Custom Push-Pull Outer Casing for Our Clients
Project Background
Our company has long been dedicated to the R&D and manufacturing of precision tubular products such as push-pull casings and spring casings for various industries, with mature process capabilities and a comprehensive quality control system. This project originated from a foreign customer’s procurement need for control cable casings used in large special-purpose equipment. The customer provided their product drawings in advance, and we undertook sample development and subsequent mass production supply.
Customer Requirements
During the technical alignment and production advancement process, after testing, the customer additionally imposed stringent rigidity and rebound performance requirements:
Wind the 10mm finished bare tube into 2 coils with a diameter of 200mm, then release and allow it to hang naturally downward. The natural sag height of the bare tube shall be ≤160mm; the natural sag height after plastic coating treatment shall be ≤230mm.
Project Challenges
The technical standards required by the customer’s drawings already far exceeded those of conventional products in the same category. The additional special requirements became the core process challenges of this project. We set extremely high requirements for the steel wire’s elastic modulus, yield strength, and heat-treatment conditions, as well as the precision of helical winding, stress control during forming, and suppression of performance degradation after plastic coating.
Solutions
In response to this challenge, our company conducted systematic optimization from two aspects: steel wire material and forming molds:
Steel wire material optimization: We re-established standards for the physical property requirements of the steel wire, significantly improving the elastic recovery capability and deformation resistance stability of the tubing, thereby fundamentally ensuring the rebound performance after winding;
Mold optimization: We redesigned and optimized key parameters, fully accounting for the stiffening effect of the plastic coating process on rigidity, ensuring that both bare tubes and coated products meet the sag requirements.
Results Achieved
After implementing the optimization plan and verifying across multiple batches, the product rebound test results are as follows:
- After winding the bare tube into 2 coils and releasing, the natural sag was stably controlled within 160mm (measured minimum: 152mm);
- For plastic-coated products, the natural sag was stably controlled within 230mm (measured minimum: 220mm).
- The product’s stiffness characteristics fully met the stringent indicators specified by the customer, with good batch consistency and process stability, and successfully entered the mass production supply stage.
Customer Feedback
After receiving the batch samples, the customer highly recognized the rebound precision, performance consistency, and appearance quality of this batch of spring tubes, confirmed that the products fully meet the requirements for vehicle installation, and has continued to place follow-up orders. Our company has been included in the customer’s premium supplier system for this product category.
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