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Case Studies

Case Studies1
Machining of automotive Vortech pulleys with toothed teeth1
Machining of automotive Vortech pulleys with toothed teeth

Machining of automotive Vortech pulleys with toothed teeth

Kingsun has long cooperated with famous European car tuning companies and specializes in customized high-precision car parts. We help our customers enhance their market competitiveness with excellent precision and outstanding appearance. This case shows how we successfully machined a toothed automotive Vortech pulley at Kingsun.

Project Overview

  • Application: Automotive supercharger systems
  • Technology: High-precision turning, wire cutting, hard anodizing, and laser engraving.
  • Tolerances: Strict tolerance control, +/-0.01mm, after anodizing the bore.
  • Various post-processing: hard anodizing and laser engraving.
  • Material: Aluminium 6061-T6
Automotive supercharger systems
Automotive supercharger systems

Process analysis before production

According to the drawings provided by the customer, the tolerance of the bore of the Vortech pulley is +/-0.01mm, which is a hard anodized tolerance; in the turning process, we need to consider the film thickness in the hard anodizing, which has a small change will change the bore size. Therefore, we need to consider the film thickness and other factors when finishing the bore to adjust the bore size appropriately to ensure that the bore is within tight tolerances.

Fabrication of parts

Fabrication of parts (2)
Fabrication of parts

Kingsun uses a high-precision CNC lathe to achieve optimum tolerances of ±0.01MM. After machining, we use pin gauges and bore calipers to accurately check the bore dimensions. The pin gauges pass through the bore smoothly, ensuring that the part meets stringent quality standards.

Wire Cutting Technology4
Wire Cutting Technology

After turning, we use wire-cutting technology to machine the positioning keys to ensure that the tolerance of the keys is controlled to ±0.05 MM. Even after oxidization, we can still maintain the precise tolerance to ensure the reliable performance of the parts.

Once the wire-cutting process is complete, we send the parts to our long-standing partner, a high-quality manufacturer, for hard anodizing. This close cooperation ensures that the quality of our products is consistently high and meets our customers’ high demands for precision and durability.

Vortech Pulley (2)

With a hard anodized finish, Vortech pulleys offer enhanced durability and resistance to wear and corrosion, making them ideal for high-performance automotive applications. The anodized surface not only enhances the pulley’s strength but also provides a smooth, professional finish that meets stringent requirements for functionality and appearance. This process ensures the pulley maintains precise tolerances while extending service life, improving vehicle performance and reliability.

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