Adjustable wrenches are core products in the hardware tool industry, and the wrench jaws are their key functional components. They are required to have high-precision tooth profiles, flat jaw surfaces and stable dimensional tolerances to ensure clamping force and service life.
Commonly used materials include 45# steel, chrome-vanadium steel, etc. Their geometric features include irregular tooth profiles, small shoulder cylindrical surfaces and multi-dimensional machined surfaces.
Common risks in traditional machining processes are as follows:
- Dimensional errors (more than ±0.05mm) caused by repeated clamping
- Insufficient tooth profile accuracy that impairs usability
- Increased scrap rate (over 5%) due to fatigue from manual operation
Traditional wrench jaw machining adopts a multi-machine step-by-step operation process: jaw surface milling → tooth top milling → small shoulder milling → tooth milling. It requires 4 times of clamping, which is not only time-consuming (single-piece processing time ≥ 3 minutes), but also leads to a scrap rate as high as 5% due to clamping errors.
Eight workers operate 4 machines simultaneously, with labor costs accounting for over 30% of the total production costs. Frequent equipment maintenance (2-3 shutdowns per month) delays order delivery cycles, resulting in an average delay of 10%. These pain points directly affect enterprises' production capacity, profitability and market competitiveness.
The 5GX Machine Tool adopts a "one-clamping full-process" design: blank (forging) → automatic feeding and clamping → jaw surface milling → tooth top milling → small shoulder milling → tooth milling → automatic discharging → inspection.
The entire process is controlled by CNC programs with no manual intervention required. It only takes 2.5 minutes per piece to convert a blank into a finished product (for 12-inch wrench jaws).
- Root/Profile (Wrench Jaw Tooth Profile): Special gear milling cutters (carbide coated) are adopted, and CNC tool paths precisely control the tooth depth (±0.01mm) and tooth pitch (±0.005mm), eliminating the problem of irregular tooth profiles caused by traditional manual gear milling.
- Cooling Holes/Auxiliary Processes: No cooling holes are required, but an automatic chip removal system is equipped to clear iron chips in real time and prevent tool jamming.
- Surface Treatment: A cutting fluid circulation system is applied during the milling process to ensure the surface roughness Ra ≤ 1.6μm without chatter marks.
- Inspection: A built-in online dimension measurement module is available, which automatically conducts random inspection every 10 pieces. The data is fed back and adjusted in a closed loop, reducing the scrap rate to below 0.5%.
Key Equipment: 4-spindle CNC system (power: 1.5/4/2.2/7.5kW), automatic feeding mechanism, fully enclosed protective cover, and online inspection unit.
| Indicator |
Traditional Process |
5GX Process |
Improvement Rate |
| Production Beat (12-inch) |
3 minutes/piece |
2.5 minutes/piece |
+20% |
| Labor Cost |
8 people/2 machines |
1 person/3-4 machines |
-160% |
| Scrap Rate |
5% |
0.5% |
-90% |
| Clamping Error |
±0.05mm |
±0.01mm |
-80% |
| Maintenance Cycle |
2-3 times/month |
1 time/quarter |
-75% |
Case Study: After a large hardware tool factory (with an annual output of 1 million adjustable wrenches) introduced 5 units of the 5GX Machine Tool, its single-shift production capacity increased from 2,000 pieces to 3,600 pieces, monthly labor costs were reduced by 120,000 yuan, the scrap rate dropped from 5% to 0.3%, and the order delivery cycle was shortened by 15%.
Applicable Scenarios: Hardware tool manufacturing, automotive repair tool production, and industrial-grade wrench machining.
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