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China Suppliers Factory Aluminum Die Cast Telecom Server Heatsink Enclosure Prototyping Part
Process Workflow
Step 01
Aluminum Die Casting
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
- a. The filling quality of the surface needs to be confirmed. No cold insulation, no bulging, or lack of material for the pillars.
- b. Pay attention to the surface to avoid sticking molds, drawing molds, or poor ejector pin convexity.
- c. 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)
Precautions
- a. Pay attention to the surface without crushing or shortage of materials.
- b. Control the appearance and size.
Step 03
IPQC Inspection
Precautions
Use measuring tools correctly and check dimensions according to drawings.
Step 04
SHAPING
Process: Back shaping
Precautions
Within 0.3mm of the front plane of the product
Step 05
IPQC Inspection
Step 06
CNC Machining
Scope: Machining of internal cavity end faces, Backside holes, Side of one end, Hole through-hole
Precautions
- a. Do not overcut, missed processing;
- b. Surface attention must not be bruised, burrs; and
- c. Ensure that the surface finish Ra0.8, size, shape and location tolerances.
Step 07
100% Material Inspection
Note
- a. The surface of the product should not be overcut, sand holes, lack of material. Burrs, and other undesirable phenomena
- b. go-no go fixed gauges inspection
- c. Test the flatness of the product according to the drawing.
- d. Hold the product lightly to prevent deformation.
Step 08
Grinding
Process: Chamfering R-angle, deburring, thimble shaving on non-machined surfaces, polishing and smoothing the shape
Note
Do not miss the processing, no sharp corners, burrs removed cleanly, connected to the R angle of the smooth.
Step 09
IPQC Inspection
Step 10
Chemical Conversion Membrane
Precautions
- a. No different colors, no dirty, not touching and scratching;
- b. Color according to the sample, uniform and consistent.
Step 11
IPQC Inspection + Special Characteristics Inspection
Precautions
- a. Surface quality confirmation after coating;
- b. Hole need to needle gauge sampling, go -no go fixed gauges inspection.
Step 12
Full Inspection of Appearance + Packaging
Process: Comprehensive inspection of products and packaging
Precautions
- 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 the go – no go fixed gauge inspection;
- c. The product is placed in the knife card, covered with white rice paper on the upper layer, and then packaged.
Step 13
FQC Inspection
Precautions
Whether the measuring tool is within the calibration period.
Step 14
Shipping
Precautions
- a. make sure the quantity is the same as order.
- b. Label and stamp on the outer box
- c. Provide a shipping report.
Step 15
OQC Shipping 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)
What equipment and material specifications are used in the die casting process?
We utilize a 500T aluminum die casting machine. The material used is HH33GR, processed under a strictly controlled furnace temperature of 670°±20° with a material handle of 20±2MM. Secondary materials are strictly prohibited.
How is surface quality controlled during the initial die casting and grinding stages?
During die casting, operators check for surface defects like cold insulation, bulging, sticking molds, or poor ejector pin convexity. In the grinding stage, deburring, chamfering R-angles, and thimble shaving are performed with air grinders and 120# sandpaper to ensure clean, smooth connections without sharp corners.
What are the key requirements for the CNC machining stage?
The CNC phase involves machining internal cavity end faces, backside holes, end sides, and through-holes. Precautions include preventing overcutting or missed processing, ensuring surfaces are free of bruises and burrs, and maintaining a surface finish of Ra0.8 alongside strict dimensional and location tolerances.
What parameters are checked during the chemical conversion membrane process?
The chemical conversion membrane must exhibit uniform and consistent color matching the physical sample. The surface must be completely free of color variations, dirt, scratches, or handling marks.
How are products inspected and packaged prior to shipment?
Products undergo a full appearance inspection (checking for dirt, scratches, or uneven glue dispensing) and tooth patterns are checked with go/no-go fixed gauges. For packaging, items are placed in knife cards, covered with white rice paper on the upper layer, and packed with cartons, dividers, bubble wrap, and desiccant.
What quality control steps (IPQC/FQC/OQC) are in place?
Quality control is integrated at multiple stages: IPQC inspections occur after die casting, shaping, grinding, and coating using calipers, projection, needle gauges, and three-dimensional tools. Final FQC and OQC shipping inspections ensure all measuring tools are calibrated and products comply with SIP and customer requirements.