Aluminum Die Casting Base Housing

The Aluminum Die Casting Base Housing, it is an customized auto part, it is produced by high pressure Die Casting process, the part is required to be as cast, so during the part development, the engineer should review the drawings very carefully to look into if all the required dimensions and tolerance are within our capability, The part is not difficult to produce, the wall thickness is uniform and continuous. The only thing out of the initial expectation is that the small flash around the ejector pins. As the tooling design, including the injection gate, cross injection gate, the runner, the venting system locations are all confirmed and approved by the customer, we didn't expect that the small flash will cause application issue.  The part has a big pocket structure, at the beginning, consider to ensure the easier mold release, the better location for the ejector pins obviously  should be at the bottom of the pocket feature.  But in application, we are told by the customer the ejector pins are supposed to have not any flash around as it will cause interference to the mating part assembly.  However, as the ejector pins are inside of the cavity, it is not possible to settle by trim mold, also hard to remove by manual work through pneumatic file. So at last, through technical discussion between the engineers of the tooling vendor and our company, they propose the idea of moving the location, changing from the bottom surface to the wall edge. Then, as the ejector pins is at the top of the part, it can be much easier to operate the file. 

The monthly demand for this part is not bad, around 10000 pieces. In this case, we applied to the trim mold to de-gate, de-slag.

The material of this part is ADC-12, a kind of Japanese aluminum alloy. The material conforms to standard of JIS H 5302-2000, it is a very common material in high pressure die casting industry. The material is equivalent to Chinese aluminum alloy YL113, the corresponding standard is GB/T 15115-2009. 

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