Aluminum Die Casting Backbone

The Aluminum Die Casting Backbone , it is an customized auto part, it is produced by high pressure Die Casting process, the part is small, the part weight is only about 35 gram, but the length of the part is about 15 cm. what's more, on one end, the part has a feature of cavity, leading to the only option to be realized by secondary slide. in this case, the injection gate can only be on the other end in terms of the geometry. Because the length of the part is long, the part will have potential failure on casting defect, such as internal porosity, chilled layer on the part surface, cold shut, cold flow, and loose grain structure etc. The part has requirement of minimum tensile strength of 300 N*m.  According to the structure of the part, based on your assessment, the part may have potential failure possibility of fracture at the thickest area. It is because the part is long, in order to have an adequate filling, the pressure to inject the melting aluminum into the mold cavity should be very large so that the material won't solid prior to fully fill the cavity. But as the injection gate section area is not big enough, we make modification or adjustment to the gate to ensure the filling reach well.

The part is small,  the projection area also is small, theoretically, the tonnage of 200 t is supposed to satisfy the shot of the die casting. By our PQ chart analysis, we learned that the section area of the injection gate should be larger, almost the whole surface of the end of the part.  In this case, the residual of the gate should be removed by machining.

The part has strict density requirement, so the tooling design, including the injection gate, cross injection gate, the runner, the venting system locations should be fully considered.

At last, the part have a through hole vertical to the joint line. which require the drilling work. The machining work is finished on the machining center, as 4 cavities on the mold, the machining fixture, also have 4 clamping station for 4 parts per cycle of machining.    

Material: ADC-12
Cavity Number: 4
Process Technology: High pressure die casting
Product Dimensions: Customized
Casting General Tolerance: Grade GB-CT4
Surface Finish: Polishing, Shot Peening
Flow Processes: Die casting, Trimming, Deburring, Shot Blasting, Machining, Cleaning, Packing, Shipping
Control Measure: Incoming Material Test, First Article inspection, Routing inspection, Final item inspection,  and Outgoing quality control
Inspection Equipment: CMM, Caliper, Plug Gage
Application: Auto Parts
Certificate: ISO/TS16949:2009
Lead Time: 30-35 days
Trade Term: FOB Ningbo