Compared to three or four decades ago, the cost of investing in human capital in today's society is significantly more expensive. When there are multiple market competitors, processing plants like aluminum alloy die-casting plants lose the benefit of having the advantage of being the only choice for employees to work for. In addition, because they no longer have this competitive advantage, these plants are unable to pay such high salaries for their employees. People in this day and age are not interested in carrying out labor that is simple, boring, or repetitive in nature. As a consequence of this, the aluminum alloy die-casting factory must decide whether to transition towards intelligent automation and intelligent manufacturing, or whether to increase the salary that is offered in order to attract new workers.
The cost of the transformation plan is very high, even higher than the cost of raising employee wages in a short period of time. Nevertheless, automation is beneficial; however, the cost of the transformation plan is very high. This is due to the fact that the plan requires a considerable amount of both time die cast parts and resources to implement. Is there, for example, a plan that makes the most sense but doesn't call for as much automation and doesn't require as much money to be spent?
The machining center in the aluminum alloy die-casting factory should be the one that is the closest to being automated at the moment; however, the operator is only responsible for the feeding and receiving of materials, so there is still no one for the operator to interview. This work is extremely monotonous, the pay is low, and it is not unusual for there to be a shortage of new employees to fill the position. The next thing that needs to be done is to automate not only the process of receiving and feeding materials but also the CNC lathe itself. Because of this, not only will it be possible to achieve higher levels of productivity, but it will also do away with the social awkwardness that results from not having enough employees.
Given that the CNC lathes used in the aluminum alloy die-casting factory are typically purchased, it should not come as a surprise that the particular application is not so straightforward. Although they are simple to operate, it is not simple to update or repair them. As a consequence of this, in point of fact, this kind of semi-automatic concept is better suited for marketing and promotion in gear manufacturers, and aluminum alloy die-casting plants can buy it from them for an additional price. Something that I have a powerful yearning for right now.
Die casting made of zinc alloy subjected to quality control using the inspection procedure
(1) Intuitive judgment.
When conducting an analysis of the surface quality of die-casting and zinc alloy die-casting using naked eye observation, it is possible to see patterns, flow marks, shrinkage, deformation, cold insulation, lack of flesh, discoloration, and spots. When viewed through a magnifying glass, these flaws may appear to be more than 5 times their original size.
(2) A consideration of the measurements involved.
1) Vernier calipers are the appropriate measuring tool to use when determining the wall thickness of zinc alloy die castings as well as the size of the aperture.
2) You will need a measuring instrument that has three coordinates in order to determine both the external dimensions of the zinc alloy die castings and the dimensions of the holes.
For the purpose of conducting the aperture test, a standard test rod is utilized.
(3) An investigation into the chemical make-up of the substance.
It is necessary to make use of both a spectrophotometer and an atomic absorption spectrometer when conducting an investigation into the chemical make-up of zinc alloy die castings. It is especially crucial to pay close attention to the amount of impurity elements that are present, as these can have an effect on flaws such as cracks, inclusions, and hard spots. Examine the material to determine whether or not the alloy satisfies the requirements.
(4) An investigation that makes use of metallography.
The process of analyzing the structure of a defective matrix and determining the location of defects such as cracks, inclusions, hard spots, and holes requires the use of a metallographic microscope as well as a scanning electron microscope. Both of these types of microscopes are used in conjunction with one another. During the metallographic phase, the edge of the shrinkage cavity is jagged, the cavity is dark, and the air hole has a smooth edge and a bright cavity. In contrast, the shrinkage cavity has an uneven edge, and the cavity is dark. The shrinkage cavity, on the other hand, has an uneven edge and a shadowy cavity within it.
The fifth step is an X-ray inspection of the item.
After acting on the photographic film to produce varying degrees of photosensitivity so that it can pass inspection of the zinc alloy die-casting using a powerful penetrating beam, it then moves on to the next step of the process. This enables the projection image of the defect to be captured on the photographic film, which can then be used to determine the location, shape, size, and distribution of the defect.
6) A check using the machine that does ultrasounds
When the vibration frequency of a sound wave is greater than 2000 Hertz, we refer to that sound wave as an ultrasonic wave. Zinc alloys will produce reflections that can be used to identify any internal flaws that may be present while the die casting process is in progress. By transmitting ultrasound from one die casting aluminum medium to the interface of another medium, it is possible to produce these reflections. Ultrasonic testing, which is another application of this method, can be used to analyze the wall thickness of die castings. This is just one of the many ways that this technique can be put to use.
(7) An investigation that makes use of fluorescence
A mercury-quartz lamp is used to excite luminescent material with ultraviolet light, which then causes the material to emit visible light. This allows for the examination of small discontinuous flaws on the surface of zinc alloy die castings, such as cold insulation and cracks. In order to identify the problems, this procedure must first be carried out. After giving the zinc alloy die-casting a thorough cleaning, the next step is to place it in the tank that contains the fluorescent liquid, wait for the liquid to completely permeate the surface of the casting, remove the casting, and then use the developing powder to dry it. During the process of casting, it was discovered that mercury lamps emitted a bright fluorescence into the environment. The luminosity can serve as a measurement to determine the severity of the defect's impact on the overall quality.
(8) A closer look at the spots and spills.
This method of defect inspection is uncomplicated, efficient, quick, and user-friendly. It consists of a cleaning agent, a penetrating agent, a developing agent, and other components. In the neighborhood of the Xiangyu Metal Products Market, you can pick up a set of DPT-5 Color Penetrant that includes a total of three cans for the price of one. This item can be utilized to locate and identify errors.
