1. Aluminum Die Casting
Equipment: 400T aluminum die casting machine
Material: ADC12 material
Process Characteristics:
a. Material handle: 20±2mm, furnace temperature: 670°±20°
b. Secondary items are 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. Pay attention to the surface and don't damage it or use insufficient material. b. Manage size and appearance.
2. Remove Spout
(Saw spout and knock out slag bag)
Equipment: Sawing machine
Tools: Wooden stick
Precautions: a. Pay attention to the surface without crushing or shortage of materials. b. Control the appearance and size.
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. Product Back Plastic Surgery
Tools: Hydraulic presses, forming tools and blade rulers
Precautions: Warning: The accuracy of the front of the product is within 0.25 mm.
5. CNC Processing
a. Use CNC processing to process the through-hole of the tooth hole, the end face of the inner cavity, and the end face of the peripheral heat dissipation tooth face.
b. Deburring: In order to make the product smooth in appearance, the sharp corners are chamfered and deburred, and the non-machined ejector pins are sharpened and polished.
c. Complete check
Tools & Equipment: Drill bits, flat bottom milling cutters, CNC machine tools, tap processing fixtures, 120# sandpaper, files, wind mill
Note: a. Avoid over-cutting, leaving no sand holes, sharp edges, or missed processing; avoid scratches and burrs; and ensure smooth connection of the R corners. b. Control dimensional and shape tolerances to ensure that the processed surface finish reaches Ra 0.8. c. Regulation and non-regulation inspections. d. Verify product is flat relative to drawing. e. Handle items carefully to avoid deformation.
6. Polishing (Hand Removal)
(Remove surface particles, slag bags, gate residues, and product wire caps.)
Note: The mold closing line should be connected smoothly, sharp edges or corners should not be ignored, and no processing should be ignored.
7. Outsourcing (Surface Treatment)
Outsourcing: Two-color spraying at different locations uses a combination of powder spraying and oil spraying.
Test Instruments: Appearance visual inspection combined with colorimeter, film thickness meter, salt spray tester, hundred grid tester, alcohol resistance test, pencil test
Precautions: a. No contrasting colors, dirt, exposed bottoms, dust accumulation, scratches or other issues; tinted and anti-bake fractals are clearly visible; b. The color is completely consistent with the sample.
8. IPQC / IQC Incoming Inspection
Note: a. Verify surface condition after powder coating; b. Holes must be randomly inspected using pin gauges, pass gauges, and stop gauges.
9. 100% Inspection
a. 100% inspect the appearance of the powder-coated.
b. Conduct random inspections for the powder-coated performance test.
Note: a. There is no obvious color, dirt, exposed bottom, dust accumulation, scratches, etc. in the coloring and baking-resistant fractal areas; b. The color exactly matches the sample.
10. Glue Dispensing
Dispense glue, the width and height are asymmetrically centered at 1.0±0.1, and glue to the designated strip area.
Tools: Dispensing jigs and machines
Precautions: a. The strips are uniform; they will not break, pile up, pull, overflow, deviate, bubble, fall off, etc. b. Verify whether the glue cannot adhere or regenerate well, whether the glue strength is optimal, etc.
11. Accessory Assembly
a. Heat dissipation copper bar assembly position corresponding to glue assembly;
b. Sheet metal part M2.5*5 screw position locking to press heat dissipation copper block;
Components: SE4450 Five Heatsink Copper Bars with glue, Three pieces of sheet metal, Six half-round screws, M2.5*5
Precautions: a) The glue is dispensed into the copper bar dispensing slot in accordance with the sample; b) Verify that the lock screw position is steady and the teeth are not slipping.
12. Drying
Carefully arrange the items on the baking line into 2 columns and 7 rows, for a total of 14 items. Bake at 150°C for 30 minutes.
Equipment: Dryer
Note: Leave enough space between products, be careful not to touch the tunnel door, hold it gently to avoid any bruises.
13. 100% Final Inspection & Packaging
Note: 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 layer of the knife card with flat cardboard, and package it.
14. FQC Inspection
Inspection Tools: Calipers, projectors, needle gauges, tooth gauges, appearance and outer packaging inspection.
Precautions: Whether the measuring tool is within the calibration period.
Precautions: a. Make sure the quantity is the same as the order. b. Labels and seals on the outer box. c. Provide shipping reports.
16. OQC Shipping Inspection
Inspection Instruments: Calipers, projectors, tooth gauges, needle gauges, appearance, outer packaging inspection.
Precautions: Whether the measuring tool is within the calibration period. Whether it is consistent with SIP requirements and customer requirements.
