Flange connectors

Project Summary

The customer’s original cast iron connector base for automated conveying equipment was heavy with excessive machining allowance, low assembly efficiency and prone to rust outdoors. Standard off-the-shelf die-cast aluminum parts had flawed internal rib structures, leading to cracking and deformation under heavy load. We adopted A380 die-cast aluminum alloy, customized integrated die-casting mold with optimized internal ribs, and supported full processes including deburring, CNC precision machining & natural passivation. The finished parts are lightweight, high-strength and corrosion-resistant, suitable for long-term heavy-duty continuous operation with stable mass delivery.

3.1 Material Selection

A380 die-cast aluminum alloy is selected for excellent fluidity for complex integrated cavity forming, balanced strength & machinability, superior impact and corrosion resistance over ordinary cast aluminum. It enables thinner casting walls for lightweight design, matching heavy-duty long-cycle operation of automation equipment.

3.2 Structure & Mold Optimization

1. Thickened internal load-bearing ribs with arc transition eliminate stress concentration and avoid load cracking
2. Optimized mold runners & exhaust grooves reduce air entrapment and cut pore defect rate fundamentally
3. Uniform casting stock allowance & symmetric datum surfaces reduce CNC machining time by 30%
4. Integrated one-step die-casting eliminates multi-part welding, boosting structural rigidity and cutting assembly steps

3.3 Core Process

Process Route: A380 aluminum melting & casting → high-pressure integrated die casting → vibratory precision deburring → CNC milling, drilling & tapping → sandblasting & passivation anti-corrosion treatment → full dimension inspection & packaging