Print Friendly Version (PDF 163KB)

Transcription

1 Print Friendly Versi (PDF 163KB) Descripti Metals Size Range Tolerances * Tooling Costs+ Part Price+ Design Freedom + Surface Finish Minimum Draft Requirements** Minimum Secti Thickness+ + Ordering Quantities Lead Time+ ++ Die Casting Molten is injected, under pressure, into hardened steel dies, often water or oil cooled. Dies open castings ejected. Zinc, Lead Limited Brass Not normally under 2 feet square. Some Al Mg Zinc ±.015 /in. Brass ±.007 /in Al & Mg: 1 to 3 Zinc: ½ to 2 Brass: 2 to 5 Al:.03 Small parts.06 Medium Parts Mg:.03 foundaries Small Parts capable of.045 larger sizes Medium ±.001 Parts to.016 across size Zinc:.025 Small Parts.040 Medium Pparts Usually 2,500 up. Samples: weeks 4-8 weeks A. Permanent Molten is gravity steel or cast ir molds, coated with ceramic mold wash. Cores can be, s, s shell or other. s open Magnesium, Zinc, some Brass, Brze, H. C., Lead, Gray Ir Limitatis mainly foundry capabilities. base ces to 100 lbs. 60 lbs. max. basic ±.015. If across ±.010 to ±.030 size. Base: Similar to investment. 2 Nferrous 3-4 Ferrous 4 Nferrous 3 Ferrous Base: N-ferrous: Outside: 2 Min. (3 desirable) Inside: 2 Min. (4 desirable) Outide: 1 Inside: 5 Nferrous:.100 Small Areas, up to ¼ Large Areas. 3/16 Small Areas, ¼ Minimum One Day s Run: (100-1,000, size) Samples: 8-20 weeks 4-8 weeks A.

2 castings ejected. New Low Pressure Perm method pressure pours with up to 15 p. s.i. Ir: ±.03 Basic Investment (Lost Wax) Metal mold makes wax or plastic replica. These are sprued, then surrounded with investment material, baked out, poured in cavity. s castable s Fracti of an ce to 150 lbs. ±.003 to ¼ ±.004 to ½ ±.005 per in. To 3 ±.003 for each itial inch Ne.030 Small Areas.060 Larger Areas under 1,000. Other s: all quantities Samples: 5-16 weeks ( complexity) weeks A. ( subsequent operatis) Plaster Plaster slurry is poured to pattern halves, allowed to set, then mold is d baked, assembled, is poured into Magnesium, Zinc, Limited Base Up to 500 square inch area. Base much smaller One side of parting line ±.005 up to 2. Over 2 ± External: 0 to ½ Internal: ½ to Usually low. Often used to prototype for die Average: pieces Samples: 2-6 weeks 2-4 weeks A.

3 cavity. s Ceramic Ceramic slurry poured over cope drag patterns, allowed to set, then molds d baked at 1800 F, producing hard, stable molds. s assembled with or without cores cavity. s castable s 5lbs. to 350 lbs. One side of parting line ±.005 up to 2. Over 2 ±.004 /in. ±.010. (Assumes Epoxy or Metal patterns) Wood 5 Epoxy or Metal to ½ 1/8 Low to medium. Often used for tooling for other casting methods Samples: 3-8 weeks ( complexity) 2-8 weeks A. ( quantity)

4 Graphite Same as Permanent, except no ceramic mold wash is needed, since Graphite molds are used. Core pins are steel. Presently limited to Zinc alloys ZA12, ZA27 One ce to 10 lbs. Currently 12 by 14 with a depth of 7 First inch: ±.005 itial inces ± (can go to.06 for very small areas) Usually 300 up Samples: 6-10 weeks 4 weeks A.S. A Resin Shell Resincoated s is poured to hot patterns, curing into shell-like mold halves. These are d assembled with or without cores. Metal is cavities. s Castable s maximum 550 square inches usable mold area. Depends N- ±.008 /in. Decreasing with size. ±.010 /in N Outside: ½ to 1 Inside ½ to 2 N- 3/32 1/8 equipment ±.005 at each to.010 foundry across Nferrous 100 up. Ferrous 1,000 up. Samples: weeks 6-10 weeks A.

5 S Casting Tempered s is packed to wood or pattern halves, d assembled with or without cores, is cavities. Various core materials can be used. s Specialized Binders now in use can improve tolerances surface finish. castable materials Limitati mainly foundry capabilities. Onces to many ts N- ± 1/32 to 6 ±.003 for each aditial inch. ± 1/32 to 3, ± 3/64 3 to 6. Wood: 5 4 Ir: Nferrous: to 5 Cores: 1 to 1 1/2 Nferrous: 1/8 to ¼ Gray Ir: 1/8 D.I. & Steel: 3/16 ±.020 to ±.090 size (Assumes Patterns) All quantities Samples: 2-10 weeks 2-4 weeks A.

6 Semi- Solid Metal (SSM) Specially prepared slugs are gradually heated to a semi-solid state, then transferred to forming machine, where ram injects (squeezes), under pressure, the into die. Die opens part is ejected. magnesium, some copper alloys Ounces to 5 lbs., some processors capable of larger sizes Al Mg Brass ±.007 ±.001 to ±.010 across size preferred ½ possible.030 2,500 pieces up (usally 50,000 pieces up) Samples: weeks 6-8 weeks A.S. A Metal Injecti ing Very fine powder, combined with binder material, is injected Primarily.0005 lbs. ± 005 /in /4.015 Small ferrous to.22 lbs. areas alloys limited Base Usally 10,000 up Samples: weeks 4-6 weeks A. Post Office Box Clevel Place Springfield, NJ Phe: (973) Fax: (973) sales@bot.com The above are generalities should be used ly as a rough guide. When in doubt, check with your TAI Sales Engineer. Often you will wish to evaluate two or more processes for a given part. He can elaborate the above informati as applied to your specific parts. Copyright 2009 Associates Inc. A.. After Sample Approval * These are for critical dimensis should not be specified where not necessary. ** draft Requirements inversely affected by depth of draw Least. ++ Size surface area influence this csiderably +++ This will vary widely business cditis foundry load. Availability of CAD files New Rapid Prototyping processes can cut sampling time in half or less.