Classification and Processing Requirements for Automotive Components

Power system components
Engine components:

Cylinder block/cylinder head: The material is primarily cast iron or aluminium alloy, requiring high dimensional stability and precision of sealing surfaces.

Crankshaft/Camshaft: Materials with high fatigue strength, roundness, coaxiality, and surface hardness must be strictly controlled.

Connecting rod: Extremely high symmetry requirements, with weight grouping accuracy within ±2 grams.

Transmission components:

Gear:Accuracy class ISO 6-8The key to noise control

Enclosure: Complex internal cavity machining, multi-axis synchronisation requirements

Clutch components: Special treatment of friction surfaces

Chassis and Suspension System
Steering knuckle: Safety component, 100% non-destructive testing

Brake discs: Heat dissipation performance and dynamic balance are equally important.

Control arm: a combined process of welding and machining

Body and interior components
Mould manufacturing: Precision of large moulds: 0.02/1000mm

Decorative components: Consistency in mirror finish and texture

Part Two: Detailed Explanation of Core Machining Technology and Equipment
1. High-speed machining technology(HSM)
Technical characteristics:

Spindle speed: 15,000–40,000 RPM

High feed rate (10–50 m/min)

Shallow cutting, high feed rate strategy

Applications in automobile manufacturing:

Machining of intake and exhaust ports on aluminium alloy cylinder heads

High-efficiency rough machining of mould cavities

Composite material component machining

Representative equipment:

DMG DMU Series 5-Axis Machining Centres

MAZAK FF Series High-Speed Machine Tools

Equipped with HSK-A63 or CAPTO shank

2. Multi-tasking machining technology
Turning and machining operations:

Complete turning, milling, drilling and tapping operations on a single machine

Reduce the number of clamping operations and enhance positioning accuracy.

Swiss-type turning and milling machining centres are employed for the machining of precision shaft components.

Example: Machining of the transmission output shaft
Traditional craftsmanship: Six pieces of equipment, eight clamping operations
Multi-tasking machining: Two clamping operations on a single machine
Effect: Machining time reduced by 65%, precision improved by 30%.

3. Flexible Manufacturing System (FMS)
System Configuration:

4 to 10 machining centres

Automatic Pallet Change System (APC)

Central Tool Magazine (120–400 tools)

Automated logistics system

Application in automotive parts factories:

Multi-variety, small-to-medium batch production

Colline production of engine components

24-hour driverless operation

Investment Return Data:

Initial investment: US$2–5 million

Staff reductions: 50–70%

Equipment utilisation rate: improved from 45% to 85%

Payback period: 2 to 3 years

4. Dedicated machine tools and production lines
Engine block production line:

Processing: Rough machining → Semi-finishing → Finishing → Cleaning → Inspection

Task duration: 3–5 minutes per item

Annual production capacity: 200,000 to 300,000 units

Principal equipment: Dedicated machine tools combined with machining centres

Typical configuration:

Roughing: Three-sided milling machine

Bore machining: Multi-axis drilling and tapping machining centre

Finishing machining: Horizontal machining centre

Online measurement: pneumatic measuring instrument + visual inspection

Part Three: The Transformation of Manufacturing Brought About by New Energy Vehicles
Motor core component machining
Rotor shaft:

Material: Electromagnetic steel laminations + shaft body

Primary requirements: Dynamic balance G2.5 grade, shaft end roundness ≤5μm

Special Engineering: Finishing Operations Following Permanent Magnet Assembly

Stator casing:

Cooling channel machining: Deep cavity machining + Seal testing

Accuracy requirement: Coaxiality of bearing position ≤ 0.01 mm

New Material: Machining of Aluminium-Silicon Alloy Die-Cast Components

Battery system components
Battery tray:

Size: Maximum 2000 × 1500 mm

Material: Aluminium alloy extruded profile

Project: High flatness (0.2/1000 mm), lightweight construction

Solution: 5-axis machining centre + vacuum chuck + deformation correction algorithm

Module end plate:

Lot: in millions

Process: Press forming + precision machining composite

Efficiency requirement: Single-item processing time ≤ 45 seconds

Part IV: Quality Assurance Systems and Inspection Techniques
Special requirements of the automotive industry
Process Review Criteria:

VDA 6.3 (German Association of the Automotive Industry standard)

IATF 16949 Quality Management System

Customer Specific Requirements (CSR)

Full-size inspection:

Frequency: First-time items + per shift + after changes

Method: Online inspection + offline three-dimensional measurement

Data Management: SPC Real-Time Monitoring

Application of Advanced Inspection Equipment
Online measurement system:

Integrated Probe for Machine Tools: Critical Dimensional Inspection Following Each Process Stage

Laser scanning: Rapid detection of shape tolerances

Visual System: Automatic Identification of Surface Defects

Example: Crankshaft Production Line Inspection Plan:

Online measurement for machining centres: real-time correction of journal diameter

Dedicated measuring machine: Full dimensions + roundness + cylindricity

Comprehensive Measuring Instrument: Dynamic Balance + Bending Degree

Surface roughness tester: Rz ≤ 2 μm control

Part V: Cost Management and Efficiency Improvement Strategies
Optimisation of Tool Management
Characteristics of Tool Consumption in the Automotive Industry:

Tooling costs account for 8 to 15 per cent of manufacturing costs.

The proportion of super-hard tools is 70% or above.

Coating tool utilisation rate: 90%

Measures for cost reduction and efficiency improvement:

Standardisation: Reduction in tool variety by 30–50%

Lifetime Management: From Fixed Lifetimes to Monitoring-Based Replacement

Regrinding plan: Precision tools can be reground 3 to 5 times.

