Explanation of Conventional Connector Shell Forming Process

There are many types of connectors, and according to their own usage needs, there are also differences in shell design and manufacturing. This article will explain the conventional connector shell forming technology through three processes.


1、 Cutting processing

This is a processing method that changes the shape of the workpiece by mechanically separating the workpiece material. The cutting method plays a major role in the preliminary and final processing of metal shell parts. Especially in the trial production and initial sample submission stages of new products, cutting processing accounts for almost 100% of the parts processing process.

Using cutting methods to process shell parts, the entire cutting process is the combined effect of machining force, machining device, and machining object. The cutting process of connector shells can be divided into turning, milling, slotting, grinding, discharge cutting, and so on. The process flow of the seat shell is: material preparation, turning, forming (rough), inserting (key processing), turning, forming (fine), milling, forming, cleaning, and warehousing.

Advantages: Compared with other machining methods, cutting machining is suitable for processing materials that are difficult to shape or do not deform, and parts with complex shapes; The tolerance of the parts is small and can achieve extremely high surface quality of the workpiece; It is economical to process small batches of parts.

Disadvantage: The biggest drawback of this processing method is that it is easy to cut off the fiber structure inside the metal, thereby damaging the mechanical properties of the parts. It also has disadvantages such as low production efficiency, waste of materials, and low economic benefits.


2、 Die casting process

This is an efficient and non cutting metal forming process. The principle of die-casting technology is to use high pressure to quickly press metal liquid into the precision mold cavity, and the metal liquid cools and solidifies under pressure to form a casting. Die-casting process is the process of unifying pressure, speed, and time by utilizing factors such as machines, molds, and alloys

Advantages: The parts are well formed in one go and can be used to manufacture metal parts with complex shapes, clear contours, and thin-walled deep cavities; High material utilization rate; Due to the high accuracy of die castings, they can be used with only a small amount of mechanical processing, and some die castings can even be used directly; High production efficiency, due to high-speed mold filling, rapid metal solidification, and fast work cycle speed, suitable for mass production.

Disadvantages: Metals are prone to stress concentration during solidification, and are prone to cracking, curling, porosity, and inclusions; The shell of the casting has poor plasticity, which makes it easy to break in some parts that require punching and riveting; In actual production, it is affected by smelting, sand cores, and other factors, resulting in a large difference in product wall thickness, making it difficult to meet the design requirements of high precision and strength.

3、 Extrusion molding process

This is also a rare and non cutting process. Extrusion forming controls the flow of metal materials through the mold cavity, utilizing the reciprocating motion of pressure machinery to put the metal material in a state of three-dimensional compressive stress. The metal volume in the mold cavity can be transferred in large quantities to form the parts with the required contour size and shape. This process is widely used in the field of material processing, such as the production of non-ferrous metal pipes and profiles, including aluminum alloys, using extrusion technology.

Advantages: Strive to avoid problems in traditional processing methods, thereby improving production efficiency, saving raw materials, and reducing production costs.