1、Automotive parts manufacturing common technology
(1) CNC Machining
CNC machining is commonly used in the customized production of automotive parts, which uses pre-programmed instructions to control the high-speed rotation of the cutting tool, gradually removing the blank material until the formation of customized parts to meet the requirements. In the field of automotive parts manufacturing, CNC machining technology is commonly used in the engine head, crankshafts, gears and other high-precision, complex shapes of automotive parts manufacturing production.
(2) 3D Printing
3D printing is an innovative automotive component manufacturing technology that rapidly prints free-form and complex plastic or metal parts based on three-dimensional digital models. In the field of automotive parts manufacturing, 3D printing technology is widely used in rapid prototyping, direct manufacturing of complex structural parts and production of personalized custom parts.
（3）Sheet Metal Working
Sheet metal parts have a wide range of applications in automotive body covering. Sheet metal working usually starts with cutting the flat contour of the part using laser or plasma technology and then bending it into the desired shape. Sheet metal working is commonly used to manufacture parts such as doors, roofs, floors, etc. and is an integral part of automotive component manufacturing.
(4) Injection Molding Processes
The injection molding process is mainly used to manufacture plastic parts in automotive parts manufacturing. By injecting molten plastic materials into pre-designed molds, the desired parts are obtained after cooling and curing. The injection molding process has the advantages of high productivity, low cost, and the ability to manufacture complex shaped parts.
(5) Casting Processing
Casting processing technology is the molten metal liquid poured into the cast cavity, to be solidified, cooled to obtain the required shape and size of the parts. Casting processing technology in the manufacture of automobile parts occupies an important position, accounting for about 10% of the weight of the car parts are obtained by casting.
2. Materials used in the manufacture of automobile parts
(1) Steel
Steel is one of the most commonly used raw materials in modern automotive component manufacturing. In automotive component manufacturing, different types of steel are used for different parts manufacturing as they provide good strength and impact absorption to the components. For example, steel is widely used in parts such as door panels and support beams. In addition, depending on the stiffness requirements, steel is also used in the manufacture of parts such as automobile roofs and exhaust pipes.
(2) Plastic
Plastics, an important raw material for automotive component manufacturing, are obtained through petrochemical processing. Studies have shown that plastics account for 8% – 10% of the weight of each automobile. Due to its good durability, it is widely used in air conditioning vents, floors, switches, handles and many parts inside the engine. With their high load-bearing capacity and wide applicability, plastics are replacing steel in some scenarios and are important in the manufacture of automotive components.
(3) Rubber
Rubber is a key material that is indispensable for the manufacture of automotive parts. About 65% of rubber production is used in the manufacture of automotive parts, and its main uses include the manufacture of various types of drive belts. Rubber is highly versatile and can be molded into different shapes as needed, playing a key role in improving automotive efficiency, heat resistance, and road safety, and keeping its shape stable during use.
(4) Aluminum
Aluminum is a premium durable material in automotive component manufacturing and its use is on the rise. Automotive component manufacturers prefer aluminum because of its combination of rigidity, toughness and low weight. Currently, aluminum is widely used in the manufacture of engine components, helping to reduce fuel consumption and improve performance, while gradually replacing some of the hard metal in the manufacture of wheels and other components.
(5) Glass
In the field of automotive component manufacturing, the role of glass is of paramount importance, especially from the point of view of securing driving vision. Different types of glass are used in automobiles in the form of lenses to provide drivers with a clear view of their surroundings. Windshields protect drivers in adverse weather conditions, and with technological advances, rear lenses are also made of glass, enhancing the clarity of rear vision. In addition, laminated glass is widely used in the manufacture of automotive components to reduce injuries in traffic accidents.
(6) Glass Fiber
Fiberglass is often used as a substitute for steel in the manufacture of automotive parts because of its resistance to rust. It is woven from small strands of air and coated with a resin coating for tensile strength and heat resistance. The main uses of fiberglass in the automotive industry include improving the fire resistance of automobiles, manufacturing components such as bumpers and wheels, and also providing insulation.
(7) Lead
Lead is primarily used in the automotive industry to maintain stability and weight balance, and its most important use is in the manufacture of automotive batteries. Batteries for both conventional fuel vehicles and electric vehicles contain lead components, as lead is effective in maintaining battery temperatures within safe ranges.
(8) Titanium
Titanium is used by some automotive component manufacturers to make specific parts, especially internal combustion engine parts, because of its corrosion resistance and low density. The use of titanium in the manufacture of components reduces fuel consumption, improves vehicle efficiency, and helps to reduce engine combustion noise. However, due to the high price of titanium, only a few manufacturers are currently using it.
(9) Magnesium
Magnesium is one of the widely used raw materials in the automotive parts manufacturing industry and its outstanding advantage is its light weight. Therefore, magnesium is commonly used in the manufacture of weight-sensitive parts such as steering wheels and interior components, which helps to improve vehicle handling. The use of magnesium in the front end of automobiles makes the vehicle more agile in turns.
(10) Copper
Although copper is not used much in the manufacture of automotive parts, it plays a key role in electrical connections. Copper has good thermal conductivity and is commonly used in radiators as well as in electrical connections in automobiles, such as starters, radios and other safety systems.
