Impeller products
4 month ago
Horizon Mold Chain Co., Ltd
9 month
Product details
Precision Gear Impeller Injection Molding Parts:
EndtoEnd Manufacturing Lead Times & Technical Excellence
In automotive manufacturing, precision gear impeller injection molding parts are critical for ensuring efficient power transmission and mechanical stability. This document outlines our standardized manufacturing lead times, technical specifications, and quality assurance processes, designed to meet the rigorous demands of automotive drivetrain systems.
I. Streamlined Manufacturing Lead Times
Following a lean production model, our 4stage process ensures predictable delivery without compromising precision:
1. Requirement Analysis & Design Confirmation (3–5 Days)
Client Collaboration: Indepth consultation to define gear parameters (module, pressure angle, number of teeth) and application scenarios (transmission systems, electric motors, pumps).
CAD/CAE Engineering: 3D modeling using UG/NX and Moldflow analysis to optimize gate locations, cooling channels, and wall thickness for minimal shrinkage (≤0.5%) and balanced material flow.
DFM Report: Delivered within 72 hours, including moldability analysis for complex geometries (e.g., helical gears, variablepitch impellers).
2. Precision Mold Fabrication (20–25 Days)
Material Selection: Mold cores/cavities crafted from premium tool steels (e.g., S136 for corrosion resistance, NAK80 for highpolish surfaces) with hardness standardized at HRC52–56.
Machining Processes:
Fiveaxis CNC machining for impeller vanes (surface roughness Ra≤0.4μm).
Wire EDM for intricate gear tooth profiles (precision ±0.002mm).
Laser texturing for antislip surfaces on contact areas.
Key Milestones: Weekly progress reports via IoTenabled tracking, showing realtime data on machining accuracy and thermal stress testing.
3. Assembly, Testing & Optimization (5–7 Days)
Mold Assembly: Handfinishing of critical components (gearing interfaces, impeller hubs) to ensure concentricity ≤0.01mm.
First Article Inspection (FAI):
100% dimensional verification using CMM (coordinate measuring machine) for gear pitch deviation (≤±0.005mm) and impeller blade angle consistency (±0.5°).
Functional testing on injection molding machines (80–200 tons clamping force) to validate cycle times (15–30 seconds) and flashfree成型.
Documentation: Supplied with FAI reports, mold flow analysis results, and material certification (e.g., IATF 16949compliant raw materials).
4. Final Delivery & AfterSales Support
Lead Time: Total 30–40 days from design approval, with expedited options (25day rush service available for urgent projects).
Logistics: Customized packaging to prevent mold damage during transit, accompanied by operation manuals and maintenance guidelines.
II. Technical Specifications for Automotive Gear Impellers
A. Dimensional Precision
Gear Accuracy: Complies with ISO 13281 Class 6 for involute gears, ensuring backlash ≤0.03mm and contact pattern ≥85% tooth surface.
Impeller Balance: Dynamic balancing tolerance ≤G2.5 (ISO 1940), minimizing vibration at operational speeds (up to 15,000 RPM).
Material Shrinkage Control: Using advanced cooling systems to maintain dimensional stability within ±0.1% of nominal dimensions.
B. Material Compatibility
Thermoplastics: Supports PA66GF30 (nylon with 30% glass fiber), POM (acetal), PBT, and specialty materials like PEEK for hightemperature applications (up to 180°C continuous use).
Metal Inserts: Pressfit or overmolded steel hubs (e.g., 1045 carbon steel, surface hardened to HRC48–52) for loadbearing interfaces.
C. Surface Finish & Treatment
Tooth Surfaces: Polished to Ra≤0.8μm for reduced friction; optional DLC (diamondlike carbon) coating for wear resistance (coefficient of friction ≤0.15).
Impeller Vanes: Textured surfaces (Ra 1.6–3.2μm) to optimize fluid dynamics in pump applications, reducing cavitation by 20%.
D. Quality Assurance
Testing Equipment: Mitutoyo CMM (accuracy ±0.0015mm), gear rolling testers, and Xray fluorescence (XRF) for material composition analysis.
Traceability: Unique mold ID coding and batch records stored for 10 years, compliant with automotive traceability standards (VDA 6.3).
III. Industry Applications
Ideal for:
Transmission Systems: Helical gear impellers for dualclutch gearboxes.
Electric Vehicles: Highspeed rotors for emotor oil pumps (noise ≤65dB at 5,000 RPM).
Engine Accessories: Water pump impellers resistant to coolant corrosion (tested per ASTM D4329).
Why Choose Our Solutions?
Experience: 15+ years in automotive mold manufacturing, 500+ gear impeller molds delivered annually.
FirstTime Pass Rate: 97% for complex gear geometries, reducing customer downtime.
Customization: Tailored solutions for microgear impellers (module ≤0.5) to largescale industrial variants (diameter >300mm).
Contact us today to discuss your precision gear impeller requirements and leverage our optimized lead times for missioncritical automotive components.
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Horizon Mold Chain Co., Ltd
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9 month
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