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China Aluminum Casting Communication Terminal Base Enclosure - Quality from Trusted Suppliers and Factory
Process
01
Aluminum die casting
Equipment & Material
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.
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.
02
Remove spout
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
03
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.
04
FRONT SHAMPING
Tools
Hydraulic presses, forming tools and blade rulers
Precautions
Within 0.3mm of the front plane of the product
05
iPQC inspection
Visual inspection of appearance
06
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.
07
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;
08
CNC
Process Details
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
09
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
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)
Q
What materials and machines are used in the die casting process?
The process utilizes a 1650T aluminum die casting machine and ADC12 material. The raw material handle is kept at 20±2mm, and the furnace temperature is maintained at 640°±20°.
Q
What are the key quality precautions for the pressed copper heat pipe stage?
During this stage, the copper tube must not warp, deform, or rupture. The filler must be fully packed without air bubbles, and the surface must remain free of bruises or burrs while ensuring accurate positioning.
Q
How is the CNC machining surface finish verified?
The CNC machining process, using flat-bottomed cutters, drill bits, and tap processing fixtures, must ensure the finish of the processed surface reaches Ra1.6, while keeping within specified size and shape tolerances.
Q
What visual requirements apply to the cleaning and powder spraying process?
The surface must show no color differences, dirt, or signs of touching and scratching. The color must remain uniform and consistent with the sample, and the powder thickness must be uniform with no accumulation or exposed bottom.
Q
How are measuring instruments verified for final quality inspections (FQC / OQC)?
Inspectors verify that all measuring instruments—including calipers, projectors, tooth gauges, and needle gauges—are within their valid calibration periods and conform to customer and SIP requirements.