Materials & Assembly

Converting Machined Parts to Die Castings

< Previous Page 2 / 3 Next >
View Comments: Newest First|Oldest First|Threaded View
Greg M. Jung
User Rank
Die Casting
Greg M. Jung   9/15/2012 3:36:50 PM
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.


Dave Palmer
User Rank
Comparing processes
Dave Palmer   8/6/2012 12:31:33 PM
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.

Partner Zone
Latest Analysis
Using 3D-printing to integrate electronics is an enthralling idea, but there's a long road ahead to commercialization.
What should have been an easy microcontroller upgrade opens up a mysterious web of problems.
Prime Minister Narendra Modi is seeking help from Tesla Motors' Powerwall technology for solar-energy storage in India.
The September release spotlights Autodesk's long-term strategy for provisioning of its CAD, CAM, and CAE software and its commitment to cloud delivery.
The transformative nature of designing and making things was the overarching, common theme at separate conferences held in Boston by two giants in the PLM space: Autodesk, with its Accelerate 2015, and Siemens’s Industry Analyst Conference 2015.
Design News Webinar Series
10/1/2015 11:00 a.m. California / 2:00 p.m. New York
9/10/2015 11:00 a.m. California / 2:00 p.m. New York
8/13/2015 11:00 a.m. California / 2:00 p.m. New York
6/25/2015 11:00 a.m. California / 2:00 p.m. New York
Quick Poll
The Continuing Education Center offers engineers an entirely new way to get the education they need to formulate next-generation solutions.
Oct 5 - 9, Standards for the Internet of Things (IoT)
SEMESTERS: 1  |  2  |  3  |  4  |  5  |  6 |  7

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

Sponsored Content

Technology Marketplace

Copyright © 2015 UBM Canon, A UBM company, All rights reserved. Privacy Policy | Terms of Service