HOME  |  NEWS  |  BLOGS  |  MESSAGES  |  FEATURES  |  VIDEOS  |  WEBINARS  |  INDUSTRIES  |  FOCUS ON FUNDAMENTALS
  |  REGISTER  |  LOGIN  |  HELP
Feature
Materials & Assembly

Converting Machined Parts to Die Castings

NO RATINGS
Page 1 / 3 Next >
View Comments: Threaded|Newest First|Oldest First
Dave Palmer
User Rank
Platinum
Comparing processes
Dave Palmer   8/6/2012 12:31:33 PM
NO RATINGS
In most cases, casting a part versus machining it from bar stock is a no-brainer.  In my career, I've only come across one part that made more sense as a screw-machined part than as a die casting.  In that case, the geometry of the part made it extremely easy to screw machine.  Also, screw machining allowed the part to be made out of a much stronger wrought alloy.  It wound up being an 80% cost savings (from $4 to about 80¢), along with a more than 50% increase in strength.

But this is far from the norm, and as this article shows, casting is almost always much cheaper.  A more interesting comparison would be between die casting and powder metallurgy.  It would also be worthwhile to compare different casting processes (die casting, semi-solid processing, permanent mold, investment casting, lost foam, etc.).  In addition to cost, these processes also vary in terms of the mechanical properties and dimensional accuracy that can be achieved.

Greg M. Jung
User Rank
Platinum
Die Casting
Greg M. Jung   9/15/2012 3:36:50 PM
NO RATINGS
I agree that converting machined parts to die casting usually makes sense.  Because die casting tools can be expensive, it is important to first do a pay-back analysis and see if the volumes justify this change over.

In many cases we use both processes during the life of the product.  When the initial design is likely to change and we need to enter the market quickly, we may start with a machined part.  Then, as the design becomes stable and production volumes increase, we plan for a smooth cut-over to die cast tooling.

 

Partner Zone
Latest Analysis
For decades there have been rumors that Microsoft essentially copied DRI's CP/M operating system and sold it to IBM as MS-DOS. In just a few days, all will be revealed.
A San Francisco startup called Otto came out of stealth mode recently and released a dramatic video demonstrating its successful test of a technology for self-driving trucks.
Researchers have found a way to use graphene to cheaply and easily turn dirty water into drinking water.
A new 1-GHz vector signal transceiver promises to offer expanded test capabilities for engineers involved in applications ranging from automotive and aerospace to semiconductors and defense.
Researchers at the Masdar Institute of Science and Technology have devised a new method for designing strong, light cellular structures of re-architected metals and plastics with optimized properties.
More:Blogs|News
Quick Poll
The Continuing Education Center offers engineers an entirely new way to get the education they need to formulate next-generation solutions.
SEMESTERS: 1  |  2  |  3  |  4  |  5  |  6 |  7 | 8 | 9 | 10


Focus on Fundamentals consists of 45-minute on-line classes that cover a host of technologies. You learn without leaving the comfort of your desk. All classes are taught by subject-matter experts and all are archived. So if you can't attend live, attend at your convenience.
Learn More   |   Login   |   Archived Classes
Twitter Feed
Design News Twitter Feed
Like Us on Facebook

Technology Marketplace

Copyright © 2016 UBM Canon, A UBM company, All rights reserved. Privacy Policy | Terms of Service