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China Zinc Alloy Server Racks - Zamak 3 Zinc Alloy Casting Parts from Reliable Suppliers and Factory
Process
Step 01
ZINC die casting
Process Characteristics:
- a. The furnace temperature is 420°±20°, and the material handle is 20±2 mm.
- b. Secondary materials can not be used.
- c. Material composition must be tested to ensure it is suitable for production.
- d. The first piece must be confirmed.
Precautions
- a. Verify the quality of surface filling. No bulging, no cold isolation, and no shortage of materials in the column.
- b. Pay attention to the surface and avoid mold stringing, sticking or insufficient ejector protrusion.
- c. 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
Things to note
- a. Pay attention to the surface and don't damage it or use insufficient material.
- b. Manage size and appearance.
Step 03
IPQC inspection
Precautions
Check dimensions against drawings and use accurate measuring equipment.
Step 04
Deburring
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.
Step 05
SHAPING
PRODUCT BACK SHAPING
Note
Within 0.2mm of the front plane of the product.
Step 06
CNC
- 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
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
Remove product clamping line draping, surface particles, slag ladle, gate residue.
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
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
Comprehensive inspection of products and packaging.
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
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 include 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 material requirements for the Zinc die casting process?
We strictly utilize ZA 3# material processed with a 138T zinc die casting machine. Secondary materials are strictly prohibited, and the material composition must be verified before production.
How are surface defects minimized during deburring and grinding?
We use precise tools including files, wind mills, and 120# sandpaper to systematically eliminate sharp corners, burrs, and gate residues. Technicians must ensure that all surfaces are ground cleanly along the specified R angles.
What precautions are taken during the CNC tapping stage?
Parts must be handled with extreme care to prevent bruising and scratching. Additionally, operators must clean the jig surfaces by blowing off residues before placing each part and strictly follow the inspection specifications.
How do you verify the dimensional accuracy of the finished parts?
We employ multi-stage testing instruments including three-coordinate measuring machines (CMM), projection systems, calipers, pin gauges, and thread/tooth gauges. All measurement devices are strictly monitored to ensure they are within their calibration windows.
What packaging standard is used to prevent shipping damage?
Following a 100% appearance check, products are organized systematically into customized knife cards, protected with flat cardboard dividers, and then securely packed inside cartons with bubble bags to block external impacts.