Our client, a manufacturer of carriages and bicycles, needed a reliable solution for bearing hubs—a small but critical component that connects the wheel and the axle. For smooth riding and long service life, these hubs had to be:
Lightweight to reduce overall vehicle weight.
Durable and corrosion-resistant to withstand outdoor conditions.
Precisely machined to guarantee balance and smooth rotation.
Cost-effective for large-scale production.
Meeting all these requirements with a single solution was a challenge—especially when the hubs needed to be both strong and finely detailed.
Our Solution: Precision CNC Machining with Aluminum Alloy
To solve this challenge, we selected aluminum alloy as the raw material. Known for its high strength-to-weight ratio, corrosion resistance, and excellent machinability, it was the perfect choice for this application.
We then combined the strengths of CNC turning and CNC milling to achieve both structural precision and fine detailing:
Cutting Aluminum Alloy Bars
High-quality aluminum bars were cut into blanks with consistent dimensions, ensuring stable quality from the very beginning.
CNC Lathe – Forming the Hub's Structure
The blanks were processed on a CNC lathe, which precisely shaped the cylindrical body and concentric bore of the hub. This step established the hub's fundamental geometry, ensuring perfect concentricity for smooth wheel rotation.
CNC Milling – Adding Complex Features
Next, the semi-finished hubs were transferred to a CNC machining center, where intricate details such as bolt holes, spoke interfaces, and flanges were milled. CNC milling allowed us to achieve tight tolerances and machine complex surfaces that conventional methods cannot handle.
Surface Treatment – Strength and Aesthetics
After machining, each hub underwent sandblasting to remove tool marks and provide a uniform matte texture. Anodizing was then applied, giving the hubs excellent corrosion resistance, greater surface strength, and the option for customized colors.
Rigorous Quality Inspection
Every hub was thoroughly inspected—measuring dimensions, checking concentricity, and verifying thread quality. This ensured each part met the client's specifications and could perform reliably under real-world conditions.
Final Packaging
The finished hubs were securely packaged to protect their anodized surfaces and precision features during shipping and storage.
Before vs After: How Our Solution Made the Difference
Aspect | Before (Traditional Hubs) | After (Our CNC-Machined Hubs) |
Weight | Heavier materials increased vehicle load. | Lightweight aluminum alloy reduced overall weight. |
Durability | Prone to corrosion and faster wear outdoors. | Anodized finish ensured corrosion resistance and longer lifespan. |
Precision | Inconsistent tolerances led to imbalance and noise. | CNC machining achieved tight tolerances, ensuring smooth rotation. |
Aesthetics | Rougher finishes with visible machining marks. | Sandblasted and anodized surfaces with customizable colors. |
Production | Higher costs and lower scalability with traditional tooling. | Efficient large-scale production with CNC turning + milling. |
The transformation was clear: our hubs not only improved performance and durability but also provided a refined appearance that enhanced the client's product value in the market.
Why CNC Turning and CNC Milling Were the Perfect Combination
CNC Lathes Provided:
High efficiency in producing round profiles.
Excellent concentricity and surface finish.
Stable quality for scalable production.
CNC Milling Added:
Ability to machine complex geometries like holes, slots, and flanges.
High precision in flat surfaces and detailed edges.
Flexibility for design changes without costly tooling.
Capability to process surfaces that are hard to reach with conventional methods.
By combining both processes, we delivered hubs that were lightweight yet durable, precise yet cost-effective, ready for mass production.
The Results
The final aluminum alloy hubs not only met but exceeded our client’s expectations. They were:
Lightweight, reducing the overall weight of carriages and bicycles.
Durable and corrosion-resistant, ensuring long service life outdoors.
Aesthetically refined, with smooth finishes and customizable anodized colors.
Manufactured efficiently, balancing high-quality results with cost control.
This successful project showcased our ability to transform customer challenges into practical, high-performance solutions.
Conclusion
By leveraging our expertise in CNC machining and aluminum alloy processing, we provided a hub solution that combined strength, precision, and efficiency.
This case demonstrates not only our manufacturing capabilities but also our commitment to solving customer problems with tailored engineering solutions.
If you are seeking a reliable partner for custom machined components, from concept to production, our team can help you achieve the same success.
