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China Zinc Alloy Server Racks - Durable Zamak 3 Casting Parts from Reliable Suppliers and Factory
Process
1
ZINC die casting
Equipment & Material
138T zinc die casting machine; ZA 3# material
Process Characteristics
- The furnace temperature is 420°±20°, and the material handle is 20±2 mm.
- Secondary materials can not be used.
- Material composition must be tested to ensure it is suitable for production.
- The first piece must be confirmed.
Precautions
- It is necessary to verify the quality of surface filling. no bulging, no cold isolation, and no shortage of materials in the column.
- Pay attention to the surface and avoid mold stringing, sticking or insufficient ejector protrusion.
- For non-machined surfaces, the ejector pin should be concave 0-0.2mm, while for machined surfaces, the ejector pin should be convex 0-0.2mm.
2
Remove spout
Tools
Stick / saw machine
Things to note
- Pay attention to the surface and don't damage it or use insufficient material.
- Manage size and appearance.
3
IPQC inspection
Testing Instruments
Three CMM, appearance visual evaluation, projection, calculator
Precautions
Check dimensions against drawings and use accurate measuring equipment.
4
Deburring
Equipment
File, Wind mill, 120# sandpaper
Sharp angle position inverted R angle, deburring, non-machining surface top needle draping, grinding and connecting shape.
Note
No sharp corners, burrs to remove clean, along the R angle.
5
SHAPING
Equipment & Process
PRODUCT BACK SHAPING
Equipment: knife-edge ruler, shaping fixture, Rubber hammers, rubber pads
Note
Within 0.2mm of the front plane of the product.
6
CNC
Specifications & Equipment
- A-Tapping two 6-32 teeth on each side face with a depth of 5.32+0.35mm/-0.15mm.
- B-Tapping four 6-32 teeth on front face with a depth 8mm.
Equipment: tapping machine, jigs
Note
- Hold the product lightly when processing, so as not to bruise the product.
- Place the products neatly and take the products to blow clean the surface of the jig.
- Refer to the requirements of the inspection specification for the appearance of the products.
- If there are any defects or other emergencies, please report to the superior immediately.
- Please pay attention to the processing and transportation process do not touch, scratch the product surface.
7
Grinding
Process & Equipment
Remove product clamping line draping, surface particles, slag ladle, gate residue.
Equipment: File, wind grinder, 120# sandpaper
Note
Do not leak processing, do not exist sharp corners, draping clean, mold closing line.
8
100% MATERIAL INSPECTION- APPEARANCE VISUAL INSPECTION
Note
- The surface of the product must be free of overcutting, sand holes, lack of material, burrs, and other undesirable phenomena.
- Via pass and stop gauge detection.
- Check the flatness of the product according to the drawings.
- Handle the product gently to prevent deformation.
9
IPQC INSPECTION
Process
Visual inspection of appearance.
10
Cleaning + Chemical Conversion Membrane + Drying
Note
No different color, dirty, not touching and scratching.
11
Full inspection of appearance + packaging
Packaging Materials
Comprehensive inspection of products and packaging.
Equipment: Carton, knife card, clapboard, bubble bag
Note
- The appearance shall be inspected according to the sample. The surface shall be free of dirt, scratches, dents and defects.
- The tooth pattern must comply with the pass-and-stop inspection.
- The product is placed in the knife card, covered with flat cardboard on the upper layer, and then packaged.
12
FQC exam
Testing Instruments
Calipers, projectors, pin gauges, tooth gauges, visual and packaging inspection are all examples of testing instruments.
Note
Verify that the measurement device is still within its calibration window.
13
Transportation
Prepare for a rainy day
- Confirm that the quantity matches the order.
- Label and stamp the outer box.
- Send reports on shipments.
14
OQC shipping inspection
Testing Instruments
Calipers, projectors, pin gauges, tooth gauges, outer packaging inspection, etc.
Note
If the measuring device is still within its calibration window. Whether it meets both customer and SIP requirements.
Frequently Asked Questions (FAQ)
What are the primary temperature and material requirements for the ZINC die casting process?
The process requires a 138T zinc die casting machine and ZA 3# material. The furnace temperature must be strictly maintained at 420°±20° with a material handle of 20±2 mm. Secondary materials are prohibited, and the material composition must be verified before production.
What tolerances and precautions are required during the shaping and CNC tapping stages?
For shaping, the surface must be within 0.2mm of the product's front plane. During CNC tapping, side face tapping requires a depth of 5.32+0.35mm/-0.15mm for two 6-32 teeth, and front face tapping requires a depth of 8mm for four 6-32 teeth. Products must be handled gently to prevent bruising.
How are deburring and grinding processes monitored to ensure surface quality?
Using files, wind mills/grinders, and 120# sandpaper, operators must clean all burrs, draping, clamping lines, slag, and gate residues. No sharp corners should remain, and all transitions must follow the designated R angle profile.
What standards must be met during the 100% material inspection and IPQC inspection?
The product surface must be free from overcutting, sand holes, material shortages, and burrs. Flatness must align with drawing specifications, and tooth patterns must be verified using pass-and-stop gauges. Visual inspections ensure the surface is clean, scratch-free, and consistent in color.
How are products protected and verified during packaging and shipping?
Products are placed in custom knife cards, covered with flat cardboard on the upper layer, and packed in cartons with clapboards and bubble bags. Prior to shipping, FQC and OQC verify that all measuring instruments are within their calibration windows and that the shipment meets both customer and SIP requirements.