEMs rely on CNC milling, drilling, and turning to produce these parts.
Drivetrains
The vehicle drivetrain and differential components connect to the gearbox and the wheels. The bevel and hypoid gears require precision movement, making them ideal candidates for CNC machining.
Lighting Systems
CNC machines can cut a variety of materials, not just metals. They’re capable of machining PMMA materials and acrylic glass used in automotive lighting systems. Interior lights and headlamp housings are examples of components suitable for CNC machining.
Other CNC Machined Automotive Parts
CNC machining plays a vital role in manufacturing many other automotive parts. You can find these machined components in brake systems, such as valves and discs, and in fuel pumps, alternator housings, CV joints, and clutch components.
Wrapping Up – CNC Machining in Rapid Prototype Development & Mass Production
Manufacturers rely on CNC machining services for the rapid prototyping of new models. CNC machines are capable of producing one-off parts, especially those requiring intricate design. However, this process is expensive since the setup costs for machining one unit are the same as cutting thousands.
CNC machining also shines when the model goes into mass production for the market. CNC machines can work around the clock to meet production goals. As a result, OEMs can launch new vehicles fast, reducing the time to market and between releasing new models.