Machining a large circular base plate requires coordinated control of thin-plate distortion, dense hole patterns and the locating relationships between opposite faces. This Xu Feng case presents the manufacturing challenges and process requirements supplied for a 7075-T6 aluminum base plate.
Project Background
The component is a large-diameter, thin circular base plate made from 7075-T6 aluminum. Its features include central bore-related geometry, numerous locating holes and multiple shaped cutouts around the perimeter. The project brief describes machining features on both faces, requiring the part to be turned over while maintaining the relationship between holes and assembly datums.
The project calls for control of flatness, parallelism and hole position. Sharp-edge chamfers must not exceed 0.1 mm, and edges must be smooth and burr-free. Specified tolerances follow the drawing. The brief lists H12/h12 and ±IT12/2 for unspecified tolerances; their application to individual dimensions must be determined from the drawing.
Manufacturing Challenges
Material removal and thin-plate distortion
The brief identifies residual stress in the 7075-T6 plate as a manufacturing risk. Machining numerous holes and perimeter cutouts involves substantial material removal, making stress-related warping a process concern. Clamping force can also bend a large thin plate, adding difficulty to flatness and parallelism control.
Hole alignment across two-sided machining
Central features, locating holes and perimeter slots must maintain their required relationships on the same plate. Turning the component over introduces locating and workholding considerations. With a dense hole pattern, positional deviations can affect alignment during equipment assembly, so individual hole size is only one part of the inspection requirement.
Surface condition and tightly limited edge chamfers
The project requires the drawing-designated areas to meet their surface-finish requirements, with no tool marks or burrs on the specified surfaces. Sharp-edge chamfers are limited to 0.1 mm to avoid excessive material removal at assembly datums. Inspection of every hole before shipment is also a stated project requirement.
Xu Feng’s Process Solution
Coordinate rough machining and stress-relief aging
The process plan calls for close control of rough machining and stress-relief aging to address warping associated with material removal. The supplied brief does not specify treatment temperature, duration or material-condition verification records. Those details should follow the confirmed manufacturing instructions for the component.
Use compliant locating fixtures to control clamping distortion
The fixture requirement is to use compliant locating arrangements and avoid heavy clamping that could bend the thin circular plate. For two-sided machining, the locating relationship between setups must be considered alongside the requirements for the plate faces and hole pattern.
Combine CMM measurement with inspection of every hole
The project specifies coordinate measuring machine (CMM) inspection of finished-part flatness, parallelism and hole position, together with inspection of all holes before shipment. Drawing tolerances, designated surface requirements and chamfer limits must also be included in acceptance checks. Product photographs do not replace measurement records.
The plan connects material stress, clamping loads, two-sided location and inspection requirements to define the process-control priorities for the circular base plate.
For circular base plates or multi-hole thin-plate components, share your drawings, 3D model, material condition and acceptance requirements with Xu Feng to discuss machining and inspection planning. Contact Xu Feng →
