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Our partner Zhejiang JG Integrated Technology Company is a leader in carbon fiber full industry chain equipment, new energy green equipment, and intelligent machinery (including carbon fiber production lines, new energy storage intelligent robots, and intelligent composite material handling systems). Its core business focuses on high-end carbon fiber equipment and advanced composite materials, requiring locked components to meet the "high-precision, high durability, and low maintenance" standards of green industrial scenarios.
In response to JG Integrated Technology Company's urgent demand for high-performance lock cores for its key equipment, MAXTECH, a professional precision CNC mechanical parts factory, has undertaken the customization and production of aluminum bronze lock cores, solving the production and application pain points of its partners.
When developing lock cores for its carbon fiber production line intelligent fixtures and new energy storage robot cabinets, Jinggong Integrated faces dual difficulties in material processing and lock core manufacturing processes:
The raw brass material has low hardness, high plasticity, and is prone to cold work hardening, which leads to severe tool wear during CNC turning and milling processes, resulting in 15% of parts not meeting the tolerance requirements of GB/T 1184-K; Frequent tool changes have also reduced production efficiency by 20%.
The high thermal expansion rate of brass during processing causes dimensional deformation of the lock core, lock hole, and threaded structure, requiring secondary correction, thereby increasing production costs.
Difficulty in deburring and edge treatment: Brass has a soft texture and is prone to burrs on the internal grooves and sharp edges of the lock core; Manual deburring cannot guarantee the consistency of 0.2-0.5mm chamfer size, which does not meet the safety standards of intelligent mechanical clamping.
Difficulties in surface quality control: The inner wall of the lock cylinder and the contact surface of the key are prone to small scratches during the polishing process; These defects trap carbon fiber dust in the production environment, triggering device sensor alarms.
Durability testing bottleneck: The brass lock core cannot withstand more than 8000 consecutive clamping cycles (required for 24/7 carbon fiber production lines); Accelerated aging testing showed a failure rate of 30%, resulting in repeated shutdowns and replacement of parts on the production line.
MAXTECH delivers customized aluminum bronze lock cores to address the production and application challenges of precision integration:
Core material: Aluminum bronze (QAl9-4) - solves the pain points of processing and durability:
Higher hardness (HV180~220) can reduce tool wear during the machining process, increase the scrap rate of cutting parts by 12%, and increase production efficiency by 25%.
The low thermal expansion rate ensures the dimensional stability of the lock core hole and thread during the machining process, eliminating the need for secondary calibration.
Wear resistance supports more than 12000 continuous clamping cycles, meeting the all-weather operation requirements of carbon fiber production lines.
Precision manufacturing (for production challenges):
Deburring and edge treatment: MAXTECH uses an automatic robot for deburring and CNC chamfering to ensure consistent rounded edges of 0.2-0.5mm; To prevent carbon fiber materials from being hooked and comply with intelligent mechanical safety standards.
Tolerance control: 5-axis CNC machining, real-time dimensional monitoring, ensuring 100% compliance with GB/T 1804-M (general tolerances) and GB/T 1184-K (shape and position tolerances) standards.
Surface treatment: high-speed precision milling+ultrasonic polishing to achieve a scratch free surface with Ra ≤ 0.8 μ m; Prevent the accumulation of carbon fiber dust and meet the "dust-free" requirements of composite material production environment.
Prototype verification: MAXTECH completed a 5-piece prototype within 3 days, successfully passing 15000 cycles of wear testing and surface quality inspection, confirming production feasibility in advance.
"The aluminum bronze lock core produced by MAXTECH completely solves our production and application pain points: the tool wear during the processing is significantly reduced, 100% of the parts meet the tolerance standards, and the scratch free surface fully meets the dust-free requirements of our carbon fiber production. Most importantly, it has withstood over 15000 clamping cycles without any malfunctions. We have signed a 2-year order for 22000 units and will promote this solution to our new energy and aerospace economy equipment production lines. ”
-Equipment R&D Director of JG Integrated Technology Company.
