The component illustrated is a custom protective housing (Cover) designed for a mechanical or electromechanical assembly. Manufactured from a solid block of Aluminum 6061, the design features a deep internal pocket, a central bearing/shaft hub, and perimeter mounting tabs.

Producing this housing requires removing over 70% of the original billet’s volume. This substantial material removal releases internal residual stresses inherent to Aluminum 6061, which can cause the workpiece to warp or distort. To mitigate this issue, a multi-stage machining strategy was implemented. Roughing operations were first performed to remove the majority of the material, while maintaining a uniform stock allowance across all surfaces. This approach helps to evenly distribute the remaining stresses and minimize dimensional instability during subsequent finishing operations.

Part type: Custom Aluminum Housing / Cover

Material: Aluminum 6061

Machining Process: 3-Axis CNC Milling

Surface Finish: As-Machined

Quantity: 160 pcs

Lead Time: 28 day

Machining Process

• Material Preparation: A solid block of 6061 aluminum was cut to the required blank size and securely fixtured on a 3-axis CNC machining center.
• Rough Machining: Initial operations involved face milling and pocketing to remove excess material, establishing the basic shape of the component.
• Semi-Finishing: Intermediate machining steps refined the contours and prepared critical features for final precision cuts.
• Finishing Operations: High-feed-rate finishing tools were used to achieve the required surface finish and dimensional accuracy on all critical surfaces.
• Quality Inspection: Post-machining inspection was performed using a coordinate measuring machine (CMM) to verify that all dimensions and tolerances were within specified limits.

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