Innovaw Mechanical has successfully developed an aluminum die-cast product—Corn Harvester Parts. These are agricultural machinery components used in equipment such as corn harvesters and tractors, and they serve assembly and sealing functions.
Product Standards and Requirements: Material ADC12; full-dimension tolerance class ISO 2768-mk; flatness 0.5; minimum dimensional tolerance -0.05. The surface must be free of any visible defects, with a surface roughness of Ra 6.3 µm. PPAP approval must be completed and obtained prior to formal mass production. The project as a whole presents a certain degree of difficulty and serves as a test of our mold design and quality control capabilities.
This product is manufactured using high-pressure aluminum die-casting combined with CNC machining, followed by shot blasting for surface treatment. The finished product not only exhibits excellent mechanical properties and good surface precision but also features good corrosion resistance and lightweight characteristics. It fully meets the customer’s design objectives and provides a more efficient and reliable solution for the design of this type of agricultural machinery.
Part Name: Corn Harvester Parts
Material: ADC12
Weight: 1870g
Process: high pressure die casting + cnc machining
Surface Finish: shot blasting
Application: agricultural machinery
Process Flow
Mould making→Pressure Die Casting→Cutting the sprue and riser→Polishing→Deburring→Shot Blasting →Machining→Cleaning→Assembly→Packaging & inspection
In accordance with the Advanced Product Quality Planning (APQP)—a core methodology required by the internationally recognized IATF 16949 standard—we formed a project development team comprising mold designers, casting engineers, machining engineers, measurement engineers, quality engineers, and sales representatives to carry out comprehensive product development.
We first conducted a DFM analysis of the product design. After consulting with the customer, we optimized certain structural details to improve manufacturability while ensuring functionality, and established mutually agreed-upon technical specifications and quality standards.
Considering the operating environment and performance requirements of this agricultural machinery component, we confirmed that ADC12 would be used as the housing material. At the same time, based on the material’s properties and the product’s core design elements, and considering technical feasibility, quality stability, and cost control, we ultimately determined a manufacturing process involving high-pressure die casting combined with CNC precision machining, utilizing a 500-metric-ton high-pressure die casting machine.
Next, our technical engineers conducted mold simulation and mold flow analysis to predict and optimize various challenges and process parameters, and established a preliminary process flowchart and process control plan.
Our company carried out work in accordance with the requirements of the initial process flowchart. At the same time, we applied the FMEA tool to conduct risk analysis and assessment of various potential failure scenarios, and applied Statistical Process Control (SPC) to core parameter data, using SPC tools for analysis, continuous monitoring, and improvement. During the product development process, we primarily encountered and resolved the following issues:
1. Adjusted the structure to optimize mold adhesion issues
2. Optimizing assembly challenges by developing specialized tooling
3. Various other surface quality issues
Leveraging the team’s extensive experience in aluminum die casting development, we resolved each issue one by one through methods such as modifying the die, adjusting die casting parameters, applying surface coatings, and machining. Furthermore, we documented the identification, causes, solutions, and outcomes of these issues in SPC, FMEA, process control plans, work instructions, and other relevant documents to ensure that similar problems do not recur.
This aluminum casting project for a corn harvester part, developed by Innovaw, served as a test of the manufacturer’s comprehensive capabilities due to its high technical complexity and stringent performance requirements. Leveraging our deep expertise in high-pressure die-casting, precision CNC machining capabilities, and a consistently rigorous quality management system, we successfully overcame these challenges and delivered high-quality products that met and even exceeded customer expectations. This fully demonstrates the professional capabilities of our casting development team in the development of complex structural components, including systematic problem analysis and rapid closed-loop improvement.
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+86-574-83008051
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