Case Study: Seal Plate
The tool is not approach during machining in the critical area of the casting. Customer need a part as cast
Project Overview
Application
Automotive, Part Weight: 0.85 grms.
Focus Area
Process Formulation
Challenge
The turbocharger intake oil flow assembly has employed the seal plate component. There is no tool approach during machining on inside of the casting. Client required as-cast with +/- 0.30mm flatness maintenance. Moreover, the casting requirement's concentricity, perpendicularity, and angular tolerance are all tightly specified.
The Problem
The turbocharger intake oil flow assembly has employed the seal plate component. There is no tool approach during machining on inside of the casting. Client required as-cast with +/- 0.30mm flatness maintenance. Moreover, the casting requirement's concentricity, perpendicularity, and angular tolerance are all tightly specified.
Our Solution
SAN Precision Alloys’ technical team experts quickly developed a process by using soluble core and made a wax pattern. The soluble core tool reached a flatness of 0.050mm. In order to attain +/- 0.10mm flatness in the wax pattern. By using this process enhancement, we were able to attain flatness +/- 0.15 mm against +/-0.30mm (as per print) in the raw casting. Our development team takes into account the tighter tolerance of concentricity, perpendicularity, and angular tolerance when creating new tools. So that the casting meets the required standard of quality. We were able to create parts as a result that were both repeatable and appropriate for their intended usage.
Impact
Besides the technical challenges, SAN Precision Alloys’ expertise in both the new product development and process development teams allowed castings to be manufactured to meet the exacting requirements of the clients. As a result, SAN Precision Alloys was able to offer a technically challenging part at a competitive price for use in the demanding automotive sectors.
Key Benefits
To meet the tight dimension as per customer requirements
To achieved the flatness as per customer print by as cast
Secondary operation for machining (Reduce the cycle time)
Increase the productivity
Less Machining Cost