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China Zinc Alloy Server Racks - Top Suppliers & Factory for Zamak 3 Zinc Alloy Casting Consumer Parts
Process
Step 01
ZINC Die Casting
Specifications & Materials
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.
Step 02
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.
Step 03
IPQC Inspection
Testing Instruments
Three CMM, appearance visual evaluation, projection, calculator
Precautions
Check dimensions against drawings and use accurate measuring equipment.
Step 04
Deburring
Process Details
Sharp angle position inverted R angle, deburring, non-machining surface top needle draping, grinding and connecting shape.
Equipment
File, Wind mill, 120# sandpaper
Note
No sharp corners, burrs to remove clean, along the R angle.
Step 05
Shaping
Process Details
PRODUCT BACK SHAPING
Equipment
knife-edge ruler, shaping fixture, Rubber hammers, rubber pads
Note
Within 0.2mm of the front plane of the product.
Step 06
CNC
Process Details
- 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
- a. Hold the product lightly when processing, so as not to bruise the product.
- b. Place the products neatly and take the products to blow clean the surface of the jig.
- c. Refer to the requirements of the inspection specification for the appearance of the products.
- d. If there are any defects or other emergencies, please report to the superior immediately.
- e. Please pay attention to the processing and transportation process do not touch, scratch the product surface.
Step 07
Grinding
Process Details
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.
Step 08
100% Material Inspection - Appearance Visual Inspection
Note
- a. The surface of the product must be free of overcutting, sand holes, lack of material, burrs, and other undesirable phenomena.
- b. Via pass and stop gauge detection
- c. Check the flatness of the product according to the drawings
- d. Handle the product gently to prevent deformation
Step 09
IPQC Inspection
Process Details
Visual inspection of appearance
Step 10
Cleaning + Chemical Conversion Membrane + Drying
Note
No different color, dirty, not touching and scratching
Step 11
Full Inspection of Appearance + Packaging
Process Details
Comprehensive inspection of products and packaging
Equipment
Carton, knife card, clapboard, bubble bag
Note
- a. The appearance shall be inspected according to the sample. The surface shall be free of dirt, scratches, dents and defects.
- b. The tooth pattern must comply with the pass-and-stop inspection.
- c. The product is placed in the knife card, covered with flat cardboard on the upper layer, and then packaged
Step 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.
Step 13
Transportation
Prepare for a rainy day
- a. Confirm that the quantity matches the order.
- b. Label and stamp the outer box.
- c. Send reports on shipments.
Step 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
What are the key parameters required for the Zinc Die Casting process?
The process uses 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 strictly prohibited.
How are dimensions and surface quality monitored during CNC processing?
CNC tapping involves tapping two 6-32 teeth on each side face (depth 5.32+0.35mm/-0.15mm) and four 6-32 teeth on the front face (depth 8mm). To prevent bruising and scratching, operators must handle products gently, blow clean the jig surfaces, and follow inspection specifications.
What precautions are taken during the grinding and deburring stages?
During deburring and grinding, files, wind grinders, and 120# sandpaper are used to remove clamping lines, surface particles, slag, and gate residue. Operators must ensure no sharp corners exist, burrs are completely cleaned, and transitions align smoothly along the R angle.
How are calibration windows managed for quality control instruments?
For both FQC (Final Quality Control) and OQC (Outgoing Quality Control), checking instruments such as calipers, projectors, pin gauges, and tooth gauges must be verified before use to ensure they remain within their active calibration windows.
What are the packaging standards to prevent transport damage?
Products must undergo a full appearance inspection (free of dirt, scratches, dents, and defects) and tooth pattern pass-and-stop verification. They are then placed in a knife card, covered with flat cardboard on the upper layer, and packed using cartons, clapboards, and bubble bags.
What preparation is required before shipping transportation?
Before shipping, logistics preparation includes confirming that the physical quantity matches the customer order, labeling and stamping the outer box, and sending comprehensive reports on the shipments.