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China Aluminum Casting Communication Terminal Base Enclosure | Quality Factory Suppliers for Durable Solutions
Process
1
Aluminum die casting:
Equipment & Materials
- 1650T aluminum die casting machine; ADC12 material
Process characteristics
- a. Material handle: 20±2mm, furnace temperature: 640°±20°;
- b. The use of secondary items is not allowed;
- c. Verify through testing that the material composition is suitable and can be manufactured;
- d. After die casting, first piece confirmation is required.
Note:
a. Verify the filling quality of the surface. It’s not the bulge, it’s not the cold insulation, it’s not the lack of material in the pillars.
b. Pay attention to the surface to prevent poor ejector pin crown, mold pulling or mold sticking.
c. For non-machined surfaces and machined surfaces, the ejector pins are concave by 0-0.2 mm. The ejector pin must have a convex shape of 0-0.2 mm.
b. Pay attention to the surface to prevent poor ejector pin crown, mold pulling or mold sticking.
c. For non-machined surfaces and machined surfaces, the ejector pins are concave by 0-0.2 mm. The ejector pin must have a convex shape of 0-0.2 mm.
2
Remove spout
Equipment
- Equipment: a wooden stick/ sawing machine
Things to note:
a. Pay attention to the surface and don't damage it or use insufficient material.
b. Adjust size and appearance
b. Adjust size and appearance
3
IPQC inspection (verify detailed dimensions in drawings)
Testing instruments
- calipers, projection, three-dimensional modeling, visual appearance inspection
Precautions:
Check dimensions against drawings and use accurate measuring equipment.
4
FRONT SHAMPING
Tools
- Hydraulic presses, forming tools and blade rulers
Precautions:
Within 0.3mm of the front plane of the product
5
iPQC inspection
- Visual inspection of appearance
6
Pressed copper heat pipe- Burying heat pipes as per drawings
Equipment
- Pressure Heat Pipe Fixture
Precautions:
a. Copper tube must not warp and deform, rupture;
b. Filler is full, no air bubbles;
c. The surface should be careful not to bruise or burr.
d. The position of copper pipe is accurate.
b. Filler is full, no air bubbles;
c. The surface should be careful not to bruise or burr.
d. The position of copper pipe is accurate.
7
IPQC INSPECTION
- Visual inspection of appearance
Precautions:
a. The copper tube must not warp and deform or rupture;
b. The filler is full and free of air bubbles;
b. The filler is full and free of air bubbles;
8
CNC:
Operations & Equipment
- Machining main Inlet, main Dump Port Face, Backside, Perforated Overbore
- Equipment: CNC machine, flat-bottomed cutter, drill bit, tap processing fixture.
Note:
a. Do not over-cut or miss processing;
b. Be careful not to scratch or burr the surface;
c. Ensure the finish of the processed surface is Ra1.6, and the size and shape tolerances.
b. Be careful not to scratch or burr the surface;
c. Ensure the finish of the processed surface is Ra1.6, and the size and shape tolerances.
9
100% material inspection- Appearance visual inspection
Precautions:
a. The surface of the product must be free of overcutting, sand holes, lack of material, burrs, and other undesirable phenomena.
b. Via pass and stop gauge detection
c. Check the flatness of the product according to the drawings
d. Handle the product gently to prevent deformation
b. Via pass and stop gauge detection
c. Check the flatness of the product according to the drawings
d. Handle the product gently to prevent deformation
10
GRIDing:
Process Details & Equipment
- The sharp corners of the product are chamfered, deburred, non-machined ejector pins are sharpened, and polished to smooth the appearance.
- Equipment: File, wind grinder, 120# sandpaper
Note:
No processing should be missed, no sharp corners or burrs should be removed, and the R corners should be connected smoothly.
11
IPQC inspection
- Visual inspection of appearance
12
Cleaning + Chemical conversion membrane + drying + power spraying
Precautions:
a. No different color, dirty, not touching and scratching
b. Color according to the sample, uniform and consistent;
c. Powder thickness uniformity, no accumulation of tumor, no exposed bottom
b. Color according to the sample, uniform and consistent;
c. Powder thickness uniformity, no accumulation of tumor, no exposed bottom
13
IPQC inspection
- Visual inspection of appearance, special characteristic inspection
Note:
a. After the film/powder coating surface quality confirmation.
b. Hole need to needle gauge sampling, tooth hole through the go-no go fixed gauges detection
b. Hole need to needle gauge sampling, tooth hole through the go-no go fixed gauges detection
14
Full inspection of appearance + packaging
Equipment
- Carton, knife card, clapboard, bubble bag
Note:
a. 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!
b. The tooth pattern must comply with go- no go fixed gauges inspection.
c. The product is placed in the knife card, covered with flat cardboard on the upper layer, and then packaged.
b. The tooth pattern must comply with go- no go fixed gauges inspection.
c. The product is placed in the knife card, covered with flat cardboard on the upper layer, and then packaged.
15
FQC inspection
Test Tools
- Caliper, projection, needle gauge, tooth gauge, appearance and outer packaging inspection
Note:
Whether the measuring tool is within the calibration period.
16
Full inspection + packaging inspection
Notes:
a. Appearance needs to be checked based on samples. There should be no dents, scratches or other blemishes on the surface and the glue application should be smooth and flawless!
b. The tooth shape needs to match the pass gauge and stop gauge;
c. Put the product into the knife card, cover the top of the knife card with a flat cardboard and package it.
b. The tooth shape needs to match the pass gauge and stop gauge;
c. Put the product into the knife card, cover the top of the knife card with a flat cardboard and package it.
17
Transportation
Note:
a. Confirm that the quantity matches the order.
b. Label and stamp the outer box.
c. Send reports on shipments.
b. Label and stamp the outer box.
c. Send reports on shipments.
18
OQC shipment inspection
Inspection instruments
- calipers, projectors, tooth gauges, needle gauges, appearance, outer packaging inspection
Prepare for a rainy day:
If the measuring device is still within its calibration window. Whether it meets both customer and SIP requirements.
Frequently Asked Questions (FAQ)
What are the temperature requirements for the Aluminum Die Casting process?
For the ADC12 material in the 1650T aluminum die casting machine, the furnace temperature must be strictly maintained at 640°±20° with a material handle of 20±2mm.
What tolerances are required during the CNC machining stage?
During CNC machining, the processed surface must achieve a finish roughness of Ra1.6, and all size and shape tolerances must meet the detailed drawing requirements without any over-cutting or missed operations.
What precautions are taken when burying copper heat pipes?
The copper tube must not warp, deform, or rupture. The filler must be fully packed without any air bubbles, and the final position of the copper pipe must be highly accurate according to drawings.
How is the quality of the powder spraying and coating verified?
The sprayed powder coating must be uniform in thickness without any accumulation of tumor or exposed bottom. The color must match the sample consistently, and the surface must be free of dirty spots, scratches, or color differences.
What is the protocol for measuring instruments used during FQC and OQC inspections?
All measuring devices (including calipers, projectors, tooth gauges, and needle gauges) must be verified to ensure they are within their valid calibration periods and conform to both customer and SIP requirements.