Project Background
An industrial equipment manufacturer required batch production of mounting brackets for securing automated control cabinets. These brackets need to withstand long-term use in humid industrial environments, demanding excellent structural strength and corrosion resistance. After comparing multiple suppliers, the client ultimately chose to collaborate with us.
Technical Requirements
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Product Name: Control Cabinet Mounting Bracket
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Material Specification: Q235B Carbon Steel, Thickness 3.0±0.1mm
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Process Requirements: Precision stamping forming, mounting hole tolerance ±0.1mm
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Surface Treatment: Zinc plating thickness ≥8μm, 48-hour salt spray test without white rust
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Delivery Quantity: Initial batch of 5,000 pieces, monthly demand of 20,000 pieces
Detailed Process Flow
Raw Material Inspection
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Use a spectrometer to conduct compositional analysis of the carbon steel plates, ensuring compliance with Q235B standards.
- Perform multi-point thickness measurements to guarantee material uniformity.
Precision Stamping Forming
- Utilize a 120-ton high-speed press with a four-stage progressive die for continuous operation.
- Die accuracy reaches ±0.1mm, ensuring product dimensional stability.
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Production cycle: 25 pieces per minute, shift production capacity of up to 10,000 pieces.
Zinc Plating Surface Treatment
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Undergo a strict pre-treatment process:
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Degreasing: Alkaline degreasing agent, temperature 60°C, time 5 minutes.
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Pickling: Hydrochloric acid concentration 18%, room temperature, time 15 minutes.
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Zinc Plating: Zinc bath temperature 450°C, immersion time 2 minutes.
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Passivation: Chromate passivation treatment to enhance anti-corrosion performance.
Quality Assurance Measures
In-Process Inspection
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First-Article Inspection: Conduct full-dimensional inspection before each shift starts.
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Patrol Inspection System: Sample and check critical dimensions hourly.
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Last-Piece Comparison: Retain the final product from each production run as a quality traceability reference.
Finished Product Testing
- Use a coordinate measuring machine (CMM) to inspect mounting hole accuracy.
- Employ a zinc coating thickness gauge for multi-point thickness measurement.
- Regularly submit samples to third-party institutions for salt spray corrosion testing.
Final Results and Customer Feedback
The zinc-plated brackets exhibit a uniform blue-white surface with a dense and even coating. During acceptance, the customer particularly praised the following product features:
- Excellent coating quality, free from defects such as missed plating or peeling.
- Mounting hole accuracy fully meets requirements.
- Strong structural stability.
Our Manufacturing Advantages
Through this case, we have demonstrated our professional capabilities in carbon steel component manufacturing:
- Mature zinc plating process expertise.
- Strict quality control system.
- Reliable delivery time assurance.
- Competitive cost control.
We specialize in providing customers with reliable quality and cost-effective metal manufacturing services. For related needs, please feel free to contact us for a solution proposal and quotation.
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