Die casting process
1. Casting: casting defects
2. CNC processing: high precision size requirements, precision processing equipment, testing equipment and fixture, and operators.
3. Surface treatment: The product needs three kinds of surface treatment, which increases the difficulty of special process control
4. Assembly and transportation: Multi-process, the probability of collision in transport operation increases.
According to the characteristics of the product, when designing the mold, fully consider the issues in casting process, such as pores, sand holes, sand falling, slag holes, shrinkage, cracks, deformation, bruises, cold insulation, sand core bad, air entrainment, slanting, swelling etc.
In order to reduce the risk of poor mold design, through the software, the flow simulation of the melt filling process, determine the reasonable gate and find the best inlet position, optimize the pouring system design, and make the melt achieve the best flow balance. Mold temperature and cooling conditions, analyze whether defects occur, such as product warpage, shrinkage, dents, etc. Analyze where the melt generates trapped air during the filling process, optimize the exhaust system, analyze and change the thickness of the product, etc.
During the melting process of molten aluminum, various reasons may change the alloy composition, such as melting speed, metal inclusions, charging order, furnace purity, etc.
During the manufacturing process, need to check the element composition and gas content.
Casting blank is treated with saw nozzle and shot blasting. Shot blasting can clean the surface sand and oxide layer, remove tiny burrs and oil stains on the surface, increase surface adhesion, and make the surface beautiful and uniform.
X-ray flaw detection
X-ray routine internal inspection
1: Detect internal cracks, if there are light-colored lines
2. Detect large bubbles inside, if there are, white spots will appear
3. Check whether the density is loose or not, if there is, it will appear light cloud-like or filamentous
4. Check whether the material contains slag, if there is, it will show a dark block
CNC machining process splitting for production process
Process separation follows the principle of process concentration, reducing the number of processes, shortening the process route, simplifying production planning and production organization; reducing the number of workpiece clamping times, ensuring the mutual position accuracy of each processing surface, and reducing the number of fixtures and the number of clamping times. Reduce the risk of processing shifts.
CNC machining, fixture design
Pneumatic fixture design, easy to operate, controlled by automatic program code, without manual control of the clamping force, to ensure the stability of repeated clamping in mass production.
CNC machining program tool simulation verification
Quickly simulate and verify the safety of the tool path, check overcuts and empty tools. Optimize the sorting of tool paths and the way of cutting, optimize the tool feed, tool speed, cutting allowance according to product tolerances, avoid chattering and burrs during the processing process, and ensure the dimensional stability of the product.
Fluorescent penetrant inspection
Coating the surface of the part with a layer of fluorescent emulsion to make it penetrate the cracks. After a period of time, the fluorescent liquid on the surface of the part is washed away. At this time, there is still fluorescent liquid in the defect, which glows under the irradiation of the black light lamp, so as to determine the location, shape and size of the defect, and detect the fine sand holes that cannot be detected by X-ray flaw detection.