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China Suppliers Factory Digital Chassis Back Panel Heat Sink for Telecom Terminal Applications
Process
Step 01
Aluminum die casting
Equipment & Material
Equipment: 1250T aluminum die casting machine
Material: ADC12
Material: ADC12
Process Characteristics
- a. Furnace temperature: 670°±20°, Material handle: 20±2MM;
- b. Secondary materials cannot be used;
- c. Test the material composition to confirm that it is OK and can be produced;
- d. 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)
Equipment
Equipment: hydraulic presses
Precautions
- a. Pay attention to the surface without crushing or shortage of materials.
- b. 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
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
Details
Visual inspection of appearance.
Step 06
CNC
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
- 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
Air tightness testing
Details
Test pressure value in 20kpa ~ 30kpa, stabilized pressure 20 seconds, test time 10 seconds, leakage control within 0.3kpa.
Equipment
Airtight Tooling, Airtightness Test Equipment.
Precautions
- a. Do a good job on the product appearance surface protection, sealing groove parts without implementation of touch scratch;
- b. Discover the phenomenon of air leakage in time to pick out the marking.
Step 08
100% material inspection
Details
Visual inspection of appearance.
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 09
Grinding
Details
Chamfering R-angle, deburring, thimble shaving on non-machined surfaces, polishing and smoothing the shape.
Equipment
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 10
IPQC inspection
Details
Visual inspection of appearance.
Step 11
CLEANNING + Chemical conversion membrane + POWER SPRAYING
Precautions
- a. No different colors, dirty, not touching and scratching;
- b. Color according to the sample, uniform and consistent;
- c. Powder thickness is uniform, no accumulation of tumors, no exposed bottom.
Step 12
IPQC inspection + Special Characteristics Inspection
Details
Visual inspection of appearance.
Precautions
- a. Surface quality confirmation after coating;
- b. Hole need to needle gauge sampling, go -no go fixed gauges inspection.
Step 13
Riveting and pressing D4.7 dowels
Equipment
Pressure riveting jig, hydraulic press
Note
- a. Check that the pins are loaded without deviation or falling off, and that there is no bulge or pressure injury on the surface of the product;
- b. Check the height dimension after pressure riveting.
Step 14
Full inspection of appearance + packaging
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 the go – no go fixed gauge inspection;
- c. The product is placed in the knife card, and then packaged.
Step 15
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 16
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 17
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 raw materials and machinery are used during the initial die casting step?
The process utilizes ADC12 material and a 1250T aluminum die casting machine under a controlled furnace temperature of 670°±20°.
Q2:
What are the specific parameters required for the Air Tightness Testing step?
The testing requires a pressure value between 20kpa to 30kpa, a stabilized pressure holding duration of 20 seconds, a test time of 10 seconds, and leakage must be controlled within 0.3kpa.
Q3:
What precautions are taken during CNC machining to ensure quality?
Operators must prevent overcutting, ensure no steps are missed, protect surfaces from bruises and burrs, and verify that the surface finish reaches Ra0.8 alongside correct size and location tolerances.
Q4:
What is checked during the riveting and pressing of the D4.7 dowels?
Inspectors verify that the pins are installed without deviation or falling off, ensure there is no surface damage or bulging, and measure the final height dimension post-riveting.
Q5:
How is the quality of the powder spraying and coating verified?
The coating is inspected to ensure color consistency matching the sample, uniform powder thickness without accumulation of tumors or exposed bottom metal, and no dirt or scratches.
Q6:
What tools are utilized during FQC and OQC shipping inspections?
Both FQC and OQC inspections rely on calipers, projection equipment, needle gauges, tooth gauges, and thorough visual checks of the product appearance and outer packaging.