TBEA Standard Power Transmission Aluminum Components

Introduction

This aluminum sheet metal formed component is engineered for high-performance lightweight structural applications requiring tight dimensional accuracy, excellent mechanical strength, and long-term stability.

Manufactured from 6061-T6 high-strength aluminum alloy, the component achieves a significant weight reduction compared to stainless steel—approximately one-third of its density—while maintaining excellent structural rigidity and load-bearing capability.

The forming process integrates multi-pass progressive metal forming with die-limited edge restraint technology, ensuring controlled material flow, minimized springback, and suppression of wrinkling defects commonly found in conventional sheet metal forming operations.

The design is optimized for seamless one-piece structural integration, eliminating weld seams and improving overall mechanical reliability.

Critical dimensions are controlled to ±0.1mm, with full inspection of mating surfaces using dedicated gauging systems to ensure consistent assembly accuracy.

Core Metal Spinning Process

Multi-Stage Progressive Aluminum Forming & Controlled Metal Spinning Technology

The component is manufactured using 6061-T6 high-strength aluminum alloy sheet material, optimized for lightweight structural performance while maintaining high mechanical strength.

A multi-stage progressive forming process is applied, combined with die-limited blank holding and controlled edge restraint to ensure stable plastic deformation throughout the forming cycle.

Key process features include:

• Multi-pass progressive metal forming
• Die-controlled flange restraint system
• Springback compensation forming strategy
• Wrinkle suppression process control
• Integrated one-piece seamless forming
• Optimized material flow direction control

This process ensures uniform stress distribution, eliminates localized deformation defects, and achieves high structural integrity with lightweight efficiency.

Precision Machining & Tolerance Control

Tight Tolerance CNC Finishing & Geometric Accuracy Control

The product follows GB/T 1804-m general tolerance grade standards for non-indicated dimensions.

Critical mating surfaces are subject to 100% inspection using dedicated gauges and precision measurement fixtures.

Precision capability includes:

• Dimensional tolerance control within ±0.1mm
• Flatness and perpendicularity controlled via CNC machining
• Stress-relief stabilization through aging treatment
• Stable long-term geometric retention
• High repeatability in batch production

The combination of CNC finishing and thermal stabilization ensures long-term structural stability without deformation under operational loads.

Surface Treatment

Deburring, Edge Radiusing & Anodized Surface Protection

All components undergo strict surface finishing requirements including deburring and edge radiusing to eliminate sharp edges and improve assembly safety.

Surface treatment process includes:

• Vibratory finishing for burr removal
• Manual precision surface refinement
• Edge rounding (R-angle control)
• Aluminum anodizing treatment (natural or black)
• Enhanced corrosion and wear resistance layer formation

Final surface characteristics:

• Uniform anodized protective layer
• Improved surface hardness
• Enhanced corrosion resistance
• Clean, industrial-grade finish
• No sharp edges or machining burrs

The anodized layer significantly improves environmental resistance and long-term durability in industrial applications.

Material Capability

6061-T6 High-Strength Aluminum Alloy

The component is manufactured from 6061-T6 aluminum alloy, widely used in structural engineering applications due to its excellent strength-to-weight ratio and machinability.

Material characteristics include:

• High strength-to-weight ratio (lightweight structural performance)
• Excellent machinability for CNC and forming processes
• Stable mechanical properties after heat treatment (T6 temper)
• Good corrosion resistance in industrial environments
• Suitable for complex forming and precision machining

The entire manufacturing process—from blanking to forming and machining—is optimized to control deformation and ensure consistent structural performance.

Technical Specifications

Related Case

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