2015-07-22

Customer P602

Project No. P602-130501

Part name DUO_LED_HOUSING_

Part number 10001115578_D11_001_201774_00

Part material Aluminum alloy, detailed brand needs to refer to 2D print

Shrinkage 6‰

Cavity number 1*1

No. of slide /

Casting machine 800T Toshiba

Part size 359.5*307.5*79

Mold insert steel (dimension)

TBD（520*470*120/105）Estimated design dimension

Mold base steel (dimension)

S50C (680*650*A130B150C165) Estimated design dimension

Mold standard DME

UNIT MM

Heat treatment hardness

HRC 44 +/- 1Deg

Part picture

Project Information

2015-07-22 1

Mold Flow Simulation

Mold flow simulation on flow pattern was created and transmitted to the customer for proof when the preliminary tooling design was completed.

2015-07-22 2

Tooling Design

Picture on tooling design. The preliminary tooling design file

(3D) was transmitted to the customer for proof.

2015-07-22 3 3 2015-07-22

Tooling Manufacturing

Mold Manufacturing. It is a work progress plan form on the right, which has been created and submitted to the customer from the beginning of manufacturing. Then the manufacturing progress will be updated each week for the customer.

2015-07-22 4

The mold was tested on cold chamber die casting machine

of Buhler 840T.

Tooling Test

Sample Inspection

The sample was inspected using our own CMM machine in our factory. Then a sample inspection report as shown on the right was created, noted and then submitted to the customer for their reference.

2015-07-22

Pictures on this page are the photos of the mold.

Photos of the Mold

2015-07-22

Certifications

The files including following items have been submitted to the customer together with the mold: Certification of Metal, Heat Treatment, Steel Tempering, Mold Base Material, etc.

2015-07-22 8

Drawing Data

The drawing data including following items have been submitted to the customer together with the mold : EDM machining drawing, 2D drawing of mold components and parts, general assembly drawing of the mold and die trial parameter report, etc.

• 1. Mold manufacturing: The main character of heat sink products is that main part of the product are ribs, and electrode discharging and polishing are the main manufacturing processes on the mold, whose costs are both relatively high.

• 2. Part forming: For ribs (especially for deep and thin ribs), venting is difficult and it tends to trap easily. In the meanwhile, the ribs are hard to form, and the venting system is hard to design on the mold. This is why vacuum system should be applied to this type of products sometimes.

• 3. Common problems of mold during production: Die Sticking, Die Cracking:

• A. Die sticking: For this kind of mold, die sticking happens easily because the strength of ribs is usually weak, and the temperature is very high on the mold’s rib feature during mass production. To this issue, we usually suggest to apply surface nitridation on the mold to improve surface hardness and smoothness, so as to decrease the rate of die sticking.

• B. Die cracking: This kind of mold is easy to crack earlier than usual mainly due to following reasons:

– a. EDM machining will produce steel stress on the mold;

– b. Hardness of ribs on mold insert is lower than usual;

– c. Heatness will be concentrated in the ribs on mold insert during mass production.

Geneally, tempering will be applied to the mold after EDM machining; When production reaches 2000-5000 shots (depending on the mold dimension), the mold should be tempered the second time. The mold can be maintained in a common way after these two times of tempering, but the first two times are especially important.

Characters of Mold for Heat Sink Products

2015-07-22 10

Thanks!