This paper introduction was written based on the 'Technical Cleanliness Process and Analysis for Aluminum Die Cast Component used in Automotive Applications' published by 'INTERNATIONAL RESEARCH JOURNAL OF ENGINEERING AND TECHNOLOGY (IRJET)'.
1. Overview:
- Title: Technical Cleanliness Process and Analysis for Aluminum Die Cast Component used in Automotive Applications
- Author: Sumit Shukla
- Publication Year: Dec 2019
- Publishing Journal/Academic Society: INTERNATIONAL RESEARCH JOURNAL OF ENGINEERING AND TECHNOLOGY (IRJET)
- Keywords: Durability, Gravimetric Analysis, Particle, Surface Tension and Vibratory Process.
2. Abstracts
ABSTRACT: The growing complexity in interfaces of today's technical products, especially within the aerospace, automotive, heavy equipment, and electrical engineering industries, has resulted in an increasingly high demand for product reliability and quality assurance. More efficient components and systems, increasing warranty claims and the reduction in start-up breakdowns are steadily driving up the demands for cleanliness management and cleanliness monitoring of production components. What started in the 90's with just a handful of components under the term of "residual contamination" has evolved since the year 2000 to become a key measure of quality in the automotive and supplier industries under the new name of "technical cleanliness. This paper explains the detailed Technical Cleanliness Process as per Automotive Industry Standards and also focusses on detailed inspection and analysis process used to verify the Technical Cleanliness Requirement of a Aluminum Die Cast component used in automotive applications.
3. Research Background:
Background of the Research Topic:
The increasing intricacy of interfaces in contemporary technical products, particularly in sectors such as aerospace, automotive, heavy equipment, and electrical engineering, has led to a heightened need for product reliability and quality assurance. The demand for cleanliness management and monitoring of production components is continuously rising due to the pursuit of more efficient components and systems, the increase in warranty claims, and the imperative to reduce start-up breakdowns. The concept of "residual contamination," which emerged in the 1990s, has evolved into "technical cleanliness" since 2000, becoming a critical quality metric in the automotive and supplier industries.
Status of Existing Research:
Initially recognized as "residual contamination" in the 1990s, the field has progressed to "technical cleanliness," now a pivotal quality parameter within the automotive sector since the year 2000. The automotive industry commonly employs technical cleanliness guidelines as stipulated by VDA 19 and ISO 16232 standards. These standards offer a framework for designing and implementing component cleanliness analyses, enabling quantifiable comparisons of component cleanliness levels.
Necessity of the Research:
This research is necessitated by the need to elucidate the detailed Technical Cleanliness Process as defined by Automotive Industry Standards. It emphasizes the importance of a thorough inspection and analysis process to ascertain the Technical Cleanliness Requirement of Aluminum Die Cast components utilized in automotive applications.
4. Research Purpose and Research Questions:
Research Purpose:
The primary purpose of this paper is to detail the Technical Cleanliness Process according to Automotive Industry Standards. Furthermore, it aims to focus on the inspection and analysis methodologies employed to verify the Technical Cleanliness Requirement of Aluminum Die Cast components specifically designed for automotive applications.
Key Research:
The key research areas include a comprehensive explanation of the Technical Cleanliness Process as per Automotive Industry Standards and the detailed inspection and analysis procedures necessary to verify the Technical Cleanliness Requirement for Aluminum Die Cast components.
Research Hypotheses:
While not explicitly stated as a hypothesis, the study operates under the premise that adherence to technical cleanliness standards is crucial for ensuring the performance and reliability of automotive components. It is implicitly hypothesized that the described Technical Cleanliness Process and analysis methods are effective in verifying and maintaining the required cleanliness levels.
5. Research Methodology
Research Design:
This paper employs a case study approach, focusing on an Aluminum Die Cast component used in an automotive application. It is descriptive in nature, detailing the technical cleanliness process and analysis based on established Automotive Industry Standards, specifically VDA 19 and ISO 16232.
Data Collection Method:
This paper is a descriptive study detailing established processes and standards. Therefore, primary data collection methods are not applicable. The information is drawn from existing industry standards and technical knowledge.
Analysis Method:
The analysis methods discussed include Gravimetric Analysis and Particle Analysis, both conducted in accordance with VDA 19 guidelines. The paper describes the process of Technical Cleanliness analysis, including the use of equipment such as the OLYMPUS CIX Series, for particle inspection and measurement.
Research Subjects and Scope:
The research focuses on an Aluminum Die Cast component designed for automotive applications, specifically a component within a control module. The scope of the paper is limited to the Technical Cleanliness Process and Analysis relevant to this type of component, as defined by Automotive Industry Standards.
