HOME  |  NEWS  |  BLOGS  |  MESSAGES  |  FEATURES  |  VIDEOS  |  WEBINARS  |  INDUSTRIES  |  FOCUS ON FUNDAMENTALS
  |  REGISTER  |  LOGIN  |  HELP
Feature
Materials & Assembly
Converting Machined Parts to Die Castings
8/6/2012

This photo provides before and after views of a part that was machined (top photos) and the same part after it was converted to die castings (bottom photos). The die cast part is able to capture much more three-dimensional detail and consistently meets close tolerances during the manufacturing process.
This photo provides before and after views of a part that was machined (top photos) and the same part after it was converted to die castings (bottom photos). The die cast part is able to capture much more three-dimensional detail and consistently meets close tolerances during the manufacturing process.

Return to Article

View Comments: Newest First|Oldest First|Threaded View
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.

 

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.

Partner Zone
Latest Analysis
Taking energy from renewable sources, recycling existing energy, and using components that don’t need much energy at all are becoming critical industrial and consumer design criteria.
Sales of semiconductors, interconnects, and other electronic components in North America were flat through the second quarter of 2015, reflecting a pattern that’s been repeating itself for several years.
Texas Instruments has produced an e-book intended to get you up to snuff on the Industrial Internet of Things.
A South African startup is combining recycled plastic with solar power to give underprivileged schoolchildren a stylish schoolbag that also supplies them with light to study by.
An in-depth survey of 700 current and future users of 3D printing holds few surprises, but results emphasize some major trends already in progress. Two standouts are the big growth in end-use parts and metal additive manufacturing (AM) most respondents expect.
More:Blogs|News
Design News Webinar Series
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
6/24/2015 11:00 a.m. California / 2:00 p.m. New York
6/11/2015 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.
Aug 31 - Sep4, Embedded System Design Techniques™ - Writing Portable and Robust Firmware in C
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