0102030405
China ADC12 Telecom Server Heatsink Enclosure Prototyping - Aluminum Die Cast Suppliers and Factory
Process
Step 01
Aluminum die casting
Equipment & Material
Equipment: 500T aluminum die casting machine
Material: HH33GR
Material: HH33GR
Process characteristics
- Furnace temperature: 670°±20°, Material handle: 20±2MM;
- Secondary materials cannot be used;
- Test the material composition to confirm that it is OK and can be produced;
- First piece confirmation is required after die-casting.
Precautions
- The filling quality of the surface needs to be confirmed. No cold insulation, no bulging, or lack of material for the pillars.
- Pay attention to the surface to avoid sticking molds, drawing molds, or poor ejector pin convexity.
- The ejector pins are concave by 0-0.2mm for non-machine-added surfaces and 0-0.2mm for machine-added surfaces. The thimble needs to be convex 0-0.2mm.
Step 02
Remove spout (Saw spout and knock out slag bag)
Equipment
Hydraulic presses
Precautions
- Pay attention to the surface without crushing or shortage of materials.
- Control the appearance and size.
Step 03
IPQC inspection
Test Tools
Caliper, projection, three-dimensional, visual inspection of appearance.
Precautions
Use measuring tools correctly and check dimensions according to drawings.
Step 04
SHAPING
Process Details
Back shaping
Equipment
Cutting edge ruler, shaping tooling, hydraulic presses
Precautions
Within 0.3mm of the front plane of the product.
Step 05
IPQC inspection
Process Details
Visual inspection of appearance.
Step 06
CNC
Process Details
Machining of internal cavity end faces, Backside holes, Side of one end, Hole through-hole.
Equipment
CNC machine, flat-bottomed gong tool, Drill Bit, Tap machining jig
Precautions
- Do not overcut, missed processing;
- Surface attention must not be bruised, burrs; and
- Ensure that the surface finish Ra0.8, size, shape and location tolerances.
Step 07
100% material inspection
Process Details
Visual inspection of appearance.
Note
- The surface of the product should not be overcut, sand holes, lack of material, burrs, and other undesirable phenomena.
- go-no go fixed gauges inspection.
- Test the flatness of the product according to the drawing.
- Hold the product lightly to prevent deformation.
Step 08
Grinding
Process Details
Chamfering R-angle, deburring, thimble shaving on non-machined surfaces, polishing and smoothing the shape.
Equipment
Air grinder, 120# sandpaper
Note
Do not miss the processing, no sharp corners, burrs removed cleanly, connected to the R angle of the smooth.
Step 09
IPQC inspection
Process Details
Visual inspection of appearance.
Step 10
Chemical conversion membrane
Precautions
- No different colors, no dirty, not touching and scratching;
- Color according to the sample, uniform and consistent.
Step 11
IPQC inspection + Special Characteristics Inspection
Process Details
Visual inspection of appearance.
Precautions
- Surface quality confirmation after coating;
- Hole need to needle gauge sampling, go -no go fixed gauges inspection.
Step 12
Full inspection of appearance + packaging
Process Details
Comprehensive inspection of products and packaging.
Equipment / Materials
cartons, dividers, bubble wrap, desiccant
Precautions
- The appearance shall be inspected according to the sample. The surface shall be free of dirt, scratches, dents and defects, and the glue dispensing shall be even and without defects!
- The tooth pattern must comply with the go – no go fixed gauge inspection;
- The product is placed in the knife card, covered with white rice paper on the upper layer, and then packaged.
Step 13
FQC inspection
Test Tools
Caliper, projection, needle gauge, tooth gauge, appearance and outer packaging inspection.
Precautions
Whether the measuring tool is within the calibration period.
Step 14
Shipping
Precautions
- make sure the quantity is the same as order.
- Label and stamp on the outer box.
- Provide a shipping report.
Step 15
OQC shipping inspection
Test Tools
Caliper, projection, needle gauge, tooth gauge, appearance and outer packaging inspection.
Precautions
Whether the measuring tool is within the calibration period. Whether it is consistent with SIP requirements and customer requirements.
Frequently Asked Questions (FAQ)
Q1: What materials and machinery are used for the initial die casting process?
A1: We utilize a 500T aluminum die casting machine and HH33GR material. The process requires a furnace temperature of 670°±20° and a material handle of 20±2MM. Secondary materials are strictly prohibited.
Q2: How is the quality of the CNC machining phase ensured?
A2: Our CNC process prevents overcutting and missed processing. We ensure the surface finish reaches Ra0.8, eliminate burrs and bruises, and strictly verify size, shape, and location tolerances.
Q3: What methods are used during IPQC and OQC inspections?
A3: Inspections are carried out using professional tools including calipers, projection systems, three-dimensional measuring instruments, needle gauges, and tooth gauges, alongside thorough visual inspections.
Q4: What precautions are taken during the chemical conversion membrane process?
A4: We ensure there is no color variation, dirt, or surface scratching. The final finish must be uniform and consistent, perfectly matching the target sample.
Q5: How are the products packaged to prevent damage during transit?
A5: After a full appearance inspection, products are placed in knife cards, covered with white rice paper on the upper layer, and securely packed using cartons, dividers, bubble wrap, and desiccant.