Supplier Management: VMI (Vendor-Managed Inventory)

Pathways to Enhanced Production Efficiency
Improving Overall Equipment Effectiveness (OEE):

Automotive Industry Benchmark: OEE ≥ 85% TP3T

Key improvements: Reducing changeover time, implementing preventive maintenance

Application of Single-Minute Exchange of Dies (SMED):

Standardisation of external operations: Pre-adjustment of jigs

Simplification of internal operations: Hydraulic quick-change system

Target: Replacement time for large components ≤ 15 minutes

Part Six: In-Depth Analysis of Typical Cases
Case Study 1: Upgrading the Engine Cylinder Head Production Line for a German Brand
Background:

Product: 4-cylinder aluminium alloy cylinder head

Annual production volume: 400,000 units

Old production line: Commenced operation in 2010, with insufficient efficiency

Upgrade Plan:

Equipment upgrade: Introduction of eight dual-spindle machining centres

Automation: Robotic material handling + Automated Guided Vehicle logistics

Intelligentisation: Tool life monitoring + adaptive machining

Quality Enhancement: Online Measurement of Critical Dimensions for 100%

Investment and Return:

Total investment: €18 million

Production efficiency: 40% upward

Staff reduction: decreased from 32 to 12 personnel

Quality improvement: Defect rate reduced from 1.21% to 0.31%

ROI: 3.2 years

Example 2: Manufacturing battery trays for new energy vehicle manufacturers
Chirenji:

Size: 1860 × 1450 mm

High precision: Flatness 0.3mm, hole position ±0.05mm

Large production scale: Initial annual output is 150,000 sets.

policy of resolving

Technological innovation:

Monobloc casting + 5-axis precision machining

Vacuum suction fixation minimises deformation

Laser Marking Tracking System

Production Line Design:

Four parallel production lines

Cycle time: 18 minutes per unit

Automation Level: 85%

Quality Management:

Three measurements per component (post-rough machining, post-finish machining, final)

Leak Test 100%

Sampling Inspection Using a Coordinate Measuring Machine 10%

Effect:

Yield rate: 99.211% stable at 3T and above

Cost: 25% lower than the high-speed welding method

Weight reduction: weight reduced by 15%

Example 3: Mass Production of Transmission Gears
Technical challenges:

Accuracy: ISO Grade 6-7

Noise: ≤68 decibels

Consistency: CPK ≥ 1.67

Advanced Process Combination:

Soft machining: Gear grinding/Gear insertion

Heat treatment: carburising and quenching

Hard machining:

Warm gear grinding (high efficiency)

Gear grinding using shaped grinding wheels (high precision)

Tooth face grinding (improvement of surface quality)

Innovative features:

Online measurement closed-loop control

Integration of machining before and after heat treatment

Intelligent Sorting System

Production data:

Single-item processing time: 3.5 minutes

Daily output: 3,500 units

Tool life: 4000 units per grinding operation

Quality costs: accounting for 1.811% of total costs

Part VII: Future Trends and Response Strategies
Trends in Technological Development
Processing technology:

Ultrasonic vibration-assisted machining: Enhancing machining efficiency for hard and brittle materials

Laser hybrid processing: integrated welding, heat treatment and cleaning

Green Manufacturing: Dry Processing / Minimal Lubrication Processing

Development of Equipment:

More electric spindle direct drives

The proliferation of linear motors

Applications of Carbon Fibre Reinforced Structural Components

Business Model Transformation
From manufacturer to solution provider:

Providing comprehensive solutions encompassing parts supply, assembly and inspection

Customer involvement in the initial design phase

Quality Data Sharing Platform

Digital Services:

Remote operation and maintenance Conservative and predictive maintenance

Cloud optimisation of machining parameters

Reducing downtime through virtual debugging

Key Focus Areas for Talent Development
New competency requirements:

Mechatronics adjustment capability

Data analysis and optimisation capabilities

Automation System Integration Capability

Acquisition of new materials and technologies

Proposal for a Training System:

Industry-academia collaboration for targeted corporate talent development

Establishment of an online learning platform

Regularisation of overseas technical exchanges

Conclusion: The Path to Survival and Development for Automotive Parts Manufacturing
The automotive components manufacturing sector is undergoing a once-in-a-century transformation. Demand for traditional internal combustion engine components is declining, while demand for electrified and intelligent components is surging. Successful enterprises will invariably:

Mastering the three balances:

Balancing flexibility and specialisation: Meeting diverse product demands while maintaining cost competitiveness

Balancing Automation and Intelligence: First achieve process automation, then advance intelligent decision-making.

Balancing quality and cost: Ensuring compliance with the automotive industry's stringent quality standards while managing expenditure

Building the Four Core Competencies:

Rapid response capability: Addressing the challenge of accelerated model change

Technology integration capability: Rapidly converting new technologies into productive capacity

Quality Management Capability: Establish a quality system enabling full traceability throughout the entire project.

Cost management capability: Maintaining price competitiveness through lean production and economies of scale

For small and medium-sized component manufacturers, the survival strategy is as follows: select a specific niche segment, pursue excellence within that field, establish deep collaborative relationships with automotive manufacturers, and moderately expand capability boundaries based on specialisation. Conversely, large enterprises are required to build technological platforms and develop multiple technical pathways in parallel.

Regardless of scale, digital transformation is no longer optional but imperative. From digital blueprints to digital factories, from data collection to data-driven decision-making—this journey demands substantial investment, yet the rewards are equally significant. Within the technology-intensive, capital-intensive and labour-intensive automotive industry, only those who sustain continuous innovation will secure the future.