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China Suppliers Factory Digital Chassis Back Panel Heat Sink for Telecom Terminals
Process Workflow
Step 01
Aluminum Die Casting
Equipment & Material
Equipment: 1250T aluminum die casting machine
Material: ADC12
Material: ADC12
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.
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
hydraulic presses
Precautions
a. Pay attention to the surface without crushing or shortage of materials.
b. Control the appearance and size.
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
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
Method
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
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.
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
Parameters
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.
b. Discover the phenomenon of air leakage in time to pick out the marking.
Step 08
100% Material Inspection
Method
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.
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
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 10
IPQC Inspection
Method
Visual inspection of appearance
Step 11
Cleaning + Chemical Conversion Membrane + Powder 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;
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
Method
Visual inspection of appearance
Precautions
a. Surface quality confirmation after coating;
b. Hole need to needle gauge sampling, go -no go fixed gauges inspection.
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.
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.
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.
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 are the key process characteristics of the aluminum die casting phase?
A1: Key characteristics include maintaining a furnace temperature of 670°±20° and a material handle of 20±2MM. Additionally, secondary materials are strictly prohibited, material composition must be verified beforehand, and a first-piece confirmation is required after die-casting.
Q2: What parameters are used for the air tightness testing?
A2: The test pressure value is set between 20kpa and 30kpa. The pressure is stabilized for 20 seconds, the test is run for 10 seconds, and the leakage must be controlled within 0.3kpa.
Q3: What are the quality requirements for the powder spraying process?
A3: The powder spraying must be uniform in thickness with no accumulation of tumors or exposed bottom. The color must match the reference sample consistently, and the surface must be free of dirty spots, scratches, or touch marks.
Q4: How is the quality of D4.7 dowels verified during pressure riveting?
A4: Operators must check that the pins are loaded straight without deviation or risk of falling off, ensure there is no surface bulging or pressure damage on the product, and measure the height dimension after riveting.
Q5: What calibration requirements apply to the inspection tools?
A5: For all quality checks, including FQC and OQC stages, all measuring tools (calipers, projection systems, needle gauges, and tooth gauges) must be verified to ensure they are within their active calibration period.
Q6: What precautions must be taken during the CNC machining process?
A6: Precautions include preventing overcutting or missed processing steps, keeping surfaces free of bruises or burrs, and ensuring that the surface finish reaches Ra0.8 along with maintaining strict size, shape, and location tolerances.