Case Study of Shrinkage Porosity in Ductile Iron Castings
2025-03-11
Development of contact ladle for automobile cylinder head
2025-03-20Deburring, descaling, grinding and polishing of aluminum die-casting gearbox housing
Aluminum alloy die-castings are widely used in the production and manufacturing of mechanical parts in the electronics, automobile, aircraft, shipbuilding, motor, home appliance and other industries. They have the advantages of beautiful appearance, light weight, high strength and corrosion resistance. However, burrs, flash, and other defects often occur during the production process, so the surface grinding process of the product is particularly important. In this case, we will share a process technology and method for the automated and efficient deburring, flash removal, oxide scale removal, and deburring of an aluminum alloy die-casting component automobile gearbox housing. This grinding process is also suitable for the surface grinding and polishing of other die-casting parts made of soft metal materials such as zinc, magnesium, and copper.
1. Aluminum alloy die-casting gearbox housing before deburring
Material: Aluminum alloy
Appearance: Burrs on the edges, oxide skin on the surface
Shape: Irregular shape
Size: 300*260*150 MM
Pre-polishing process: High-pressure casting
Post-polishing process: Finished product packaging
2. Grinding and polishing requirements:
Remove burrs and flash, remove oxide scale.
The surface is smooth, without burrs or oxide scale.
3. Aluminum alloy die-casting gearbox housing polishing process details:
Machine equipment: Vibration grinding and finishing machine --------- Vibration grinding and finishing machine --------- Vibration drying machine
Amplitude and speed: High speed ----------------- High speed ----------------- High speed
Grinding materials: Conical resin grinding stone ----- Oblique cylindrical high-aluminum porcelain grinding stone----- Corn cob abrasive
Abrasive to workpiece ratio: 4:1 ----------------- 6:1----------------- 8:1
Grinding aids: Grinding liquid ------------------- Cleaning agent ------------------- None
Water: Appropriate amount, liquid level does not exceed abrasive -------- Appropriate amount, liquid level does not exceed abrasive -------- None
Processing time: 60 minutes ------------------ 15 minutes ------------------ 15 minutes
Remarks: Automatic screening and taking out, rinse with clean water ------ Automatic screening and taking out, rinse with clean water ------ Vibration water absorption and drying
4. The effect of grinding and deburring the aluminum alloy die-casting gearbox housing
5. Additional Notes
The gearbox housing is produced by high-pressure casting of aluminum alloy. The product has high precision and a smooth surface, but the edges of the edges and holes will produce burrs and burrs, which need to be polished and sharpened. Therefore, a grinding process combining rough grinding and cleaning is adopted. The rough grinding adopts a vibration grinding and polishing machine, and the conical resin abrasive with medium cutting force is used for rough grinding. The sharp angle of the grinding stone can penetrate into the grooves, corners, and inner walls to achieve the effect of removing burrs and flash.
For cleaning, a vibration grinding and polishing machine is used. The abrasive adopts a precision grinding material without cutting force, an oblique cylindrical high-aluminum porcelain abrasive. The abrasive has a large specific gravity and has a polishing and brightening effect, which can further reduce the surface roughness.
In order to improve the anti-rust performance of the product after water, a vibration dryer is used after polishing, and corn cob abrasive is used to absorb moisture and dry the moisture on the inner and outer surfaces for drying.
6. Final summary
In this case, we demonstrated the automated surface deburring, flash removal, oxide scale removal and polishing process of a precision die-cast aluminum product spare part gearbox housing used in the auto parts industry.