CNC Turning & Polishing · 6063 Aluminum
6063 Aluminum Ball-Head Screws: 100,000 Parts per Month
OUJI produces this small 6063 aluminum ball-head screw for an automotive application at 100,000 parts per month. A 5.970–6.000 mm ball-diameter requirement had to be met alongside a smooth spherical surface free from scratches, steps and dents. Tool, CNC program and feed optimization, followed by walnut-media tumbling and polishing, established the production route.
By Tom Yi, Project Support | Custom Machining & Technical Coordination
Published
At a Glance
- Material
- 6063 aluminum / EN AW-6063
- Process
- Optimized CNC turning → walnut-media tumbling and polishing
- Project production volume
- 100,000 parts per month
- Ball diameter requirement
- Ø6 mm, +0 / −0.03 mm; limits 5.970–6.000 mm
- Surface requirement
- Smooth spherical surface without scratches, steps or dents
- External thread
- M4
From the production drawing
A 0.030 mm diameter band, plus a surface requirement
The ball diameter is specified as Ø6 mm, +0 / −0.03 mm: 5.970–6.000 mm. The drawing separately requires a smooth spherical surface without scratches, steps or dents. Only the part illustration and these requirements are retained; identifying information and unrelated dimensions have been removed. Download the redacted drawing excerpt.
01
The Challenge
The ball head could not be accepted on diameter alone. Its spherical surface also had to meet the drawing’s appearance requirements. The rejected sample shows the visible surface issue that prompted the process work. Both the 0.030 mm-wide diameter band and the condition of the ball surface mattered at a production volume of 100,000 parts per month.
02
OUJI's Approach
OUJI optimized the cutting tools, CNC program and feed used to turn the ball head, then used walnut media for tumbling and polishing. The turning changes established the repeatable machining process; the polishing operation addressed the final smooth-surface requirement. Outside-micrometer photographs provide separate evidence of ball-diameter checks.
03
The Result
The revised turning and walnut-media polishing route supported production at 100,000 parts per month, with the smooth surface appearance required for this project. The photographed micrometer displays of 5.980 mm and 5.974 mm are within the 5.970–6.000 mm drawing limits. The monthly volume and process outcome are confirmed by OUJI; the photographs document individual dimensional checks.
Production sequence
From ball-head requirements to repeat production
The process addressed dimensional control and appearance together, with walnut-media polishing following CNC turning.
Define both acceptance requirements
Use the 5.970–6.000 mm ball-diameter limits and the drawing’s separate surface criteria.
Optimize the turning process
Adjust the cutting tools, CNC program and feed for stable production of this small ball-head component.
Tumble and polish with walnut media
Follow turning with walnut-media polishing to achieve the smooth appearance required for the project.
Rejected sample / appearance requirement
A visible surface issue on the ball head
This sample was rejected for its ball-head surface appearance. The arrow identifies the area of concern. A diameter reading alone would not resolve the appearance requirement, so the machining and finishing route had to address both.
Finishing after CNC turning
Walnut-media tumbling for the smooth surface
After optimizing the turning process, OUJI used walnut media for tumbling and polishing. The photograph shows the drum equipment and its media used in this project. This operation formed part of the route used to achieve the required ball-surface appearance.
100,000 parts per month
A process used for recurring volume
OUJI confirms production at 100,000 parts per month for this ball-head screw. The workshop photograph shows the parts collected in volume. That figure describes this project’s monthly output; the equipment photograph is not a per-machine capacity specification.
Photographed dimensional check
Ball-diameter checks: 5.980 mm and 5.974 mm
The outside micrometer is shown contacting the ball head. Both photographed displays fall within the 5.970–6.000 mm diameter limits.
| Characteristic | Requirement | Photographed evidence |
|---|---|---|
| Ball diameter · top photo | 5.970–6.000 mm | 5.980 mm; within the specified interval |
| Ball diameter · bottom photo | 5.970–6.000 mm | 5.974 mm; within the specified interval |
| Spherical surface | Smooth; no scratches, steps or dents | Separate appearance requirement; a micrometer does not assess the surface |
How to read this evidence
These are individual diameter checks. The photographs are not identified as post-polishing measurements and do not establish polishing size loss, sphericity, batch yield or statistical process capability. No numerical surface-roughness result is published.
Project questions
What tolerance was required on this 6063 aluminum ball head?
The drawing specifies Ø6 mm with +0 / −0.03 mm deviations, giving limits of 5.970–6.000 mm. This is a 0.030 mm-wide diameter band, separate from the surface-appearance requirement.
How did OUJI achieve the required ball-surface appearance?
OUJI optimized the cutting tools, CNC program and feed for turning, then used walnut media for tumbling and polishing. The route supported the required smooth appearance and production at 100,000 parts per month for this project.
What should buyers specify for similar aluminum ball studs?
Provide the drawing and model, aluminum grade and temper, ball-diameter tolerance, surface acceptance criteria and monthly demand. Specify required inspection records, cleanliness and packaging so the machining and finishing route can be reviewed together.
Have a project-specific question?
Planning a similar aluminum turned part?
Send your 2D drawing and 3D model with the aluminum grade and temper, ball-diameter tolerance, surface acceptance criteria and monthly demand. Include inspection, cleanliness and packaging requirements for a machining and finishing review.
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