Machining Complex Mechanical Parts: High-Precision Module Housing for Industrial Equipment

Sector

Industrial Equipment – Machining of Complex Mechanical Parts for Electromechanical System Assembly

Solutions

Machining complex mechanical parts using CNC turning and 4-axis milling, enabling simultaneous processing of multiple mounting faces, key slots, and sealing surfaces

Client Feedback

“IDEA delivered a highly complex part with exceptional surface finish. This is a critical component in our mechanical assembly, and we have full confidence in IDEA’s capabilities.”

Project Overview

This project focused on the precision machining of complex mechanical parts, specifically a module housing designed to connect rotary shafts and guide components in industrial equipment systems. The client is a company specializing in mechatronics modules for factories and advanced laboratories.

The part was made from hardened alloy steel and required multi-face machining with tight tolerances, including bearing holes, threaded flange holes, square key slots, and tight-fitting surfaces — all demanding absolute dimensional consistency.

Challenges

Multi-process machining coordination: CNC turning of cylindrical surfaces, milling flat faces, tapping, and keyway broaching.
Maintaining concentricity between hole groups and rotary axis alignment.
Surface finish requirements with no re-cutting marks allowed. complex mechanical parts
Asymmetrical geometry made repositioning difficult without a dedicated multi-step fixture.

Solutions & Implementation

1. CNC Programming with Combined Turning and Milling

The part was initially rough-shaped on a 2-axis CNC lathe to define the outer reference surface. It was then transferred to a 4-axis CNC machining center for milling flat faces, square pockets, threads, and complex profiles.

2. Custom Fixture Design

IDEA’s engineering team developed a dual-step clamping fixture to stabilize the complex mechanical part across multiple orientations during milling without sacrificing precision.

3. Precision Surface Finishing & Quality Control

Post-machining, the part was mechanically polished, and geometric accuracy was verified using dial indicators and CMM (Coordinate Measuring Machine) to ensure concentricity.

complex mechanical parts

Results

Achieved geometric deviation < 0.01mm and flatness/concentricity of hole groups within 0.015mm.
Surface roughness met Ra 1.6 with no visible tool marks — ready for immediate application with no secondary finishing required.
Total machining time, including setup and inspection, was only 5 days.
The client praised it as “one of the most mechanically precise parts ever outsourced in Asia”.
They are currently planning to scale up orders for similar complex mechanical parts to integrate into their next-generation production systems.