Turning Manufacturing Inspection System: Comprehensive Process Control to Ensure Precision and Performance of Rotating Components
As the core process for forming rotating components in metalworking, turning manufacturing requires inspection procedures to span the entire production lifecycle to ensure parts meet precision and performance standards. This section systematically outlines the turning manufacturing inspection system from multiple dimensions, including inspection content, procedures, inter-process coordination, and key considerations.
一. Core Inspection Content
Inspection of turned parts must focus on three core metrics: dimensional accuracy, surface quality, and geometric tolerances.
1. Dimensional Accuracy Inspection
For critical dimensions of CNC-turned shafts, sleeves, and similar components (e.g., diameter, length, step height, thread parameters), employ graded inspection tools:
- Basic dimensions: Digital calipers and micrometers (accuracy up to 0.001mm) High-precision mating surfaces (e.g., bearing seats) require coordinate measuring machines to ensure tolerances within IT5-IT7 grades (e.g., φ50mm shaft diameter tolerance ≤±0.005mm). For complex structures with tapered or curved features, profile gauges must compare actual surfaces against theoretical curves in design drawings.
2. Surface Quality Inspection
Visually inspect for defects such as vibration marks, tool marks, or scratches. Measure Ra values using a surface roughness tester (e.g., TR200). Standard turned parts require Ra 1.6–3.2 μm, while precision components (e.g., hydraulic valve spools) must achieve Ra < 0.8 μm. Simultaneously perform penetrant testing to detect surface microcracks, particularly for high-strength steel parts.
3. Geometric Tolerance Verification
Use a runout gauge to inspect radial runout on shaft components (≤0.01mm/m). Employ a flat plate with dial indicator to measure end face perpendicularity (≤0.02mm/100mm). For slender shafts with length-to-diameter ratios >10, control bending deformation using a straightness tester (≤0.05mm/m).
二. Standardized Inspection Procedures
1.Preparatory Phase
Review drawings and process documents to identify key quality control points; calibrate measuring tools (CMM requires annual third-party certification); inspect raw material condition to exclude defects and confirm sufficient machining allowance.
2.First-Article Inspection (Full Inspection)
Conduct 100% full inspection of the first piece before batch production; record SPC data; verify tool parameters and clamping methods (e.g., soft jaws for thin-walled parts). Batch production may commence only after the first article is approved.
3.In-Process Inspection (Dynamic Monitoring)
For every 50-100 parts produced, 3-5 are sampled for rechecking key dimensions and geometric tolerances; monitor cutting parameters, and immediately adjust if dimensional deviation exceeds one-third of the tolerance. Online measurement can be introduced for large batches.
4.Final Inspection (Warehousing Check)
Full re-inspection of finished products is conducted, and inspection reports (including actual dimensions, surface quality ratings, and geometric tolerance data) are issued; non-conforming products are categorized (rework with defined process, scrap identified and isolated). Qualified parts must be marked with traceability information (e.g., production batch, inspector ID) to provide quality basis for subsequent processes such as Precision Milling Service.
三. Key Considerations in the Inspection Process
Measuring tools must be regularly calibrated (1-2 times per year), with daily checks for zero point and accuracy; use of expired or damaged tools is strictly prohibited.
Select appropriate measuring tools based on accuracy requirements: calipers for basic dimensions, CMM for high-precision surfaces, thread ring/plug gauges combined with projector for thread parameters.
Precision inspections should be conducted in a constant temperature (20±2°C) and clean environment to prevent thermal deformation and contamination.
Non-conforming products must be immediately isolated and recorded; rework requires a defined process, and scrap must be approved before centralized disposal. Inspection records should be traceable, and regular SPC analysis should drive process optimization. Through systematic inspection, turning manufacturing can ensure its own quality and provide reliable basic components for the entire metal manufacturing chain (e.g., Sheet Metal Bending, Sheet Metal Welding, assembly).
