How are cycle life and dimensional tolerance validated in production?
How Are Cycle Life and Dimensional Tolerance Validated in Production?
Importance of Cycle Life and Dimensional Accuracy
Cycle life and dimensional tolerance are critical quality parameters for mechanical components, especially in locking systems, enclosures, and moving assemblies. These factors directly impact the functional reliability, fit, and wear resistance of parts subjected to repetitive mechanical stress or precise mating. In die casting production, validation ensures every part meets design intent and application longevity.
Cycle Life Testing Procedures
Cycle life validation simulates repeated use of a part under realistic or accelerated conditions. This ensures mechanical durability across its intended service life.
Typical cycle life testing includes:
Automated actuation cycles: Components like handles, latches, or buttons are subjected to 10,000–100,000 open/close or rotate/push cycles.
Force and load simulation: Functional loads are applied under controlled conditions to assess deformation, wear, or fracture risks.
Environmental simulation: Thermal cycling and humidity are added to replicate operating environments and aging effects.
Neway conducts mechanical endurance testing for zinc and aluminum castings using internal test rigs or based on customer-specific validation plans.
Dimensional Tolerance Validation
Dimensional accuracy is ensured using standardized metrology processes aligned with ISO 8062-3 or customer 2D/3D drawings. Die cast components are validated for key characteristics like flatness, roundness, hole spacing, and profile geometry.
Validation methods include:
CMM inspection: High-precision coordinate measuring machines verify critical dimensions against CAD models.
Go/No-Go gauges: Applied for tight-tolerance features such as shafts, pins, or fit zones.
3D scanning: Used for complex shapes or surfaces requiring full-surface comparison.
SPC (Statistical Process Control): Ensures process stability across batches and highlights trends before out-of-spec conditions occur.
Tolerances typically achievable for zinc die casting are ±0.05–0.10 mm, while tighter tolerance zones can be post-machined via CNC machining.
In-Process Control and Validation Records
Neway implements robust in-process controls during production:
First Article Inspection (FAI) for tool qualification
In-line visual and dimensional checks
Tool wear tracking and preventive maintenance schedules
Traceable inspection records using digital logging systems
For long-life or safety-critical parts, accelerated life testing and statistical dimensional sampling are conducted during pilot and mass production runs.
Neway’s Full-Scale Validation Capabilities
Neway ensures high-performance parts meet durability and dimensional targets through:
Customized mechanical cycle testing and endurance rigs
Complete CMM and metrology capability for tolerance validation
High-repeatability casting via precision tool and die
Dimensional and performance consistency via integrated assembly and quality control