6. Main Research Results:
Key Research Results:
The study elucidates the Technical Cleanliness Process for manufacturing Aluminum Die Cast components, outlining a detailed process flow diagram (Fig.3) that identifies potential sources of particle contamination and incorporates control measures. Key findings include the identification of critical process steps such as Vibratory Finishing and Machining as potential contamination sources. The paper also details drawing specifications for technical cleanliness, including surface tension and particle quantity limits (Fig.6 & Fig.7). Furthermore, it provides an explanation of Technical Cleanliness Analysis as per VDA 19 / ISO 16232, covering extraction and analysis methods (Fig.9 & Fig.10). The Gravimetric Analysis and Particle Analysis results for a case study component are presented, demonstrating the practical application of these methods (Fig.13, Fig.14, Fig.15).
Analysis of presented data:
The Gravimetric Analysis conducted using the Millipore Test for a sample component revealed a contamination mass of 0.1mg, which is within the specified limit of 0.5mg (Fig.13). This result indicates that the component meets the gravimetric cleanliness requirements. Particle Analysis results, presented in tabular format, categorize metallic and non-metallic particles and fibers by size classes (Class H, I, J, K) for multiple component samples (Part 1 to Part 5). Microscopic images (Fig.15) provide visual examples of particle evaluation, illustrating the types and sizes of contaminants detected.
Figure Name List:
- Fig.1: Functional surface (green)
- Fig.2: Component mounting features (blue)
- Fig.3: Process Flow Diagram
- Fig.4: Equipment and Principle
- Fig.5: Detailed Process Flow Diagram
- Fig.6: Technical Cleanliness drawing definition example
- Fig.7: Technical Cleanliness drawing general surface note example
- Fig.8: Surface Tension Measurement using Ink Test Pen
- Fig.9: Test method as per VDA 19 Part 1
- Fig.10: Technical Cleanliness Flow Diagram
- Fig.11: Technical Cleanliness Analysis setup (OLYMPUS CIX Series)
- Fig.12: Gravimetric Analysis
- Fig.13: Gravimetric Analysis Report
- Fig.14: Equipment used for Aluminum Die Cast Technical Cleanliness Analysis
- Fig.15: Particle evaluation pictures
7. Conclusion:
Summary of Key Findings:
The study underscores the critical role of Technical Cleanliness Requirements in ensuring the functional performance and reliability of automotive components. As noted by Lev Pekarsky from Ford Motor Co., even minute debris can compromise the function of precision electro-hydraulic components in automatic transmissions. Standardized procedures, as outlined in VDA 19/ISO 16232, are essential for systematically recording, analyzing, and documenting component cleanliness. Specifications for technical cleanliness encompass production environment, testing methodologies, packaging, handling, storage, and transport, all of which significantly influence overall costs.
Academic Significance of the Study:
This paper serves as a handbook-level exposition of the Technical Cleanliness Process and Analysis pertinent to Aluminum Die Cast components. It emphasizes the academic and industrial relevance of adhering to VDA 19 and ISO 16232 standards within the automotive industry, providing a structured understanding of these critical quality control measures.
Practical Implications:
For die cast manufacturers, this paper offers practical guidelines for implementing robust Technical Cleanliness processes. It provides valuable insights into inspection and analysis techniques necessary for verifying Technical Cleanliness Requirements, thereby aiding in the production of reliable and high-performance automotive components. The emphasis on controlled manufacturing processes highlights the importance of minimizing contamination to ensure component longevity and system integrity.
Limitations of the Study and Areas for Future Research:
This paper is primarily a descriptive case study focused on explaining existing standards and processes rather than presenting novel empirical research. Future research could explore quantifying the specific impact of varying contamination levels on the performance and lifespan of Aluminum Die Cast components. Further investigation into optimizing cost-effective Technical Cleanliness processes and emerging technologies in cleanliness monitoring would also be beneficial.
8. References:
- [1], [2] & [3]: ZVEI_Guideline_Technical-Cleanliness-in-Electrical-Engineering_second-extended-edition_Version-2019
- Fig. 09 & 10: ZVEI_Guideline_Technical-Cleanliness-in-Electrical-Engineering_second-extended-edition_Version-2019
9. Copyright:
- This material is "Sumit Shukla"'s paper: Based on "Technical Cleanliness Process and Analysis for Aluminum Die Cast Component used in Automotive Applications".
- Paper Source: WWW.IRJET.NET
This material was summarized based on the above paper, and unauthorized use for commercial purposes is prohibited.
Copyright © 2025 CASTMAN. All rights reserved.