3. Types of automobile parts
3.1: Mechanical parts
(1) Engine parts
The engine, as the core power component of the car, is like the heart of the car, converting fuel into mechanical energy and providing power for the car to move. Its key components include cylinder block, piston, turbocharger and fuel injector. The quality and performance of these components directly affect the efficiency and reliability of the engine, which is the key concern in the manufacture of automotive parts.
(2) Transmission components
The transmission system is responsible for transferring the power generated by the engine to the wheels to ensure that the vehicle can travel at the right speed. The main transmission components are the gearbox, clutch and drive train. Quality transmission components ensure smooth and efficient power transmission.
(3) Suspension and steering components
Suspension and steering systems are critical to ensuring a smooth and comfortable ride as well as maintaining the stability and handling of the vehicle. Struts, shock absorbers and tie rods are key components of the system. These components work in tandem to enable the vehicle to cope with a wide range of road conditions while traveling, providing the driver with a good driving experience.
3.2:Electrical parts
(1) Battery and charging system
The battery is the heart of a vehicle’s electrical system, providing power to start the engine and run other electrical devices. The alternator, which charges the battery, and the starter motor, which starts the engine, are key components. The performance and reliability of these components are directly related to the normal operation of the vehicle electrical system.
(2) Ignition and starting system components
Ignition and starting system components are responsible for igniting the fuel-air mixture in the engine and maintaining combustion. The ignition coil converts the battery voltage to a higher voltage and the spark plug ignites the fuel mixture.
(3) Lighting and instrumentation components
Lighting and instrumentation components are critical for drivers to monitor vehicle performance and ensure visibility in a variety of driving conditions. Headlights, taillights and instrument panel gauges are key components of the system. Good lighting and clear instrument displays enhance driving safety and comfort.
3.3: Body and interior parts
(1) External body parts
Exterior body components not only affect the aesthetics of a vehicle, but also play an important role in its aerodynamic performance and structural integrity. The hood, fenders, doors and bumpers are key exterior body components.
(2) Interior parts
Interior components and accessories are important for enhancing the comfort, functionality and safety of the vehicle cabin. High-quality interior components can provide passengers with a comfortable riding environment and convenient use experience.
3.4:Other auto parts
(1) Turbocharger
Turbocharger is one of the highly sought after automotive components in the current market, which enhances the engine performance by increasing the air intake and improves the combustion, thereby increasing the power output.
(2) Advanced Driver Assistance Systems (ADAS)
ADAS is a fast-growing area of the automotive industry, encompassing technologies such as adaptive cruise control, lane departure warning systems and automatic emergency braking.
(3) Lithium ion battery
With the rise of electric vehicles, lithium-ion batteries have become a key component of automobiles.
(4) Automotive Sensors
Sensors play a vital role in modern vehicles, with applications ranging from engine management to safety systems.
4、Automotive parts manufacturing process
(1) Design phase
Automotive component manufacturing begins with design, which involves identifying requirements, CAD design and design process planning. All parties collaborate to determine part requirements, design and test using CAD software. The design process includes concept development, validation, prototyping, testing and refinement, and final approval.
(2) Mold Casting
It covers pattern making (selection of materials depending on the part and casting method), mold formation (sand molds, permanent molds, ceramic shell molds for different parts), melting and pouring, cooling and solidification, taking the casting and finishing.
(3) Prototyping and testing
Prototyping: including 3D printing, CNC machining, and hand modeling; functional prototyping to evaluate performance and assembly; and pre-production prototyping to test the manufacturing process.
Testing: Performance testing (stress, durability), environmental testing (temperature, humidity, corrosion), safety testing (crash, impact), regulatory compliance testing.
(4) Bulk Manufacturing and Assembly
- Stamping: blanking, forming, punching and trimming.
- Welding: Spot welding, MIG and TIG welding, robotic welding for different situations.
- Welding: Spot welding, MIG and TIG welding, robotic welding for different situations.
- Painting: preparation, electrostatic painting, curing, inspection.
- Final assembly: installation of components, integration of electrical systems, functional testing, final inspection.
(5) Quality control
- Inspection and testing: in-process inspection, non-destructive testing, performance testing.
- Statistical process control: data processing and problem correction.
- Final quality assurance: complete vehicle testing and aesthetic inspection.
5、automotive parts manufacturing surface treatment technology
(1) Powder coating
Powder coating is one of the most common customization methods when it comes to custom auto parts painting. Most customers want their car to have a different color, matte finish, cool pattern, or specific picture.
(2) Anodizing
Anodizing is commonly used for custom aluminum automotive parts. Anodizing is a simple process for thickening the aluminum oxide layer by inserting the part into an electrolyte and placing it in a current anode, which causes ions to detach from the metal surface, forming deep microscopic pores on the surface and thickening the oxide film around the pores. If the pores are filled with paint, a metallic luster effect is achieved.
(3) Polishing
Polishing requires the use of abrasive pastes and soft tools to obtain a perfect surface finish.
conclude
In summary, automotive parts manufacturing is a complex and diversified field, covering from advanced manufacturing technology to a variety of material applications, from a rich variety of parts to rigorous manufacturing processes. Understanding these contents helps us to deeply understand the auto parts manufacturing industry.
