Hydraulic Cylinder Manufacturing Solutions

Hydraulic cylinders convert fluid power into linear force and motion. Their reliability depends on tube straightness and surface finish, rod hardness and plating quality, weld integrity, sealing performance and pressure/leak resistance. 

Common Customer Challenges

  • Tube ID surface and straightness affecting seal life and stick‑slip; honing consistency across batches
  • Rod surface hardness/plating thickness and corrosion resistance (salt‑spray) under harsh environments
  • Weld quality (circumferential/end‑cap/port) and distortion control for pressure vessels
  • Seal groove precision and cleanliness management in assembly; leakage and break‑in failures
  • Mixed bore/stroke variants with short lead time; traceability for cylinders and components
  • Pressure test automation and data logging for compliance and warranty control

Wing Structural Parts Manufacturing Solutions

Cylinder Tube

  • Technical Points: Deep‑hole boring, ID honing to plateau finish, straightness and roundness control.
  • Process Route: Tube cutting → Deep‑hole boring → Hone/plateau finish → Port machining → Cleaning.
  • Success Case: ID Ra≤0.2–0.4 μm, straightness ≤0.05 mm/m, roundness ≤0.01 mm.
Cylinder Tube
Piston Rod

Piston Rod

  • Technical Points: Hardness, chrome/HVOF thickness, surface finish and corrosion resistance; thread/eye accuracy.
  • Process Route: Bar prep → Turning/grinding → Chrome or HVOF → Polish → Thread/eye machining.
  • Success Case: Surface hardness ≥58 HRC (coating dependent), thickness 20–40 μm (Cr) or 80–150 μm (HVOF), NSS ≥240–720 h.

Head/Cap & Clevis

  • Technical Points: Precision bores, seal grooves, port threads; weld‑fit geometry and distortion control.
  • Process Route: CNC milling/turning → Seal groove machining → Port/thread → Weld prep.
Head/Cap & Clevis

Hydraulic Cylinder Manufacturing Process

Raw Materials And Incoming Materials Inspection
  • Process step description: Verify aluminum/titanium alloy grade, thickness, surface quality and heat treat condition; sample chemistry and mechanical properties.
  • Equipment: Optical spectrometer, universal testing machine, CMM, ultrasonic thickness gauge, hardness tester, metallographic microscope.
Tube Cutting And Preparation
  • Process step description: Cut to length, face/chamfer and prepare for deep‑hole boring/honing.
  • Equipment: Tube saw, facing/chamfering machine, deburring tools.
Deep‑Hole Boring And Honing (Tube)
  • Process step description: Bore and hone tube ID to target geometry and plateau texture for seal life and low drag.
  • Equipment: Deep‑hole boring machine, CNC honing machine, air gauges, surface roughness tester.
Rod Turning/Grinding And Coating
  • Process step description: Turn/grind rod OD, apply hard chrome or HVOF thermal spray, then polish to finish.
  • Equipment: CNC lathe, OD grinder, chrome plating line or HVOF system, polishing machine, thickness gauge.
Head/Cap/Clevis Machining
  • Process step description: Machine bores, seal grooves, ports and threads to tolerance; verify critical fits.
  • Equipment: CNC milling/turning centers, boring/reaming tools, thread gauges, CMM.
Cleaning And Surface Preparation
  • Process step description: Multi‑stage aqueous/ultrasonic washing; surface prep (e.g., phosphating/activation) for coating/assembly.
  • Equipment: Ultrasonic/aqueous washers, surface preparation line.
Welding & Fabrication
  • Process step description: Robotic circumferential/fillet welds for heads/caps/ports; control distortion; NDT coverage per spec.
  • Equipment: Robotic welding cells, positioners, preheat systems, weld gauges, UT/MT/PT.
Heat Treatment / Stress Relief (As Required)
  • Process step description: Stress‑relieve welded assemblies or harden specific parts per drawing.
  • Equipment: Heat‑treat/tempering furnace, temperature monitoring.
Seal Assembly And Final Build
  • Process step description: Clean‑room assembly of seals, piston and rod; torque/angle control and functional fit checks.
  • Equipment: Clean benches, assembly fixtures, torque/angle tools, seal installers.
Testing & Validation
  • Process step description: Automated hydrostatic proof/burst, leakage at temperature, friction/drag and cushioning checks with data logging.
  • Equipment: Hydrostatic/leak benches, pressure transducers, flow meters, NVH/friction rigs, data acquisition.
Final Inspection, Marking And Packaging
  • Process step description: Dimensional/visual checks, laser ID/traceability, VCI anti‑corrosion packing and crating.
  • Equipment: CMM/gauges, laser marker, barcode/RFID, VCI packaging, wooden crates.
Packaging And Shipping
  • Process step description: Apply protective packaging and shipping preparation to prevent damage during transportation and storage.
  • Equipment: Protective packaging system, shipping fixtures, environmental monitoring, handling equipment.
Data Traceability And Quality Control
  • Process step description: Maintain complete traceability of materials, processes and inspections for airworthiness compliance and quality control.
  • Equipment: MES, data acquisition system, quality management system, barcode/RFID system, document management.

Wing Structural Parts Production Line

Production Line Layout And Configuration

  • Overall Layout: Adopt linear layout, arranged in process sequence to minimize material handling distance
  • Workstation Division: Material preparation area → Rough machining station → Heat treatment station → Precision machining station → Assembly station → Inspection station → Packaging area
  • Logistic Passage: Main channel width 5m, auxiliary channel 3m, ensuring smooth transportation of large structural components
  • Buffer Zone Setup: Set 4-8 hour buffer inventory between each station to balance production rhythm

Equipment Configuration And Automation

Rough Machining Station Equipment Configuration

  • Large Milling Machines: 3 units, table size 4m×2m, spindle power 50kW
  • Turning Centers: 2 units, maximum machining diameter 2m, length 6m
  • Gantry Machining Centers: 2 units, table size 6m×3m, 5-axis linkage
  • Automation: Automatic loading/unloading system, automatic tool change, automatic machining parameter adjustment

Heat Treatment Station Equipment Configuration

Precision Machining Station Equipment Configuration

  • 5-Axis Machining Centers: 4 units, table size 3m×2m, spindle speed 15000rpm
  • Precision Grinding Machines: 3 units, machining accuracy ±0.002mm
  • CNC Drilling Machines: 4 units, drilling accuracy ±0.05mm, automatic tool change
  • Automation: Online inspection system, automatic compensation, real-time quality data collection

Assembly Station Equipment Configuration

  • Assembly Platforms: :2 units, size 8m×4m, load capacity 50 tons
  • Lifting Equipment: 2 bridge cranes, lifting capacity 20 tons each
  • Assembly Fixtures: Specialized fixture systems, rapid positioning
  • Automation: Automatic assembly system, torque control, assembly data recording

Production Flow And Material Handling

  • Material Flow:  Raw materials → Rough machining → Heat treatment → Precision machining → Assembly → Inspection → Packaging
  • Information Flow: Order information → Process parameters → Quality data → Traceability information
  • AGV System: 15 AGVs, automatic transportation of large structural components
  • Warehouse System: Automated storage and retrieval system, storage capacity 2000 pieces

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